fuel RENAULT TWINGO RS 2009 2.G Engine Diesel Injection Service Manual

13B-212V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
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. Run TEST 1 Low pressure circuit check.
–Ensure that the correct fuel is being used. Run 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 adapter of 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.
–Run the test cold, PR064 "Coolant temperature" < 30
°C or equal to ambient temperature.
–Engage the starter for 5 seconds.
–Read the maximum rail pressure value PR038 Rail pressure during the test on the diagnostic tool.
A
DCM1.2_V48_TEST6/DCM1.2_V4C_TEST6/DCM1.2_V50_TEST6/DCM1.2_V54_TEST6/DCM1.2_V58_TEST6/DCM1.2_V5C_TEST6

13B-213V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
IMV = fuel flow actuator
TEST 6
CONTINUED
PR038 > 1050 bar?
–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 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 if there is no fuel leak in the high
pressure circuit. Run 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
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, Diesel fuel injector:
Removal - Refitting).Replace the high pressure pump (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, High pressure pump: Removal - Refitting).
A
NOYES
NOYES

13B-216V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 8
CONTINUED 1
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 766 - 768 (Clio III and Modus); K9K 724 (Mégane
II and Scénic II) K9K 740 - 718 (New Twingo); K9K 800 - 802 - 812 (Kangoo 2).
35 ml maximumfor Euro 3 type engines: K9K 750 - 752 (Clio III and Modus),
If the back-leakage volume of any of the injectors is more than the values above, only replace the faulty injector
(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, Diesel fuel 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,
–run 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-217V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 8
CONTINUED 2
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 four tubes of internal diameter 4 mm and approximately 50 cm long 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 adapter,
–disconnect the four injectors electrically,
–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 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, Diesel fuel 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.
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),
–disconnect the four injectors electrically,
–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 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.
A

13B-218V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 9 Diesel filter check
Check the conformity of the diesel filter.
Is the diesel filter in order?Replace the air filter with an original part
(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, 13A, Fuel
mixture, Air 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 holder and shake it firmly while holding the caps in place. Tap the edge of the filter with
a screwdriver handle to detach any contamination. Empty the contents of the filter into a glass container by lifting
a protective plug, then loosening and completely removing the bleed screw.
Are black particles present on 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_V48_TEST9/DCM1.2_V4C_TEST9/DCM1.2_V50_TEST9/DCM1.2_V54_TEST9/DCM1.2_V58_TEST9/DCM1.2_V5C_TEST9

13B-223V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 11 Air line at the turbocharger
Check that the air filter is present.
Check the replacement interval of the air filter on the maintenance booklet.
Compare the part nos. of the fitted air filter on the vehicle and of the air filter recommended by the manufacturer.
Check the direction of fitting of the air filter.
Is the air filter correctly fitted on the vehicle?
Check the condition of the air filter
Visually inspect the condition of the filtering section of the air
filter.
Is 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 364
(Mégane II), 370 (Scénic II), 392
(Clio III), 385 (Modus), 411
(New Twingo) or 417 (Kangoo II)
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 up to the compressor inlet,
–air flowmeter mountings.
Is one of these components incorrect (pipes dislodged,
torn, bent, pierced or kinked)?Replace the faulty parts (see MR
364 (Mégane II), 370 (Scénic II)
392 (Clio III), 385 (Modus), 411
(New Twingo) or 417 (Kangoo II),
Mechanical, 12B,
Turbocharging).
YESNO
YES
NO
YES
NO
A
DCM1.2_V48_TEST11/DCM1.2_V4C_TEST11/DCM1.2_V50_TEST11/DCM1.2_V54_TEST11/DCM1.2_V58_TEST11/DCM1.2_V5C_TEST11

