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

13B-7V1 MR-376-X76-13B000$020.mif
13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
I - RISKS ASSOCIATED WITH CONTAMINATION
The high pressure direct injection system is highly sensitive to contamination. The risks caused by the introduction
of contamination are:
– damage to or destruction of the high pressure injection system,
– a component seizing up,
– a component losing its sealing.
All After-Sales operations must be performed under very clean conditions. This means that no impurities
(particles a few microns in size) should have penetrated the system during dismantling.
The cleanliness guidelines must be applied from the filter through to the injectors.
What are the sources of contamination?
– metal or plastic chips,
– paint,
–fibres:
– from cardboard,
– from brushes,
– from paper,
– from clothing,
–from cloths,
– foreign bodies such as hair,
– the ambient atmosphere,
–etc.
IMPORTANT
Cleaning the engine using a high pressure washer is prohibited because of the risk of damaging connections. In
addition, moisture may collect in the connectors and create faults in the electrical connections.
DIESEL INJECTION
Fault finding – Cleanliness guidelines

13B-10V1 MR-376-X76-13B000$030.mif
13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
System outline
The DCM 1.2 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 circuit contains the high pressure pump, the rail, the injector holders and the high pressure pipes.
The injection system contains a number of sensors and actuators for controlling and monitoring the entire system.
Functions provided
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 (Crankshaft +Cam for synchronisation).
– Accelerator pedal.
– Turbocharging pressure and air temperature (Turbocharger pressure).
– Coolant temperature.
– Air temperature.
– Air charge (Flow and Pressure).
– Pressure in the rail.
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 for which the supply to the injector holder is on.
Each injector holder is controlled by an electrical current which is sent according to previously calculated data. The
system makes one or two injections (one pilot injection, one main injection).
The general principle is to calculate an overall injected flow, which is then divided into the main injection flow and a
pilot injection flow to promote correct combustion and help reduce pollutant emissions.
DIESEL INJECTION
Fault finding – System operation

13B-12V1 MR-376-X76-13B000$030.mif
DIESEL INJECTION
Fault finding – System operation13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
Idling speed regulation
The computer handles the calculation of idling speed. This has to take account of the instantaneous power level to
be supplied, according to the following factors:
– engine coolant temperature,
– gear ratio engaged,
– battery charge,
– electrical consumers (Additional heating, Air conditioning, Fan Unit, electric windows, etc.) active or inactive,
– system faults detected.
Individual injector correction (C2I)
The DCM 1.2 system injectors must be calibrated with correction values so that their flow may be adjusted precisely.
Each injector is calibrated for different pressures on a test bench, and its specifications are shown on a label
attached to the body of the injector holders. These individual correction values are then entered into the computer
EEPROM, which can then control the injectors, taking their manufacturing variations into account.
Measuring the angular position (Cylinder reference sensor)
The angular position is measured using a magneto-inductive sensor triggered by machined teeth on the shaft
flywheel. This flywheel has sixty teeth separated by six degrees minus two missing teeth, that form a notch.
A second sensor (Hall effect) triggered by a machined tooth on the high pressure pump drive pulley (synchronised
with the camshaft), which rotates at half the engine speed, supplies an injection cycle running signal. By comparing
the signals from these two sensors, the computer's APS module (Angular Position Subsystem) is able to supply the
synchronisation components to the system assembly, namely:
– the angular position of the flywheel
– the speed and number of the active injector
– the injection cycle progress.
This module also supplies the system with the engine speed signal.
Flow capacity function (VLC)
Because of the combination of several parameters such as the diesel fuel temperature, part wear, clogging of the
diesel filter etc., the system limit may be reached during its service life. If this happens, the rail pressure cannot be
maintained because the pump lacks the necessary capacity. If the pump lacks the necessary capacity, this
programming will therefore reduce the requested flow to a value that will enable the pressure monitoring system to
control the pressure again.
The customer may have noticed a loss of vehicle performance when this program is activated (confirmed by status
Flow capacity function). This is part of normal operation.

