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

13B-8V6 MR-413-X44-13B000$020.mif
13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
I. HAZARDS ASSOCIATED WITH CONTAMINATION
The high pressure direct injection system is highly sensitive to contamination. The risks associated with
contamination are:
–damage to or destruction of the high pressure injection system,
–components jamming,
–components losing seal integrity.
All After-Sales operations must be performed under very clean conditions. This means that no impurities
(particles a few microns in size) should have entered the system during dismantling.
The cleanliness principle must be applied from the filter to the injectors.
What are the sources of contamination?
–metal or plastic swarf,
–paint,
–fibres: from cardboard,
from brushes,
from paper,
from clothing,
from cloths.
–foreign bodies such as hair,
–ambient air
–etc.
II. ADVICE TO BE FOLLOWED BEFORE ANY OPERATION
Check that you have plugs for the unions to be opened (set of plugs available from the Parts Department). The plugs
are single-use only. After use, they must be discarded (once used they are soiled and cleaning is not sufficient to
make them reusable). Unused plugs must also be discarded.
Check that you have hermetically resealable plastic bags for storing removed parts. Parts stored in this way will be
less susceptible to the risk of contamination. The bags are single-use only. Once used, they must be thrown out.
Use lint-free cleaning cloths (cloth part reference 77 11 211 707). Using normal cloth or paper is prohibited. They are
not lint-free and could contaminate the fuel circuit. Each cloth should only be used once.
Use fresh cleaning agent for each operation (used cleaning agent is contaminated). Pour it into an uncontaminated
container.
For each operation, use a clean brush in good condition (the brush must not shed its bristles).
Use a brush and cleaning agent to clean the unions to be opened.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 electrical connection faults.
IMPORTANT
Before any work is carried out on the high pressure injection system, protect:
–the accessories and timing belts,
–the electrical accessories, (starter, alternator, electric power-assisted steering pump),
–the flywheel surface, to prevent any diesel from running onto the clutch friction plate.
DIESEL INJECTION
Fault finding – Cleanliness guidelines

13B-10V6 MR-413-X44-13B000$030.mif
13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
High and low pressure pump:
This pump is located upstream of the common rail.
Solenoid injectors:
The injectors are fitted on the cylinder head after the common rail.
Turbocharger:
The turbocharger is located after the exhaust manifold.
Turbocharger control solenoid valve (K9K 724, 766, 802, and 812 only):
This solenoid valve is located close to the turbocharger, is position depends on the vehicle.
Air flowmeter:
The air mass flow meter is located at the air circuit inlet and integrates the air temperature sensor.
EGR valve:
The EGR valve is located between the inlet manifold and the exhaust manifold.
Accelerator pedal potentiometer:
The potentiometer is located on the accelerator pedal.
Clutch pedal switch:
The switch is located on the clutch pedal.
Catalytic converter:
The catalytic converter is located downstream of the turbocharger on the exhaust system.
Cruise control/speed limiter on/off switch:
This switch is located in the passenger compartment to the left of the steering wheel near the lighting dimmer.
Heater plugs:
The heater plugs are located on the cylinder head.
Inlet manifold pressure sensor:
The inlet manifold pressure sensor is located upstream of the turbocharger.
Air temperature sensor:
The air temperature sensor is located at the air circuit inlet, in place of the air flowmeter or integrated into it if
the flowmeter is present, and/or in the inlet manifold.
Water in diesel fuel sensor (New Twingo and Kangoo 2 only):
This sensor is located in the diesel filter.
Fuel temperature sensor:
This sensor is positioned on the injection pump.
Rail pressure sensor:
This sensor is fitted to the common rail.
Atmospheric pressure sensor:
This sensor is incorporated in the computer.
TDC sensor:
This sensor is located on the flywheel.
Camshaft sensor:
This sensor is located at the end of the camshaft.
DIESEL INJECTION
Fault finding – List and location of components