13B-230V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 13 Diesel fuel conformity check
WARNING
During this operation, it is essential to:
–refrain from smoking or bringing incandescent objects close to the work area,
–protect yourself against fuel splashes due to residual pressure in the pipes,
–wear safety goggles with side guards,
–wear leaktight gloves (Nitrile type).
IMPORTANT
–To avoid any corrosion or damage, protect the areas on which fuel is likely to run.
–To prevent impurities from entering the circuit, place protective plugs on all fuel circuit components
exposed to the open air.
Preparations:
Weigh an empty 1300 ml plastic cup (part no. 77 11 171 413) with its cover (part no. 77 11 171 416) using an
electronic scale similar to those used in body paint workshops (for example: PANDA part no. 77 11 224 995).
Record the weight of the empty cup.
This type of plastic cup is used to prepare paint.
Take a 1 l fuel sample from the diesel fuel filter outlet (see MR 364 (Mégane II) or MR 370 (Scénic II), MR 385
(Modus), MR 392 (Clio III), MR 411 (New Twingo), MR 417 (Kangoo 2), Mechanical, 19C, Tank, Fuel tank
draining), using a pneumatic transfer pump (part no. 634-200) and place it in the 1300 ml plastic cup.
Cover the plastic cup with its cover and let it settle for approximately2 minutes.
Is the fuel cloudy or does it
separate into two parts?The diesel fuel contains water and is not compliant.
Drain the fuel circuit, including the tank (see MR 364 (Mégane II)
or MR 370 (Scénic II), MR 385 (Modus), MR 392 (Clio III), MR 411
(New Twingo), MR 417 (Kangoo 2), Mechanical, 19C, Tank, Fuel
tank drain).
YES
NO
A
DCM1.2_V48_TEST13/DCM1.2_V4C_TEST13/DCM1.2_V50_TEST13/DCM1.2_V54_TEST13/DCM1.2_V58_TEST13/DCM1.2_V5C_TEST13

13B-231V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 13
CONTINUED 1
Weigh the diesel fuel and note the fuel weight after subtracting the weight of the empty plastic cup and its cover.
Does the fuel weight fall between the minimum and maximum weights given in the table below?
Calculated weight (g.) Fuel
temperature (
°C)
Min. weight Max. weight
821 846 13
821 846 14
820 845 15
819 844 16
819 844 17
818 843 18
817 842 19
816 841 20
816 841 21
815 840 22
814 839 23
814 839 24
813 838 25
Check the fuel temperature by immersing a thermometer in the plastic cup.
End of test.The fuel is not correct.
If the fuel weight is less than the minimum value then there
is petrol in the diesel fuel.
If the fuel weight is greater than the maximum value then
there is oil in the diesel fuel.
Drain the fuel circuit, including the tank (see MR 364
(Mégane II) or MR 370 (Scénic II), MR 385 (Modus),
MR 392 (Clio III), MR 411 (New Twingo), MR 417
(Kangoo 2), Mechanical, 19C, Tank, Fuel tank drain).
A
YESNO

13B-232V6 MR-413-X44-13B000$190.mif
DIESEL INJECTION
Fault finding – Tests13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
TEST 13
CONTINUED 2
Note:
If the weight measured hits the upper and lower limits, the measurement can be performed with a 2230 ml plastic
cup (part no. 77 11 171 414) and its cover (part no. 77 11 171 417):
–Carry out a quick test drive in order to mix the fuel, then remove 2 l of fuel.
–Perform the test again and check the results by multiplying the limit values by 2.
Contact the Techline if you have doubts or problems with the customer.

13B-237V6 MR-413-X44-13B000$210.mif
DIESEL INJECTION
Fault finding – Fault finding charts13B
DCM 1.2 Injection
Program No.: 4D
Vdiag No.: 48, 4C, 50,
54, 58, 5C
ALP2 The engine will not start
NOTESOnly consult this customer complaint after a complete check with the diagnostic tool.
Check that the fuel tank is correctly filled and that the fuel is correct: run TEST 13 Diesel fuel conformity check.
Check the levels of engine oil and coolant.
Check the air inlet circuit: run TEST 5 Air inlet circuit check.

Is the catalytic converter clogged or damaged?Replace the catalytic converter (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, 19B, Exhaust, Catalytic
converter: Removal - Refitting).
Check the electrical circuit: run TEST 2 Electrical circuit check.
Check the electrical conformity of the heater plugs (the resistance value of the heater plug must be less
than 2 Ω).

Is the timing set correctly? Carry out the necessary repairs.
Visually check the condition of the engine wiring harness.
YES
NO
NO
YES
A
DCM1.2_V48_ALP2/DCM1.2_V4C_ALP2/DCM1.2_V50_ALP2/DCM1.2_V54_ALP2/DCM1.2_V58_ALP2/DCM1.2_V5C_ALP2