13B-79
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF056
PRESENT
OR
STOREDAIR FLOW SENSOR CIRCUIT1.DEF: Permanent low level
2.DEF: Permanent high level
3.DEF: At maximum limit
4.DEF: At minimum limit
NOTESPriorities when dealing with a number of faults:
– DF089 Inlet manifold pressure sensor circuit.
Special notes:
If fault DF056 is present: air flow regulation stops and the EGR valve is closed.
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Check the condition of the air filter, replace the air filter if necessary (see MR388 (Logan/Sandero), MR423 (Thalia
2 / Symbol 2) or MR451 (Duster), Mechanical, 12A Fuel mixture, Air filter: Removal – Refitting).
Check that the inlet manifold is not obstructed (clogged).
Run TEST 5 Inlet circuit check.
Run TEST 11 Air line at the turbocharger
Check the connection and condition of the air flowmeter connector, component code 799.
Check the condition of the injection computer connector, component code 120.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Check for + 12 V after ignition feed on connection 3FB (or 3FBA) of the connector of the air flowmeter,
component code 799.
Check for + 5 V on connection 3KJ of the connector of the air flowmeter, component code 799.
Check the earth on connection NH on the connector of the air flowmeter, component code 799.
If the connection(s) are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or
Technical Note 9804A (Dacia), Repairing electrical wiring, Wiring: Precautions for repair), repair the wiring,
otherwise replace it.
DCM1.2_V08_DF056

13B-81
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF057
PRESENT
OR
STOREDWATER IN DIESEL FUEL DETECTOR CIRCUIT
CO.1: Open circuit or short circuit to + 12 V
CC.0: Short circuit to earth
1.DEF: Above maximum threshold
NOTESSpecial note:
If fault DF057 is present, the level 1 warning light is lit.
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Check for the presence of water in the diesel filter; if water is present, bleed the diesel filter.
If there is a great amount of water, run the first part of Test 13: Diesel fuel conformity check (Is the fuel cloudy
or does it separate into 2 parts?)
Check the connection and condition of the connector of the water in diesel fuel sensor, component code 414.
Check the connection and condition of the injection computer connector, component code 120.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Check for a voltage between 13V and 14V (with the engine running) and between 11.5 V and 12.5 V (with the
ignition on and engine stopped) on connection 3FB (or 3FB2, or 3FBA) on the connector of the water in diesel
fuel sensor.
If the connection is faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise
replace it.
Check the insulation and continuity of the following connections:
●3WT between components 120 and 414,
●M (or 3WU) between components 120 and 414,
●3FB (or 3FB2 or 3FBA) between components 414 and 983.
If the connection(s) are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or
Technical Note 9804A (Dacia), Repairing electrical wiring, Wiring: Precautions for repair), repair the wiring,
otherwise replace it.
If the fault is still present, replace the water in diesel fuel sensor.
If the fault is still present, contact the Techline.
DCM1.2_V08_DF057

13B-116
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF886
PRESENT
OR
STOREDPRESENCE OF WATER IN THE DIESEL FUEL
1.DEF: Open circuit on the line or presence of water in the diesel fuel
NOTESFault finding procedure application conditions:
The fault is declared present after the engine has been started.
Priorities when dealing with a number of faults:
– DF057 Water in diesel fuel detector circuit,
Special note:
If the fault is present, the level 1 warning light comes on or the water present in
diesel fuel warning light comes on (if present on the instrument panel and if
configured in injection).
Use the Wiring Diagrams Technical Note for Logan, Sandero, Duster, Thalia 2/
Symbol 2 or Kangoo VLL.
Check for the presence of water in the diesel filter; if water is present, bleed the diesel filter.
If there is a great amount of water, run the first part of Test 13: Diesel fuel conformity check (Is the fuel cloudy
or does it separate into 2 parts?)
Check the connection and condition of the connector of the water in diesel fuel sensor, component code 414.
Check the connection and condition of the injection computer connector, component code 120.
If the connectors are faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the connector, otherwise
replace the wiring.
Check for a voltage between 13V and 14V (with the engine running) and between 11.5 V and 12.5 V (with the
ignition on and engine stopped) on connection 3FB (or 3FB2, or 3FBA) on the connector of the water in diesel
fuel sensor, component code 414.
If the connection is faulty and if there is a repair procedure (see Technical Note 6015A (Renault) or Technical
Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the wiring, otherwise
replace it.
DCM1.2_V08_DF886