13B-15V6 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
Angular position measurement
Engine speed sensor:
The angular position is measured using a magneto-inductive sensor triggered by machined teeth on the shaft
flywheel. This flywheel has sixty teeth, six degrees apart, minus two missing teeth that form a notch.
Cylinder reference sensor:
A second sensor (Hall effect) triggered by a machined tooth on the high pressure pump drive pulley (synchronised
with the camshaft), turning at half the engine speed, supplies a signal about the progress of the injection cycle.
By comparing the signals from these two sensors, the computer's APS module (Angular Position Subsystem) can
supply the entire system with the synchronisation factors, which are: the angular position of the flywheel, the engine
speed, the number of the active injector and the injection cycle timing.
This module also supplies the system with the engine speed signal.
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 a procedure called new pump chamber filling, which prevents starting for
approximately 10 seconds, which is the time required for filling the pump and starting. For vehicles with keys,
if the key is released before the end of this "initial starting" phase there is no need for a power latch phase to be
completed before a fresh attempt to start the vehicle.
This procedure is run after the first start in the factory, after a computer is replaced if the parameters relating to
the rail pressure have not been copied into the new computer, and also after reprogramming of the injection
computer.
Variable Low Capacity (VLC) output function
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 (depending on
the vehicle, this programming can be confirmed by ET563 Flow capacity function). This is normal operation of
the injection system.
Function: Air flow management
EGR valve control
K9K 766 and 768 (Euro 4) engines (fitted on Clio III and Modus) and K9K 724 (Euro 4) engines (fitted on
Mégane II and Scénic II) and K9K 740 engines (fitted on New Twingo) and K9K 800, 802 and 812 engines
(fitted on Kangoo 2):
The EGR (Exhaust Gas Recirculation) system consists of a DC proportional EGR valve, which incorporates
a valve position feedback potentiometer. The EGR valve is closed-loop controlled based on its position via
the potentiometer and/or based on changes in the estimated air flow.
K9K 750 and 752 (Euro 3) engines (fitted on Clio III and Modus):
The EGR system (Exhaust Gas Recirculation) consists of an EGR solenoid valve, which incorporates a valve
position feedback potentiometer. The EGR valve is closed-loop controlled based on its position via
the potentiometer and/or based on changes in the estimated air flow.

13B-18V6 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
Cruise control - speed limiter (CC / SL) management
When activated, the cruise control function maintains the vehicle at a preselected speed, regardless of the
driving conditions encountered. Using the control buttons, the driver can increase or reduce the speed of the vehicle.
The cruise control function can be deactivated either using the control buttons, or by switching off the cruise control
function selector switch or when system events are detected such as the brake or clutch pedal being depressed,
or when system errors are detected such as an inconsistent vehicle speed or excessive vehicle deceleration.
The cruise control function can also be temporarily overridden when the driver wants to resume control of
the vehicle and exceed the selected cruising speed by pressing the accelerator pedal, which causes the controlled
fuel flow to be exceeded. The cruising speed is resumed when the driver releases the accelerator pedal.
It is possible to reactivate cruise control and to return to the last cruising speed after the function has been
deactivated for whatever reason, during the same cycle of use (computer supply voltage not cut off). The vehicle will
then attempt to return to the cruising speed using a controlled vehicle acceleration rate.
When activated (using the selection switch), the vehicle speed limiter function limits the vehicle speed to
a preselected value.
The driver controls the vehicle in the normal way using the accelerator pedal until the limit speed is reached. If an
attempt is made to exceed this speed, the system will ignore the pedal request and will limit the vehicle speed,
provided that the driver continues to depress the accelerator pedal.
As with the cruise control function, the limit speed can be altered using the control buttons by pressing briefly or by
pressing and holding (pressing and holding not active on Kangoo 2).
For safety reasons, the limit speed can be exceeded by depressing the accelerator pedal beyond the pedal position
limit value. The vehicle speed will then be totally controlled by the pedal until the speed falls back below the cruising
speed when the speed limiter function will once again be reactivated.
The driver has the following controls for the cruise control - speed limiter function:
–accelerator pedal,
–brake pedal,
–clutch pedal (not for sequential gearbox),
–function selector switch, used to select cruise control or speed limiter operating mode,
–activation switch on the steering wheel,
–required speed adjustment switch on the steering wheel.

13B-21V6 MR-413-X44-13B000$050.mif
13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
High and low pressure pump:
The pump draws in fuel from the tank, which passes through a fuel filter and supplies the fuel injectors.
Injector rail:
The injector rail receives and redistributes fuel under high pressure to the injectors.
Solenoid injectors:
These injectors enable rapid, precise metering of the quantity of fuel injected, with excellent injection process
repetitiveness.
Catalytic converter:
Its role is to convert pollutant gases into harmless gases.
Heater plugs:
The heater plugs create a hot point in the combustion chamber to improve starting in low temperature conditions.
They are also used to improve idle speed stability under some conditions.
Turbocharger:
The turbocharger is used to supply the engine with more air.
Turbocharger control solenoid valve (K9K 724, 766, 802, and 812 only):
This solenoid valve controls the turbocharger wastegate.
Air flowmeter (if present on the vehicle):
The flowmeter measures the amount of fresh air which goes back into the engine.
EGR valve:
The exhaust gas recirculation enables nitrogen oxide (NOx) emissions to be reduced significantly.
Cruise control - speed limiter on - off switch:
This switch turns the cruise control/speed limiter on or off.
Accelerator pedal potentiometer:
The accelerator potentiometer informs the computer about the position of the accelerator pedal (engine load).
Clutch pedal switch:
The clutch pedal switch informs the computer about the pedal status.
TDC sensor:
The angular position is measured using a magneto-inductive sensor triggered by machined teeth on the flywheel.
This sensor gives the engine speed as well as the position of the crankshaft for injection.
Camshaft sensor:
This sensor gives a signal to perform the injection cycle.
When the piston of cylinder 1 is at top dead centre (TDC), it can be either at the end of the compression stroke
or at the end of the exhaust stroke. The camshaft sensor enables a distinction to be made between these two states.
Refrigerant pressure sensor:
Its role is to measure the refrigerant pressure in the air conditioning circuit.
Engine coolant temperature sensor:
The engine coolant temperature sensor informs the computer about the engine coolant temperature.
Water in diesel fuel sensor (New Twingo and Kangoo 2 only):
This sensor determines if there is water present in the diesel fuel.
DIESEL INJECTION
Fault finding – Role of components

