ESP RENAULT TWINGO 2009 2.G Engine Diesel Injection Workshop Manual

13B-3V6 MR-413-X44-13B000$010.mif
DIESEL INJECTION
Fault finding – Introduction13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
To cut off + after ignition feed, proceed as follows:
Faults
Faults are declared present or stored (depending on whether they appeared in a certain context and have
disappeared since, or whether they remain present but are not diagnosed within the current context).
The present or stored status of faults should be taken into consideration when using the diagnostic tool after
switching on the + after ignition feed (without any system components being active).
For a present fault, apply the procedure described in the Interpretation of faults section.
For a stored fault, note the faults displayed and apply the Notes section.
If the fault is confirmed when the instructions are applied, the fault is present. Deal with the fault.
If the fault is not confirmed, check:
–the electrical connections that correspond to the fault,
–the connectors for this connection,
–the resistance of the component detected as defective,
–the condition of the wires.
Refer to paragraphs 4.1 Checking wiring and 4.2 Checking connectors
Conformity check
The aim of the conformity check is to check data that does not produce a fault on the diagnostic tool because
the data is inconsistent. Therefore, this stage is used to:
–carry out fault finding on faults that do not have a fault display, and which may correspond to a customer complaint.
–check that the system is operating correctly and that there is no risk of a fault recurring after repairs.
This section gives the fault finding procedures for statuses and parameters and the conditions for checking them.
If a status is not behaving normally or a parameter is outside the permitted tolerance values, consult
the corresponding fault finding page.
Customer complaints - Fault finding chart
If the test with the diagnostic tool is OK but the customer complaint is still present, the fault should be processed by
customer complaints. Note:
the left and right-hand xenon bulb computers are powered when the dipped headlights are lit.
Therefore fault finding can only be carried out on them after the ignition has been switched on in fault finding mode
(forced + after ignition feed) and the dipped headlights have been switched on.
For vehicles with a radio frequency remote control - key, use the key to switch off the ignition.
For vehicles with a Renault card,
press the Start button twice briefly (less than 3 seconds),
check that the forced + after ignition feed has been cut off by checking that the computer warning lights on
the instrument panel have extinguished.
A synopsis of the general procedure to follow is provided on the following page in the form of a flow chart.

13B-12V6 MR-413-X44-13B000$040.mif
13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
System outline
The DCM1.2 injection system used on the K9K engine is an electronically-managed high pressure injection system.
The fuel is compressed by a high pressure pump then stored in a rail that feeds the injectors. Injection takes place
when a current pulse is applied to the injector holders. The amount injected is proportional to the rail pressure
and the applied pulse length, and the start of injection is synchronised with the start of the pulse.
The system includes two subsystems, which have different fuel pressure levels:
–The low pressure circuit contains the tank, the diesel fuel filter, the transfer pump and the injector holder
return pipes,
–the high-pressure system includes the high-pressure pump, rail, injector holders and high-pressure pipes.
Finally, there are a certain number of sensors and regulating actuators for controlling and monitoring the entire
system.
Functions performed:
Function: Fuel supply management (timing, flow and pressure).
Quantity of fuel injected and injection timing setting
The injection checking parameters are the quantities to be injected and their respective timing.
These are calculated by the computer using signals from the following sensors:
–engine speed sensor (Crankshaft + Cam lobe for synchronisation),
–accelerator pedal sensor,
–coolant temperature sensor,
–rail pressure sensor,
–atmospheric pressure sensor,
–accelerometer,
–inlet manifold pressure sensor.
Specific vehicle / engine suffix details:
Modus
K9K 750 752 (Euro 3)Inlet manifold temperature and pressure sensor (a sensor which has two functions),
management by the turbocharger control solenoid valve inlet pressure.
K9K 766 (Euro 4)Either a flow sensor with an integrated temperature sensor or a temperature sensor
instead of a flow sensor with inlet manifold temperature sensor, inlet manifold pressure
sensor, management by turbocharger control solenoid valve programming.
K9K 768 (Euro 4)Flow sensor with integrated temperature sensor, inlet manifold pressure sensor,
management by the turbocharger control solenoid valve inlet pressure.
DIESEL INJECTION
Fault finding – Function

