Renault Clio: Diesel return pipe: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Diesel Injection / Diesel return pipe: Removal - Refitting

K9K, and 764 or 772

IMPORTANT

Consult the safety instructions and cleanliness advice and the operation recommendations before carrying out any repairs (see Diesel injection: Repair precautions).

IMPORTANT

Before carrying out any work on the injection system, check using the Diagnostic tool :

• that the rail is not under pressure,
• that the fuel temperature is not too high.

Working on the circuit with the engine running is strictly forbidden.

IMPORTANT

Be careful when removing the injectors or the injection rail as there will be a quantity of fuel in the rail and the union.

IMPORTANT

Loosening a high pressure pipe union when the engine is running is strictly prohibited.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Position the vehicle on a two-post lift (see Vehicle: Towing and lifting) (02A, Lifting equipment).
• Switch off the ignition and wait 30 seconds before starting work on the injection system.
• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Remove the engine undertray.

• Remove the air inlet sleeve (1).

• Disconnect the inlet pressure sensor connector (2).
• Remove:
  • the intercooler air outlet pipe,
  • the air pipe at the intercooler inlet,
  • the turbocharger outlet air pipe.

• Unclip the rail protector cover at (3).
• Remove:
  • the rail protector cover bolts,
  • the rail protector cover.
• Protect the alternator from fuel outflow.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Disconnect the diesel temperature sensor connector (4).
• Clean the diesel return union (5) on the high pressure pump (see 13B, Diesel injection, Diesel injection: Precautions for the repair, 13B-1).
• Disconnect the diesel return union (5) from the high pressure pump.

Note: Make preparations for the fuel outflow.

• Fit blanking plugs to:
  • the diesel return pipe,
  • the high pressure pump.
• Clean the diesel return unions (6) on the injectors (see 13B, Diesel injection, Diesel injection: Precautions for the repair, 13B-1).

First stage in removing the injector fuel return unions

• Using a fine flat-blade screwdriver, push the lower tabs (7) of the injector fuel return union clips towards the rocker cover in order to unfasten them and fully fit them on the rocker cover.

Note: Take care not to dislodge the clip fully from its housing in case it becomes damaged when extracting the diesel return union.

Any clips that become completely separated from a diesel injector that has not been removed must always be replaced: to do this, it is essential that the diesel injector in question is removed (see 13B, Diesel injection, Diesel injector: Removal - Refitting, 13B-83) (13B, Injection).

Second stage in removing the injector fuel return unions

• Using a fine flat-blade screwdriver, push down (A) on the lower tabs of the clips, which were first resting on the rocker cover, without separating them fully from their injectors.
• Manually remove the injector diesel return unions at (B), while pressing (A) on the lower tabs of the clips using a fine flat-blade screwdriver.

Note: With sufficient force applied to the clip while pressing continuously with the screwdriver, the injector diesel return unions will come out effortlessly.

WARNING

Do not use the screwdriver as a lever on the injector fuel return unions.

• Fit blanking plugs on:
  • the diesel return unions on the injectors,
  • the diesel return openings on the injectors.

• Unclip the diesel return pipe from the rocker cover at (8).
• Remove the diesel return pipe.

Note: If the diesel return pipe is to be reused, keep it in a sealed bag throughout the removal operation.

REFITTING

I - REFITTING PREPARATION OPERATION

WARNING

Only remove the blanking plugs from the protected components at the last possible moment.

Also, do not remove the components from their packaging until just before fitting them to the vehicle.

II - REFITTING OPERATION FOR PART CONCERNED

WARNING

Check the condition of the seals on the fuel return unions on the injectors.

Replace the entire diesel return pipe if one of the components is damaged.

• Push the retaining clips for the diesel return unions on the injectors towards the front of the vehicle until they are in their original positions.
• Remove the blanking plugs from the injector fuel return openings, and discard.
• Remove the diesel return pipe from its packaging.
• Lubricate the injector diesel return unions with SILICONE FREE LUBRICANT (see Vehicle: Parts and consumables for the repair) (04B, Consumables - Products) so that the seals are completely covered.

• Offer up the diesel return unions to the injector diesel return openings, starting with injector number 4 (9).
• Clip the injector diesel return unions onto the injectors, starting with injector number 4.

Note: Check that the diesel return unions are clipped on properly.

• Clip the fuel return pipe onto the rocker cover.

III - FINAL OPERATION.

• Connect the diesel temperature sensor connector.
• Refit:
  • the rail protector cover,
  • the intercooler air outlet pipe,
  • the air pipe at the intercooler inlet,
  • the turbocharger outlet air pipe.
• Torque tighten the intercooler inlet air pipe nut on the alternator (8 Nm.)
• Refit the engine protector.
• Reprime the fuel circuit using the priming bulb.
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Check the high pressure circuit (see 13B, Diesel injection, High pressure pipe: Check, 13B-99) (13B, Injection).

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