Renault Clio: Injector rail - Injectors: Removal - Refitting

Renault Clio III (2005-2013) Service Manual / Engine And Peripherals / Fuel Supply / Injector rail - Injectors: Removal - Refitting

D4F, and 740 or 742 or 764

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting).
• Remove:
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17),
  • the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45).

IMPORTANT

During this operation, it is essential to:

• be aware of fuel splashes when disconnecting the supply union,
• protect sensitive areas from fuel outflow.

IMPORTANT

Wear gloves during the operation.

II - OPERATION FOR REMOVAL OF PART CONCERNED

ON THE WORKBENCH

• Disconnect the injector wiring harness.
• Remove:
  • the mounting bolts (1) from the injector rail,
  • the injector rail.
• Remove the injector wiring harness.

• Remove:
  • the clips (2) from the injectors,
  • the injectors (3).

REFITTING

I - REFITTING PREPARATION OPERATION

• Always replace:
  • the injectors' O-rings,
  • the injector mounting clips,

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the injectors,
  • the injector clips,
• Refit the injector wiring harness.
• Refit:
  • the injector rail,
  • the injector rail mounting bolts,
• Connect the injector wiring harness.

III - FINAL OPERATION.

• Refit:
  • the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45),
  • the air filter box (see 12A, Fuel mixture, Air filter unit: Removal - Refitting, 12A-17).
• Connect the battery (see Battery: Removal - Refitting).

K4J - K4M

IMPORTANT

During this operation, be sure to:

• be careful of fuel splashes when disconnecting the union.

IMPORTANT

Wear goggles with side protectors for this operation.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting) (80A, Battery).
• Remove the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45).

• Disconnect the fuel supply pipe union from the injector rail (1).

WARNING

To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

• Insert the blanking plugs.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Remove:
  • the injector rail bolts (2),
  • the " injector rail-injector " assembly by pulling it carefully towards the front of the vehicle.
• Disconnect the connector from each injector (3).

• Remove:
  • the injector retaining clips (4),
  • the injectors (5).

REFITTING

I - REFITTING PREPARATION OPERATION

• parts always to be replaced: injector clip on injector rail.
• parts always to be replaced: injector seal.

II - REFITTING PART CONCERNED

• Refit:
  • new seals on each injector,
  • the injectors on the injector rail,
  • a new clip on each injector.
• Fit the " injector rail-injector " assembly.
• Torque tighten the injector rail bolts (10 N.m).
• Connect the connector on each injector.

III - FINAL OPERATION

• Remove the blanking plugs.
• Connect the fuel supply pipe union on the injector rail.
• Refit the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A- 45).
• Connect the battery (see Battery: Removal - Refitting) (80A, Battery).

M4R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting).
• Remove the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A- 45).

• Disconnect:
  • the fuel supply union (1) on the injector rail,
  • the injector connectors (2).

IMPORTANT

During this operation, it is essential to:

• be aware of fuel splashes when disconnecting the supply union,
• protect sensitive areas from fuel outflow.

IMPORTANT

Wear gloves during the operation.

II - REMOVAL OF PART CONCERNED

• Remove:
  • in order, the injector rail mounting bolts,
  • the " injector rail-injector " assembly by pulling carefully towards the front of the vehicle.

• Remove:
  • the injector mounting clips,
  • the injectors.

REFITTING

I - REFITTING PREPARATION OPERATION

• The O-rings and the injector mounting clips must be replaced with new ones.

  The O-rings are different, do not mix them up. O-ring (3) is green and O-ring (4) is black.

II - REFITTING PART CONCERNED

• Refit the " injector rail-injector " assembly.

• Tighten to torque and in order the injector rail mounting bolts (25 Nm).

III - FINAL OPERATION

• Connect:
  • the injector connectors,
  • the fuel supply union onto the injector rail,
• Refit the inlet manifold (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45).
• Connect the battery (see Battery: Removal - Refitting).

F4R

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Disconnect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Remove:
  • the motorised throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, 12A-33),
  • the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45).

II - OPERATION FOR REMOVAL OF PART CONCERNED

IMPORTANT

Wear gloves during the operation.

IMPORTANT

During this operation, be sure to:

• beware of fuel splashes when disconnecting the union,
• protect sensitive areas from fuel outflow.