13B-13V6 MR-413-X44-13B000$040.mif
DIESEL INJECTION
Fault finding – Function13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
The quantities to be injected and their respective timing are converted into:
–a reference tooth,
–the time between this tooth and the start of the pulse,
–the time during which the supply to the injector holder is on.
An electrical current (pulse) is sent to each injector holder according to previously calculated data. The system
carries out one to four injections (one pilot injection, one pre-injection, one main injection, one post-injection).
The general principle is to calculate the total injection flow which is then divided between the injection stages to
promote correct combustion and reduce pollutant emissions.
An accelerometer checks some of the fuel injection deviation. This has several functions:
–Protecting the engine by detection of injection system leaks.
–Checking the quantity injected by measuring deviations and variations.
By changing both the injection duration and advance, the system readjusts the quantity of fuel injected
and the mixture's moment of ignition.Clio III
K9K 750 752 (Euro 3)Inlet manifold temperature and pressure sensor (a sensor which has two functions),
management by the turbocharger control solenoid valve inlet pressure.
K9K 766 (Euro 4)Either a flow sensor with an integrated temperature sensor or a temperature sensor
instead of a flow sensor with inlet manifold temperature sensor, inlet manifold pressure
sensor, management by turbocharger control solenoid valve programming.
K9K 768 (Euro 4)Flow sensor with integrated temperature sensor, inlet manifold pressure sensor,
management by the turbocharger control solenoid valve inlet pressure.
Megane II / Scenic II
K9K 724 (Euro 4)Either a flow sensor with an integrated temperature sensor or a temperature sensor
instead of a flow sensor with inlet manifold temperature sensor, inlet manifold pressure
sensor, management by turbocharger control solenoid valve programming.
New Twingo No UPC (Protection and Switching Unit).
K9K 740 (Euro 4)Temperature sensor instead of the flow sensor with inlet manifold pressure
and temperature sensor, management by the turbocharger control solenoid valve inlet
pressure, water in diesel fuel sensor depending on target export countries.
Kangoo 2
K9K 800 802 (Euro 4)The flow of fresh air entering the engine is given by a hot wire ratiometric sensor. This
flow sensor facilitates control of the amount of exhaust gas sent for recirculation, thus
ensuring the best possible recirculation rates. An air temperature sensor is integrated
into the flow sensor.
Air flow measurement facilitates closed-loop control via the EGR valve.
K9K 812 (Euro 3)Temperature sensor instead of the flow sensor with inlet manifold pressure
and temperature sensor, management by the turbocharger control solenoid valve inlet
pressure.

13B-17V6 MR-413-X44-13B000$040.mif
DIESEL INJECTION
Fault finding – Function13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
Function: Hosted functions
Air conditioning management assistance
On models with air conditioning, the DCM1.2 system allows the air conditioning to be deactivated under certain
operating conditions:
–when requested by the driver,
–when starting the engine,
–if the engine overheats (in order to reduce the power the engine has to supply),
–when the engine speed is kept at a very high level (to protect the compressor),
–during transition phases (e.g. high acceleration demand for overtaking, anti-stalling and moving off). These
conditions are only taken into account if they do not occur repeatedly, so as to prevent system instabilities
(erratic deactivation),
–when certain faults appear.
Cold loop air conditioning management
The air conditioning is the cold loop type and its management shared between several computers. The injection
computer is responsible for:
–managing demand for cold air according to the passenger compartment commands and the pressure value,
–determining the power absorbed by the compressor from the pressure,
–determining the fan unit commands according to vehicle speed and pressure.
The driver requests the instrument panel to switch on the air conditioning. The signal is sent to the injection computer
via the multiplex line network. The cold air request is authorised or denied depending on the pressure measured. If
this pressure is outside the operating limits, the cold loop program is not activated.
Thermal regulation of the passenger compartment heating circuit
In a direct injection engine, fuel is injected directly into the combustion chamber. This leads to heat being lost
through the upper part of the engine and consequently, the cylinder head cooling system is smaller in size.
The effect of this is that the temperature of the coolant which flows through this circuit rises more slowly. This coolant
is also used by the passenger compartment heating system. In very cold conditions, it is therefore difficult to achieve
a comfortable passenger compartment temperature quickly.
To reduce the time taken to produce heat, air heating elements, called passenger compartment heating resistors,
are fitted in the passenger compartment heating circuit. The UCH decides whether or not to switch on the passenger
compartment heating resistors, and the UPC or the injection physically controls the heating elements. The injection
computer determines whether to reduce the power supplied to the passenger compartment heating resistors
according to the alternator load and also whether to inhibit the operation of the passenger compartment heating
resistors according to the engine speed, the load, and the vehicle speed.Note:
Fan unit actuation requests can be sent by the injection computer, but these are sent via the multiplex line. These
requests depend on the air conditioning, but also on the engine coolant temperature and vehicle speed.

