RENAULT KANGOO 2013 X61 / 2.G Diesel DCM 1.2 Injection Workshop Manual

13B-191V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 6 High pressure system check
NOTESSpecial note:
Certain faults make it impossible to carry out this test - deal with these first.
WARNING
Running the starter motor for more than 5 seconds is dangerous and serves no useful
purpose.
Preliminary Checks:
– Check for the presence of fuel
– Check that there is no air in the low pressure circuit. Apply TEST 1 Low pressure circuit check.
– Ensure that the correct fuel is being used. Apply TEST 13 Diesel fuel conformity check.
The pump's capacity to produce high pressure can be checked by the following procedure:
–With the ignition off, disconnect the low pressure actuator from the pump (IMV brown connector) and
connect a test IMV or the MOT adapter. 1711 adapter.
– Electrically disconnect the four injectors.
– Switch on the ignition, connect the diagnostic tool and re-establish dialogue with the injection system.
– Go to the Main computer statuses and parameters screen.
– Run the test cold, PR064 "Coolant temperature" < 30 °C or equal to ambient temperature.
–Activate the starter for 5 seconds.
– Read the maximum rail pressure value PR038 Rail pressure during the test on the diagnostic tool.
PR038 > 1050 bar?
A
NO
B
YES
DCM1.2_V08_TEST06

13B-192V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
IMV = fuel flow actuator
TEST 6
CONTINUED
– Switch off the ignition, reconnect the electrical
connections to the four injectors and the low-pressure
actuator.
– Switch on the ignition again, and clear the injection
faults using the diagnostic tool.
– Check if there is no fuel leak in the high pressure
circuit. Run TEST 7 High pressure circuit sealing
check
– Check the conformity of the diesel filter. Run TEST 9
Diesel fuel filter check.
– Carry out fault finding on the injectors by checking the
return flow volume of the four injectors, run TEST 8
Injector return flow.
Is TEST 8 OK?The pump can supply the operating pressure.
Switch off the ignition, reconnect the electrical
connections
to the four injectors and the low pressure
actuator. Switch on the ignition again, and clear
the injection faults using the diagnostic tool.
– Check that there is no fuel leak in the high
pressure circuit, apply TEST 7 High pressure
circuit sealing check.
– Carry out fault finding on the injectors by
checking the return flow volume of the four
injectors, run TEST 8 Injector return flow.
If TEST 8 is correct, the high pressure fuel circuit
is correct.
Replace the faulty injector(s) (see MR
388 (Logan/Sandero), MR 451
(Duster), MR 423 (Thalia 2/Symbol 2)
or MR 374 (Kangoo VLL), Mechanical,
13B, Diesel injection, Diesel injector:
Removal - Refitting).Replace the high pressure pump (see MR 388 (Logan/Sandero),
MR 451 (Duster), MR 423 (Thalia 2/Symbol 2) or MR 374
(Kangoo VLL), Mechanical, 13B, Diesel injection, High
pressure pump: Removal - Refitting).
AB
YESNO

13B-193V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 7 High pressure circuit sealing check
NOTESSpecial note:
Certain faults make it impossible to carry out this test - deal with these first.
The command AC029 High pressure circuit sealing test enables a high pressure circuit sealing test to be
carried out when the engine is running.
This command can locate a leak in the high pressure circuit if a union is incorrectly fitted or screwed on. This test
does not identify a minor leak due to a union not being tightened to torque.
This command can be used only if the engine temperature is greater than 60ºC.
Watch out for any objects (tool or others) on the sides of the engine housing during the 4 accelerations
(possible vibrations).
Run command AC029 High pressure circuit sealing test, the engine will automatically carry out a cycle of
four accelerations to increase the rail pressure and check for leaks in the high pressure circuit.
DCM1.2_V08_TEST07