13B-25V6 MR-413-X44-13B000$060.mif
DIESEL INJECTION
Fault finding – Replacement of components13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
REPLACING THE INJECTORS:
The system can be set up using the diagnostic socket with the RENAULT CLIP diagnostic tool.
The C2I parameters must be replaced after replacing an injector or injectors.
To do this, reprogram C2I into the computer using the following commands:
Cylinder 1 injector: command VP001 Cylinder 1 injector code (cylinder at flywheel end)
Cylinder 2 injector: command VP002 Cylinder 2 injector code
Cylinder 3 injector: command VP003 Cylinder 3 injector code
Cylinder 4 injector: command VP004 Cylinder 4 injector code
The four C2I can be entered using command SC002 Enter injector codes.
The technician can use the appropriate command to re-enter the new C2I for the replaced injector and to erase
the old C2I.
Only after simultaneously replacing at least three injectors, reset the injector adaptives, using command
RZ004 Pressure regulation adaptives.
HIGH PRESSURE PUMP REPLACEMENT
PROCEDURE
Refer to Technical Note 5011A, Repriming Delphi high pressure pumps on K9K engines.
EGR VALVE REPLACEMENT:
If replacing the EGR valve, it is essential to program the new valve's offset position. To do this, clear the old offset
using the EGR programming clearing procedure and run command RZ002 EGR adaptives. Note:
C2I (individual injector correction) is a calibration carried out in the factory on each injector to adjust the flow
of each injector precisely.
The correction values are written on a label affixed to each injector and then are entered in the computer, which
can then actuate each injector by taking account of their manufacturing variation.
IMPORTANT
When reprogramming the computer, only carry out the following procedure after command AC028 Static
test has been run (see Computer reprogramming operation).

13B-156
AFTER REPAIRDeal with any faults. Clear the faults from the computer memory.
Switch off the ignition and carry out a road test followed by a test with the diagnostic
tool.
V6 MR-413-X44-13B000$150.mif
DIESEL INJECTION
Fault finding – Interpretation of statuses13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
ET415
CONTINUED 2
STATUS 4Cancel button pressed
The cruise control/speed limiter function is deactivated each time the suspend button is
pressed.
Status ET415 becomes STATUS 4, when driving if:
–either the cruise control is active or
–the speed limiter is active,
–and the driver presses the 0 button.
This action deactivates the Cruise control/Speed limiter.
Reinitialise status ET415 on the injection computer by running command RZ001
"Fault memory".
If status ET415 becomes STATUS 4 without pressing the 0 button, consult the
interpretation of status ET703 Cruise control / speed limiter buttons and run fault
finding on the R/0 control button located on the right-hand side of the steering wheel.
STATUS 5Cruise control or speed limiter monitoring
This status appears when the vehicle brakes or decelerates sharply without the injection
computer receiving a signal indicating that the brake pedal switch has been pressed.
If status ET415 is STATUS 5, consult the interpretation:
–of status ET042 Cruise control/Speed limiter
–of status ET703 Cruise control/Speed limiter buttons,
–of status ET704 Brake switch no. 1,
–and status ET705 Brake switch no. 2,
to test the cruise control/speed limiter system components and find the defective
component.
Also check the operation of the accelerator pedal, and check for any faults on the
diagnostic tool relating to this component. Deal with them if necessary.
Reinitialise status ET415 on the injection computer by running command RZ001
"Fault memory".
If status ET415 becomes STATUS 5, deal with the present or stored faults in the injection
computer.
If the fault is still present, contact the Techline.