13B-35
AFTER REPAIRDeal with any faults displayed by the diagnostic tool.
Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V6 MR-413-X44-13B000$090.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
DF007
PRESENT
OR STOREDRAIL PRESSURE SENSOR CIRCUITCC.0: Short circuit to earth
C0.1: Open circuit or short circuit to +12 V
1.DEF: Inconsistency
2.DEF: Below minimum threshold
3.DEF: Above maximum threshold
4.DEF: Value outside permitted tolerance
NOTESPriority for dealing with a combination of faults:
–DF113 Sensor supply voltage.
Conditions for applying fault finding procedures to stored faults:
The fault is declared present after the engine starts.
Special note:
If fault DF007 is present: the engine stops and cannot be restarted and the level 2
warning light illuminates, with the message Faulty injection displayed on the
instrument panel.
See the Technical Note Wiring Diagrams for the vehicle.
Check the connection and condition of the rail pressure sensor connector, component code 1032.
Check the connection and condition of connector B (brown 48-track) of the injection computer, component
code 120.
If the connector(s) is faulty and if there is a repair procedure (see Technical Note 6015A, Repairing electrical
wiring, Wiring: Precautions for repair), repair the connector, otherwise replace the wiring.
Check for +5 V on connection 3LX of component 1032.
Check for earth on connection 3LZ of component 1032.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
Check the insulation and continuity of the following connections:
–3LX between components 1032 and 120,
–3LY between components 1032 and 120,
–3LZ between components 1032 and 120.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
DCM1.2_V48_DF007/DCM1.2_V4C_DF007/DCM1.2_V50_DF007/DCM1.2_V54_DF007/DCM1.2_V58_DF007/DCM1.2_V5C_DF007

13B-37
AFTER REPAIRDeal with any faults displayed by the diagnostic tool.
Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V6 MR-413-X44-13B000$090.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
DF008
PRESENT
OR STOREDPEDAL POTENTIOMETER CIRCUIT GANGED CIRCUIT 1CO.0: Open circuit or short circuit to earth
CC.1: Short circuit to +12 volts
1.DEF: Inconsistency between pedal gangs 1 and 2
2.DEF: No signal
3.DEF: Jammed component
NOTESPriority for dealing with a combination of faults:
–DF113 Sensor supply voltage.
Special note:
If fault DF008 is present: the idle speed is fast (1000 rpm), the engine performance is
reduced to 75%, and the level 1 warning light illuminates with the message Check
injection displayed on the instrument panel.
If DF008 and DF009 Pedal potentiometer circuit gang 2 are present: the engine
speed increases to 1300 rpm or 1700 rpm if the vehicle is fitted with a sequential
gearbox (fault on gangs 1 and 2), and the level 1 warning light illuminates with
the message Check injection displayed on the instrument panel.
Note: possible risk of the engine speed racing with no load for 1 second.
See the Technical Note Wiring Diagrams for the vehicle.
1.DEF
3.DEF
NOTESNone.
Disconnect connector A (black) of the injection computer, component code 120 and the connector of the pedal
potentiometer, component code 921.
Check the insulation between connections 3LS and 3LW of component 120.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
If the fault is still present, replace the accelerator pedal potentiometer, component code 921 (see MR 364
(Mégane II), MR 370 (Scénic II), MR 385 (Modus), MR 392 (Clio III), MR 411 (New Twingo), MR 417 (Kangoo 2),
Mechanical, 13B, Diesel injection, Accelerator pedal potentiometer: Removal - Refitting).
If the fault is still present, contact the Techline.
DCM1.2_V48_DF008/DCM1.2_V4C_DF008/DCM1.2_V50_DF008/DCM1.2_V54_DF008/DCM1.2_V58_DF008/DCM1.2_V5C_DF008