• Disconnect:
  • the injector connectors (1),
  • the fuel supply union (2) on the injector rail.

• Remove:
  • the injector rail mounting bolts (3),
  • the injector rail, pulling it carefully.

Separating the injectors from the injector rail

• On a clean workbench:
  • remove the retaining clips (4) from the injectors,
  • separate the injectors from the injector rail.

REFITTING

I - REFITTING PREPARATIONS OPERATION

• The O-rings and the injector mounting clips must be replaced with new ones.

Separating the injectors from the injector rail

• On a clean workbench:
  • assemble the injectors fitted with new seals on the injector rail,
  • refit the injector retaining clips.

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the injector rail fitted with its injectors with new seals,
  • the injector rail mounting bolts,
• Torque tighten the injector rail mounting bolts (10Nm).
• Connect:
  • the fuel supply union on the injector rail,
  • the injector connectors.

III - FINAL OPERATION.

• Refit:
  • the intake distributor (see 12A, Fuel mixture, Inlet distributor: Removal - Refitting, 12A-45),
  • the throttle valve (see 12A, Fuel mixture, Throttle valve: Removal - Refitting, 12A-33).
• Connect the battery (see Battery: Removal - Refitting) (MR 392, 80A, Battery).
• Use the Diagnostic tool to check that there are no faults stored by the computer; clear any faults if need be.

D4F, and 784 or 786

IMPORTANT

During this operation, be sure to:

• be careful of fuel splashes when disconnecting the union.

IMPORTANT

Wear goggles with side protectors for this operation.

IMPORTANT

Wear latex gloves during the operation.

WARNING

To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

REMOVAL

I - REMOVAL PREPARATION OPERATION

• Remove the front engine cover.
• Disconnect the battery (see ) (MR 392, 80A, Battery).

• Disconnect the air filter unit air inlet pipe (1).

• Remove the turbocharger air outlet pipe bolt (2) from the intake distributor.
• Remove the turbocharger air outlet pipe clip (3) from the turbocharger.

Note: If the clip (4) is removed from the heat resistant protector, the latter must be replaced.

• Move aside the turbocharger air outlet pipe.

• Detach at (5) :
  • the throttle valve wiring harness,
  • the vacuum pipe.
• Remove the intercooler air outlet pipe bolts (6).
• Move the intercooler outlet air pipe to one side.

II - OPERATION FOR REMOVAL OF PART CONCERNED

• Disconnect:
  • the wiring harness connector (7) from the injector rail,
  • the turbocharger pressure sensor connector (8),
  • the connector (9) from the oxygen sensor,
  • the petrol inlet duct (10) from the injector rail.

• Remove:
  • the injector rail bolts (11),
  • the " injector rail - injector " assembly by pulling it gently.
• Disconnect the wiring harness connectors on the injectors.
• Remove the wiring harness from the " injector rail - injector " assembly.

• Remove:
  • the clips (12) from the injectors,
  • the injectors (13).

REFITTING

I - REFITTING PREPARATIONS OPERATION

• Always replace:
  • the injectors' O-rings,
  • the injector clips,

II - REFITTING OPERATION FOR PART CONCERNED

• Refit:
  • the injectors with new seals,
  • the new injector clips,
  • the injector rail - injector wiring harness.
• Connect the injector wiring harness connectors.
• Refit:
  • the " injector rail - injector " assembly making sure the centring pins are correctly positioned on the intake distributor,
  • the " injector rail - injector " assembly bolts.
• Torque tighten the injector rail - injector bolts (4.5 Nm).
• Connect:
  • the petrol inlet duct to the injector rail,
  • the oxygen sensor connector,
  • the turbocharger pressure sensor connector,
  • the wiring harness connector to the injector rail.

III - FINAL OPERATION.

• Refit:
  • the intercooler outlet air pipe,
  • the intercooler air outlet pipe bolts.
• Clip:
  • the vacuum pipe,
  • the throttle valve wiring harness.
• Refit the turbocharger air outlet pipe on the turbocharger.
• Attach the turbocharger air outlet pipe to the turbocharger.
• Refit the turbocharger air outlet pipe bolt on the intake distributor.
• Refit the air filter box air inlet pipe.
• Connect the battery (see ) (MR 392, 80A, Battery).
• Refit the engine cover.

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