13B-162
AFTER REPAIRDeal with any faults. Clear the faults from the computer memory.
Switch off the ignition and carry out a road test followed by a test with the diagnostic
tool.
V6 MR-413-X44-13B000$150.mif
DIESEL INJECTION
Fault finding – Interpretation of statuses13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
ET703CRUISE CONTROL/SPEED LIMITER BUTTONS
STATUS DEFINITIONINACTIVE: This status indicates that no button has been pressed.
INCREASE: This status indicates that the increase button is pressed.
DECREASE: This status indicates that the decrease button is pressed.
SUSPEND: This status indicates that the 0 is pressed.
RESUME: This status indicates that the R button is pressed.
Conformity check: Engine stopped, ignition on or engine running.
INACTIVEStatus ET703 becomes INACTIVE when none of the cruise control/speed limiter buttons
is pressed. These buttons are located on the steering wheel.
To be able to remove the driver's airbag and carry out the measurements safely
(see 88C, Airbag and pretensioners).
If status ET703 does not display INACTIVE,
●check the condition of the cruise control/speed limiter ± button and the condition
of its connector.
●check the condition of the cruise control/speed limiter R/0 button and the
condition of its connector.
Repair if necessary.
INCREASEStatus ET703 becomes INCREASE when the + cruise control/speed limiter button is
pressed. This button is on the steering wheel, on the left-hand side.
To be able to remove the driver's airbag and carry out the measurements safely
(see 88C, Airbag and pretensioners).
If status ET703 does not display INCREASE, check the condition of the cruise control/
speed limiter
± button, and the condition of its connector. Repair if necessary.
Measure the resistance of the button between connections 86M and 86G while
pressing on the + button.
If the resistance is not approximately 300 Ω, check the continuity of the connection when
the button is in the rest position.
If there is continuity, replace the
± control button (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, 83D, Cruise control, Steering wheel switch: Removal -
Refitting).
DCM1.2_V48_ET703/DCM1.2_V4C_ET703/DCM1.2_V50_ET703/DCM1.2_V54_ET703/DCM1.2_V58_ET703/DCM1.2_V5C_ET703

13B-163
AFTER REPAIRDeal with any faults. Clear the faults from the computer memory.
Switch off the ignition and carry out a road test followed by a test with the diagnostic
tool.
V6 MR-413-X44-13B000$150.mif
DIESEL INJECTION
Fault finding – Interpretation of statuses13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
ET703
CONTINUED 1
DECREASEStatus ET703 becomes DECREASE when the - button of the cruise control/speed limiter
is pressed. This button is on the steering wheel, on the left-hand side.
To be able to remove the driver's airbag and carry out the measurements safely
(see 88C, Airbag and pretensioners).
If status ET703 does not display DECREASE, check the condition of the cruise control/
speed limiter
± button, and the condition of its connector.
If there is a repair method (see Technical Note 6015A, Repairing electrical wiring,
Wiring: Precautions for repair), repair the wiring, otherwise replace it.
Measure the resistance of the button between connections 86M and 86G while
pressing on the - button.
If the resistance is not approximately 100 Ω, check the continuity of the connection when
the button is not pressed.
If there is continuity, replace the
± control button (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, 83D, Cruise control, Steering wheel switch: Removal -
Refitting).
SUSPENDStatus ET703 becomes SUSPEND when the cruise control/speed limiter "0" button is
pressed. This button is located on the steering wheel, to the right.
To be able to remove the driver's airbag and carry out the measurements safely
(see 88C, Airbag and pretensioners).
If status ET703 does not become SUSPEND, check the condition of the cruise control/
speed limiter "R/0" button and the condition of its connector.
If there is a repair method (see Technical Note 6015A, Repairing electrical wiring,
Wiring: Precautions for repair), repair the wiring, otherwise replace it.
Measure the resistance of the button between connections 86M and 86G while
pressing on the 0 button.
If the resistance is not about 0 Ω, replace the R/0 control button (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, 83D, Cruise control, Steering wheel switch: Removal
- Refitting).
If there is continuity, replace the R/0 control button (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, 83D, Cruise control, Steering wheel switch: Removal -
Refitting).

13B-164
AFTER REPAIRDeal with any faults. Clear the faults from the computer memory.
Switch off the ignition and carry out a road test followed by a test with the diagnostic
tool.
V6 MR-413-X44-13B000$150.mif
DIESEL INJECTION
Fault finding – Interpretation of statuses13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
ET703
CONTINUED 2
RESUMEStatus ET703 becomes RESUME when the cruise control/speed limiter "R" button is
pressed. This button is located on the steering wheel, to the right.
To be able to remove the driver's airbag and carry out the measurements safely
(see 88C, Airbag and pretensioners).
If status ET703 does not change to RESUME, check the condition of the cruise control/
speed limiter R/0 button, and the condition of its connector.
If there is a repair method (see Technical Note 6015A, Repairing electrical wiring,
Wiring: Precautions for repair), repair the wiring, otherwise replace it.
Measure the resistance of the button between connections 86M and 86G while
pressing on the R button.
If the resistance is not approximately 900 Ω, check the continuity of the connection when
the button is not pressed.
If there is continuity, replace the R/0 control button (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, 83D, Cruise control, Steering wheel switch: Removal -
Refitting).