13B-40
AFTER REPAIRDeal with any faults displayed by the diagnostic tool.
Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V6 MR-413-X44-13B000$090.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
DF009
PRESENT
OR STOREDPEDAL POTENTIOMETER TRACK 2 CIRCUITCO.0: Open circuit or short circuit to earth
CC.1: Short circuit to +12 volts
NOTESPriority for dealing with a combination of faults:
–DF122 Pedal potentiometer gang 2 supply voltage.
Special note:
If fault DF009 is present: the idle speed is fast (1000 rpm), the engine performance is
reduced to 75%, and the level 1 warning light illuminates with the message Check
injector displayed on the instrument panel.
If DF009 and DF008 Pedal potentiometer circuit gang 1 are present: the engine
speed increases to 1300 rpm or 1700 rpm if the vehicle is fitted with a sequential
gearbox (fault on gangs 1 and 2), and the level 1 warning light illuminates with
the message Check injection displayed on the instrument panel.
Note: possible risk of the engine speed racing with no load for 1 second.
See the Technical Note Wiring Diagrams for the vehicle.
CO.0
NOTESSpecial note:
None.
Check the connection and condition of the pedal potentiometer connector, component code 921.
Check the connection and condition of connector A (black 32-track) of the computer, component code 120.
If the connector(s) is faulty and if there is a repair procedure (see Technical Note 6015A, Repairing electrical
wiring, Wiring: Precautions for repair), repair the connector, otherwise replace the wiring.
Check for + 5 V on connection 3LU of component 921.
Check for earth on connection 3LV of component 921.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
Disconnect connector A of the computer, component code 120 and the connector of the pedal potentiometer,
component code 921.
Check the insulation against earth of connection 3LW on component 120.
If the connection is faulty and if there is a repair procedure (see Technical Note 6015A, Electrical wiring repair,
Wiring: Precautions for repair), repair the wiring, otherwise replace it.
DCM1.2_V48_DF009/DCM1.2_V4C_DF009/DCM1.2_V50_DF009/DCM1.2_V54_DF009/DCM1.2_V58_DF009/DCM1.2_V5C_DF009

13B-43
AFTER REPAIRDeal with any faults displayed by the diagnostic tool.
Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V6 MR-413-X44-13B000$090.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
DF010
PRESENT
OR STOREDEGR POSITION SENSOR CIRCUIT1.DEF: Above maximum threshold
2.DEF: Below minimum threshold
NOTESPriority for dealing with a combination of faults:
–DF113 Sensor supply voltage.
See the Technical Note Wiring Diagrams for the vehicle.
K9K 724, 740, 766, 768, 800, 802, and 812 ENGINES (Euro 4):
Check the connection and condition of the EGR valve connector, component code 1460.
Check the connection and condition of connector B (brown 48-track) of the computer, component code 120.
If the connector(s) is faulty and if there is a repair procedure (see Technical Note 6015A, Repairing electrical
wiring, Wiring: Precautions for repair), repair the connector, otherwise replace the wiring.
Check the insulation and continuity of the following connections:
–3GC between components 1460 and 120,
–3EL between components 1460 and 120,
–3JM between components 1460 and 120.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
Check for + 5 V on connection 3GC of component 1460.
Check for earth on connection 3JM of component 1460.
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
Measure the resistance of the EGR valve, component code 1460:
–with the engine stopped, the exhaust gas recirculation valve will be closed (unless there is a fault),
–wait for the ambient temperature around the valve to stabilise (approximately 20
°C),
measure the resistance between connections 3VP and 3VQ of component 1460. The resistance must be between
0.5 ΩΩ Ω Ω
< R < 50 Ω (while running command AC002 EGR solenoid valve).
If the value is not correct, replace the EGR valve (see MR 364 (Mégane II), MR 370 (Scénic II), MR 385 (Modus),
MR 392 (Clio III), MR 411 (New Twingo), MR 417 (Kangoo 2), Mechanical, 14A, Emission control, Exhaust
gas recirculation solenoid valve: Removal - Refitting).
After replacing the EGR valve, use command RZ002 EGR Adaptives to reinitialise the EGR valve offsets.
If the fault is still present, contact the Techline.
DCM1.2_V48_DF010/DCM1.2_V4C_DF010/DCM1.2_V50_DF010/DCM1.2_V54_DF010/DCM1.2_V58_DF010/DCM1.2_V5C_DF010

