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

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-11V1 MR-376-X76-13B000$030.mif
DIESEL INJECTION
Fault finding – System operation13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
An accelerometer is used to monitor some of the fuel injection deviation. This has several roles:
– Protecting the engine by detecting injection leaks (disabled on the basic version).
– Checking the pilot quantity by measuring deviation and dispersion.
By changing both the injection duration and advance, the quantity of fuel injected and the mixture's moment of
ignition can be readjusted.
Rail pressure check
The quality of combustion is influenced by the size of the atomised droplets in the cylinder.
In the combustion chamber, smaller fuel droplets will have time to burn fully, and will not produce smoke or
unburned particles. To meet emission control requirements, the droplet size, and therefore the size of the injection
holes, must be reduced.
With smaller holes, less fuel will be able to be introduced at a given pressure, which limits the power. To offset this
disadvantage, the quantity of fuel injected must be increased, which means increased pressure (and more holes in
the injector nozzles).
For the DCM 1.2 injection system, the pressure reaches 1400 bar - 1600 bar in the rail and must be constantly
regulated. The measuring circuit comprises an active pressure sensor on the rail connected to an analogue port on
the computer.
The high pressure pump is supplied at low pressure (5bar) by a built-in transfer pump. This pump supplies the rail.
The rail filling pressure is controlled by the fuel flow actuator (IMV) and the discharge pressure is controlled by the
injector valves. This compensates for pressure drops. The flow actuator enables the high pressure pump to supply
the exact quantity of diesel fuel required to maintain the rail pressure. This mechanism minimises the heat generated
and improves engine output.
In order to discharge the rail using the injector valves, the valves are actuated by short electrical pulses which are:
– short enough in amplitude not to open the injector (and pass through the return circuit from the injectors),
– long enough in time to open the valves and discharge the rail.
The fuel surplus is sent back to the fuel filter or the tank, according to its flow. If there is no fuel flow actuator control,
the rail pressure is limited by a discharge valve fitted on the pump.
New pump chamber filling procedure (pump boosting)
The pump lubrication goes through a booster cycle during which the pump is filled and pressurised before
"transferring" the diesel fuel to the rail.
This lubrication goes through programming called "filling the new pump chamber", which prohibits starting for
approximately 10 seconds (the time required to fill the pump and to start if the key is released before the end of this
"first starting" phase). Power latch is not necessary before attempting to start the vehicle again.
This procedure runs when a computer is replaced if the parameters relating to the rail pressure have not been
copied into the new computer, or otherwise, after reprogramming of the injection computer.

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-16V1 MR-376-X76-13B000$030.mif
DIESEL INJECTION
Fault finding – System operation13B
DCM 1.2 Injection
Program no.: 4C
Vdiag No.: 08
Faults that activate the OBD warning light
Water present in fuel warning light (depending on the instrument panel)
This warning light is used to warn the driver about the presence of water in the fuel filter, which leads to engine
damage. It lights up for 3 seconds when the power comes on (automatic test procedure). When the vehicle is not
fitted with this warning light or if it is not configured, this function is provided by the Level 1 warning light. Tool fault Diagnostic tool title Specification
DF016EGR control circuitCO - CO.0
CC.1 - 1.DEF
DF026Cylinder 1 injector circuit controlCO - CC
DF027Cylinder 2 injector circuit controlCO - CC
DF028Cylinder 3 injector circuit controlCO - CC
DF029Cylinder 4 injector circuit controlCO - CC
DF038Computer3.DEF
DF107Computer memory2.DEF
DF114EGR solenoid valve circuit4.DEF
DF209EGR valve position sensor circuitCC.1-CO.0

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-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