13B-194V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 8 Injector return flow
NOTESSpecial note:
Certain faults make it impossible to carry out this test - deal with these first.
Does the engine start?
Command AC029 High pressure circuit sealing also checks the return volume of each injector to detect any
leaks around the injectors.
Be careful with any objects (tool or other) on the engine housing during the four cycles of the operation
(possible vibrations).
Tooling required
–Mot. 1711 Injector flow measuring kit.
Or: Use four pipes with internal diameter 4mm and approximately 50 cm in length, and four graduated
measuring cylinders.
Procedure
– Ensure that the engine coolant temperature is above 60°C,
– switch off the ignition,
– disconnect the return pipes from the four injectors,
– cap the pump venturi tube to prevent the low-pressure circuit from depriming,
– connect the four transparent tubes in place of the return pipes,
– put the other ends of the four pipes into four graduated measuring cylinders.
NOA
YES
DCM1.2_V08_TEST08

13B-195V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 8
CONTINUED 1
When all the preparations are complete, start the engine and leave it running:
For 30 seconds at idle speed for Euro 4 type engines: K9K 714 - 718 - 740 - 792 - 796.
Let it idle for 2 minutesfor the euro 3 type engines: K9K 790 - 794.
Note:
These time periods must be respected for the test results to be interpreted correctly.
–Run command AC029 High pressure circuit sealing check
.The engine will automatically carry out a cycle of four accelerations to increase the rail pressure and measure
the internal injector leaks under these conditions.
–When the cycle has finished, run command AC029 High pressure circuit sealing test a second time to
obtain the correct return volume reading for each injector.
Switch off the engine at the end of the cycle.

13B-196V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 8
CONTINUED 2
At the end of the idling phase and these two cycles, the return volume of each injector must be:
45 ml (maximum)for Euro 4 type engines: K9K 714 - 718 - 740 - 792 - 796.
35 ml (maximum).for the euro 3 type engines: K9K 790 - 794.
If the return volume of one of the injectors is more than the values above, only replace the faulty injector (see
MR388 (Logan/Sandero) or MR451 (Duster), Mechanical, 13B, Diesel injection, Diesel injector: Removal -
Refitting).
Disconnect the 4 transparent pipes and reconnect the injector return circuit.
Carry out the following test to confirm the repair:
– With the ignition off, disconnect the low pressure actuator from the pump (brown IMV connector) and connect
the test adapter (test IMV, Mot. 1711),
– electrically disconnect the 4 injectors,
– switch on the ignition, connect the diagnostic tool and re-establish dialogue with the injection system,
– Go to the Main computer statuses and parameters screen,
– activate the starter for 5 seconds,
– read the maximum rail pressure value PR038 Rail pressure during the test on the diagnostic tool.
If the rail pressure (PR038 Rail pressure) is lower than 1050 bar, run test 6 High pressure system check.
– Switch off the ignition, and reconnect the four injectors electrically,
– disconnect the test filling actuator (test IMV) and reconnect the low pressure actuator connector (IMV) to the
pump,
– switch on the ignition again, and clear the injection faults using the diagnostic tool.
If the rail pressure (PR038) is greater than 1050 bar, the repair is correct.
End of TEST8.

13B-197V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 8
CONTINUED 3
If the engine does not start, only the static leakage can be measured, i.e. the leakage with the injector closed, not
actuated and under high pressure.
Make sure that the ignition circuit is working correctly (minimum engine speed 200 rpm).
Tooling required
–Mot. 1711 Injector flow measuring kit.
Or: Use 4 pipes with internal diameter 4mm and approximately 50 cm in length, and a test adapter (TEST
IMV).
Procedure
– Switch off the ignition,
– disconnect the return pipes from the four injectors,
– cap the pump venturi tube to prevent the low-pressure circuit from depriming,
– connect the four transparent pipes in place of the return pipes (Mot. 1711),
– disconnect the low pressure actuator from the pump (brown IMV connector) and connect a test IMV or the Mot.
1711,
– electrically disconnect the four injectors,
– switch on the ignition and engage the starter for 5 seconds,
– measure the amount of diesel fuel in each pipe.
If the return leakage is greater than 10 cm, replace the injector(s) (see MR 388 (Logan/Sandero) or MR 451
(Duster), MR 423 (Thalia 2/Symbol 2) or MR 374 (Kangoo VLL), Mechanical, 13B, Diesel injection, Diesel
injector: Removal - Refitting).
Switch off the ignition, and reconnect the four injectors electrically.
Disconnect the test low pressure actuator and reconnect the low pressure actuator connector to the pump.
Disconnect the four transparent tubes and reconnect the injectors return circuit. Switch on the ignition again, and
clear the injection faults using the diagnostic tool.
A