13B-81
AFTER REPAIRDeal with any faults displayed by the diagnostic tool.
Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V6 MR-413-X44-13B000$110.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
DF050
CONTINUED
Check the insulation and continuity of the following connections:
–5A between components 160 and 120,
–BPT between components 160 and 645 (for Mégane II, Scénic II, Modus, and Clio III),
–BPT2 between components 160 and 645 (for Kangoo 2),
–SP17 between components 160 and 260 (for Kangoo 2),
–AP10 between components 160 and 1016 (for New Twingo),
–65A between components 160 and 645 (vehicle without ESP),
–65G between components 160 and 645 (vehicle with ESP).
If the connection or connections are faulty and there is a repair procedure (see Technical Note 6015A, Electrical
wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise replace the wiring.
If the fault is still present, replace the brake switch, component code 160 (see MR 364 (Mégane II), MR 370
(Scénic II), MR 385 (Modus), MR 392 (Clio III), MR 411 (New Twingo), MR 417 (Kangoo 2), Mechanical, 37A,
Mechanical component controls, Brake light switch: Removal - Refitting).
If the fault is still present, contact the Techline.

13B-83
AFTER REPAIRDeal with any faults displayed by the diagnostic tool.
Clear the computer fault memory.
Carry out a road test followed by another check with the diagnostic tool.
V6 MR-413-X44-13B000$110.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
DF052
PRESENT
OR
STOREDINJECTORS CONTROL CIRCUIT
CC.1: short circuit to +12 volts.
CC.0: short circuit to earth
NOTESPriorities when dealing with a number of faults:
–DF026 Cylinder 1 injector control circuit,
–DF027 Cylinder 2 injector control circuit,
–DF028 Cylinder 3 injector control circuit,
–DF029 Cylinder 4 injector control circuit,
the fault finding procedure remains the same, but the combination of faults makes it
possible to identify the defective injector(s).
Special notes:
When the fault occurs: there is engine noise, the engine speed is unstable, the engine
performance is reduced, and the level 2 warning light comes on with the message
Faulty injection displayed on the instrument panel.
See the Technical Note Wiring Diagrams for the vehicle.
Switch off the ignition, check the condition and connection of the injector connectors, component codes 193,
194, 195, and 196.
If the connector(s) are faulty and there is a repair procedure (see Technical Note 6015A, Repairing electrical
wiring, Wiring: Precautions for repair) repair the connector(s), otherwise replace the wiring.
Switch off the ignition, disconnect the injectors (or the injector identified by faults DF026 Cylinder 1 injector
control circuit, DF027 Cylinder 2 injector control circuit, DF028 Cylinder 3 injector control circuit,
DF029 Cylinder 4 injector control circuit) and switch on the ignition again.
Using the diagnostic tool, check for changes to fault DF052.
Is DF052 present or stored?
DCM1.2_V48_DF052/DCM1.2_V4C_DF052/DCM1.2_V50_DF052/DCM1.2_V54_DF052/DCM1.2_V58_DF052/DCM1.2_V5C_DF052