13B-117
AFTER
REPAIRDeal with any faults declared by the diagnostic tool.
Clear the computer memory.
Carry out a road test followed by another check with the diagnostic tool.
V1 MR-376-X76-13B000$072.mif
DIESEL INJECTION
Fault finding – Interpretation of faults13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
DF886
CONTINUED
A) Make sure the water in diesel fuel detection sensor is properly connected.
– If not, clear the fault,
– Carry out a road test (speed >12 mph (20 km/h) and engine speed >1200 rpm) for more than 30 seconds.
– If the fault does not reappear, end of fault finding procedure.
– If the fault reappears, go to step B.
B) If the sensor is properly connected:
– Bleed the diesel filter unit (see MR 388 (Logan/Sandero), MR 451 (Duster), MR 423 (Thalia 2/Symbol 2) or
MR 374 (Kangoo VLL), Mechanical, 13A, Fuel supply, Diesel filter: Removal - Refitting).
– Clear the fault.
– Carry out a road test (speed >12 mph (20 km/h) and engine speed >1200 rpm) for more than 30 seconds.
If the fault does not reappear, end of fault finding procedure.
C) If the fault recurs:
Check the insulation and continuity of the following connections:
–3WT between components 120 and 414,
–M (or 3WU) between components 120 and 414.
If the connection or connections are faulty and if there is a repair procedure (see Technical Note 6015A (Renault)
or Technical Note 9804A (Dacia), Electrical wiring repair, Wiring: Precautions for repair), repair the wiring,
otherwise replace it.
If none of these checks reveal any faults:
– Replace the water detection sensor (see MR 388 (Logan/Sandero), MR 451 (Duster), MR 423 (Thalia 2/
Symbol 2) or MR 374 (Kangoo VLL), Mechanical, 13A, Fuel supply, Diesel filter: Removal - Refitting).
– Clear the fault.
– Carry out a road test (speed > 12 mph (20 km/h) and engine speed > 1200 rpm) for more than 30 seconds, to
confirm the repair.
Note:
When the water level in the fuel filter unit is below the sensor's electrodes, some driving conditions (turning,
inclines) may cause the injection fault warning light to come on erroneously (the sensor's off-centre position in the
fuel filter unit, combined with the driving condition, shows water detection, and hence the light comes on).
If the fault is still present, contact the Techline.

13B-159
AFTER REPAIRCarry out a road test followed by a check with the diagnostic tool.
V1 MR-376-X76-13B000$150.mif
DIESEL INJECTION
Fault finding – Fault Finding Chart13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
ALP4
CONTINUED
Control the injectors using commands:
– AC005 Cylinder 1 injector,
– AC006 Cylinder 2 injector,
– AC007 Cylinder 3 injector,
– AC008 Cylinder 4 injector.
Can you hear the valve moving when you are 1 metre
from the vehicle?Run TEST 9 Diesel filter check.
If the test is correct, only 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).
Check the high pressure system by running TEST 6 High pressure system check.
Check the condition of the computer connections (for bent pins, signs of oxidation, silicone, etc.) and check that
the computer connectors lock correctly.
Contact the Techline if the customer complaint is still present.
A
NO
YES

13B-169
AFTER REPAIRCarry out a road test followed by a check with the diagnostic tool.
V1 MR-376-X76-13B000$150.mif
DIESEL INJECTION
Fault finding – Fault Finding Chart13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
ALP10
CONTINUED
Is status ET563 Flow capacity function
"ACTIVE"?The vehicle has entered the "Flow capacity
function" program. This function is activated
more easily when: the external temperature is
high, the fuel level in the tank is at 1/4, the
vehicle is laden and if the vehicle speed is high.
Check the condition of the computer connections
(for bent pins, signs of oxidation, silicone, etc.) and
check that the computer connectors lock correctly.Check the diesel filter.
Is it close to the replacement mileage?
Contact the Techline if the customer complaint is
still present.
Replace the diesel filter (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).
Contact the Techline if the customer complaint is
still present.
A
YES
NO
YES

13B-170
AFTER REPAIRCarry out a road test followed by a check with the diagnostic tool.
V1 MR-376-X76-13B000$150.mif
DIESEL INJECTION
Fault finding – Fault Finding Chart13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
ALP11 Loss of power
NOTESSpecial note:
Only address this customer complaint after a complete check with the diagnostic
tool.
See explanation for flow capacity function in system operation.
Is status ET563 Flow capacity function "ACTIVE"?
Using the diagnostic tool, check that the
injector codes (C2I) are correctly
entered on the identification screen. If not,
configure the correct injector codes using
command SC002 Enter injector codesCheck the diesel filter.
Is it close to the replacement mileage?
Replace the diesel filter (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).
Check the air inlet circuit by running TEST 5 Inlet circuit check.
Is the engine oil level correct? Top up the oil level.
NOYES
NO
YES
NO
A
YES
DCM1.2_V08_ALP11