13B-198V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 8
CONTINUED 4
Carry out the following test to confirm the repair:
–With the ignition off, disconnect the low pressure actuator from the pump (brown IMV connector) and
connect the test adapter (test IMV, Mot. 1711),
– electrically disconnect the four injectors,
– switch on the ignition, connect the diagnostic tool and re-establish dialogue with the injection system,
– go to the Main computer statuses and parameters screen,
– engage the starter for 5 seconds,
– read the maximum rail pressure value PR038 Rail pressure during the test on the diagnostic tool.
If the rail pressure (PR038 Rail pressure) is lower than 1050 bar, run TEST 6 High pressure system check.
– Switch off the ignition, and reconnect the four injectors electrically,
– disconnect the test IMV and reconnect the low-pressure actuator connector to the pump,
– switch on the ignition again, and clear the injection faults using the diagnostic tool.
End of TEST 8

13B-199V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 9 Diesel filter check
Check the conformity of the diesel filter.
Is the diesel filter in order?Replace the filter with an original
part (see MR 388 (Logan/Sandero),
MR 451 (Duster), MR 423 (Thalia 2/
Symbol 2) or MR 374 (Kangoo VLL),
Mechanical, 13A, Fuel supply, Fuel
filter: Removal - Refitting).
Switch off the ignition and analyse the diesel fuel in the diesel filter.
– Disconnect the diesel supply and return hoses from the filter.
– Block the filter inlets and outlets straight away with appropriate plugs.
– Remove the filter from its support and shake it well keeping the plugs in place and empty the contents of the
filter into a glass container by lifting up a protective plug and undoing the bleed screw.
Check whether there are black particles present at the bottom of the container.
Pass a magnet beneath the container to collect all the
metal particles.
Take the magnet away from the container.Diesel filter in good order.
Do the particles collected using the magnet cover a surface
area greater than 1 cm
2?
Replace the entire injection
system.Diesel filter in good
order.
NO
YES
YESNO
YESNO
DCM1.2_V08_TEST09

13B-200V1 MR-376-X76-13B000$160.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
TEST 11 Turbocharger air chain
Check for the air filter
Check the replacement interval of the air filter on the maintenance booklet.
Compare the part numbers of the air filter fitted to the vehicle and that of the air filter recommended by the
manufacturer.
Check the air filter direction of fitting.
Is the air filter fitted to the vehicle correct?
Check the condition of the air filter
Visually inspect the condition of the filtering section of the
air filter.
Is either the air filter or its seal damaged?
Is the air filter fouled (does it contain a lot of
impurities)?Replace the air filter (see MR 388
(Logan/Sandero), MR 423
(Thalia 2/Symbol 2), MR 451
(Duster) or MR 374 (Kangoo
VLL), Mechanical, 12A, Fuel
mixture, Air filter: Removal -
Refitting).
Low pressure circuit check
Note:
Depending on the vehicle type, the best visual access will
be either from above or from below.
Visually inspect the condition of the following
components:
– fresh air inlet scoop on the front panel of the vehicle,
– air inlet pipe to the air filter,
– air pipe of the filter until the compressor inlet,
– mountings of the air flowmeter.
Is one of these components incorrect (disconnected,
cut, bent, pierced or kinked pipes)?Replace the faulty parts (see MR
388 (Logan/Sandero), MR 451
(Duster), MR 423 (Thalia 2/
Symbol 2) or MR 374 (Kangoo
VLL), Mechanical, 12B,
Turbocharging).
YESNO
YES
NO
YES
A
NO
DCM1.2_V08_TEST11