Renault K9K 1.5L DCI Engine Service & Repair Manual

© Renault s.a.s. 2006 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. The reproduction or translation in part of whole of the present document, as well as the use of the spare parts reference numbering system, are prohibited without the prior written consent of Renault. 77 11 328 422 MARCH 2004 Edition Anglaise Technical Note6006A KXX, and K9K K9K engine Engine workshop repair manual Edition 2

K9K engine Contents Page K9K engine ContentsPage 10A ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications 10A-1 Engine: Precautions for repair 10A-4 Engine: Parts and consumables for the repair work 10A-14 Upper engine: Tightening torque 10A-15 Lower engine: Tightening torque 10A-20 Diesel injection: Tightening torque 10A-23 Accessories belt: Tightening torque 10A-26 Upper engine: Specifications 10A-28 Engine peripherals: Specifications 10A-36 Standard replacement 10A-46 Special tooling 10A-47 Equipment 10A-65 Engine: Dismantling 10A-84 Accessories belt: Removal 10A-89 Timing - cylinder head: Removal 10A-90 Cylinder head: Dismantling 10A-113 Upper engine: Cleaning 10A-129 Upper engine: Checking 10A-135 Cylinder head: Refitting 10A-144 Cylinder block: Dismantling 10A-192 Running gear:Removal 10A-204 Piston base cooling jet: Removal 10A-207 Lower engine: Cleaning 10A-209 Lower engine: Check 10A-211 Piston base cooling jet: Refitting 10A-224 Running gear Refitting 10A-227 Cylinder block: Refitting 10A-239 Timing - cylinder head: Refitting 10A-280 Accessories belt: Refitting 10A-326 Engine: Refitting 10A-329 Timing belt: Removal 10A-336 Timing belts: Refitting 10A-351 10A ENGINE AND LOWER ENGINE ASSEMBLY

10A- 1 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications 10A I - ENGINE IDENTIFICATION The engine can be identified by markings (6) located on the cylinder block. Details of markings The markings consist of: - (1) : the engine type - (2) : the engine approval letter - (3) : the engine suffix - (4) : the factory where the engine was fitted - (5) : the engine production number 107307 113741 19858

10A- 2 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications 10A II - ENGINE SPECIFICATION TABLES Vehicle After- Sales Type: Engine type Engine suffix Cubic capa- city (cc) Bore (mm) Stroke (mm) Com- pression ratio Renault CLIO II XB07 XB1W XB24 K9K 700 1461 76 80.5 18.25:1 XB08 702 XB07 704 XB24 704 17.9:1 XB23 XB2E 706 XB09 710 18.25:1 XB2G 712 17.9:1 Renault KANGOO XC07 K9K 700 1461 76 80.5 18.25:1 XC08 XC1S 702 XC07 XC08 704 XC1R 704 17.6: 1 XC09 710 18.25:1 XC1E 714 17.9:1 XC1F 716 XC1G 718 Renault MEGANE II XM0F K9K 722 1461 76 80.5 18.25:1 XM0T 722 17.6:1 XM1F 724 17.9:1 XM02 728, 729 17.9:1 XM13 728 17.6: 1 XM1E 732 15.3:1 Renault CLIO III XR0H K9K 764 1461 76 80.5 15.3:1 XR0F 766 17.9:1 XR0G 768

10A- 3 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Specifications 10A Renault MODUS XP0D K9K 750 1461 76 80.5 17.6: 1 XP08 XP0E 752 XP0F 760 17.9:1 XP0G 762 ,768 XP0H 764 15.3:1 XP0F 766 17.9:1 Renault DACIA XS0J K9K 790 1461 76 80.5 17.9:1 XS0K 792 Nissan ALMERA - K9K 260 1461 76 80.5 18.25:1 Nissan MICRA - K9K 270, 272, 274, 276 1461 76 80.5 18.25:1 Vehicle After- Sales Type: Engine type Engine suffix Cubic capa- city (cc) Bore (mm) Stroke (mm) Com- pression ratio

10A- 4 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair 10A I - SAFETY General information All information contained in these manuals is intended exclusively for automotive industry professionals. The documentation is intended to cover all vehicles in the RENAULT range throughout the world, but may not cover equipment designed for use in specific countries. The methods and fault finding procedures recommended and described in this manual have been designed by automotive industry repair professionals. a - General recommendations Observe basic principles of vehicle repair. The quality of repair depends first and foremost on the care exercised by the person in carrying it out. To ensure good repair: - use recommended professional products and original Renault parts, - observe the tightening torques, - replace the recommended roll pins, nuts or bolts, after each removal, - clean and degrease the sections to be bonded, to ensure they bond correctly. The design quality of our vehicles demands that no- thing is left to chance in making a good repair, and it is essential to refit parts or components exactly as they were originally (for instance: heat shields, wiring routing, pipe routing). Use professional products and apply them with care, for example do not apply too much sealant to the joint face. b - Special tooling - ease of use The repair procedures have been designed using special tools; they must therefore be carried out using these tools to ensure a high degree of working safety and quality of repair. The equipment we have approved has undergone ca- reful research and testing, and must be used and main- tained with care. c - Reliability - updating Since component specifications are subject to change during their commercial life, it is essential to check whether there are any Technical Note updates when seeking information. d - Safety Certain devices and parts must be handled with particular attention to safety and cleanliness and, above all, with due care. The safety symbol used in this manual indicates that special attention must be paid to the procedure or the tightening torque values. Working safely: - use appropriate tools which are in good condition (using « multipurpose » tools, such as adjustable pliers, should be avoided wherever possible), - adopt a correct posture and technique when perfor- ming heavy work or lifting loads, - check that the working area is clean and tidy during the operation, - use personal protection (gloves, safety goggles, work shoes, masks, skin barrier creams, etc.), - always follow the safety instructions associated with the operation to be performed, - do not smoke when working on vehicles, - do not use toxic products in unventilated rooms, - do not ingest any chemicals (brake fluid, coolant, etc.). Respecting the environment: - sort waste according to its particular qualities, - do not burn waste products (tyres, etc.). e - Conclusion The procedures contained in this document merit your attention. Please read them carefully in order to reduce the risk of injury, and avoid using incorrect procedures that could damage the vehicle or make it dangerous to use. Following the recommended procedures will help you to provide a quality of service which will ensure the vehicles achieve the highest levels of performance and reliability. Equipment required offset thread repair kit WARNING Do not use flammable products to clean parts.

10A- 5 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair 10A Maintenance and repair operations must be carried out under the proper conditions to ensure that our vehicles run safely and reliably. II - CLEANLINESS Risks relating to contamination The high-pressure direct injection system is highly sensitive to contamination. The risks caused by contamination are: - damage to or destruction of the high-pressure injection system, - a component seizing, - a component not being properly sealed. All After-Sales operations must be performed under very clean conditions. Having carried out an operation in good conditions means that no impurities (particles a few microns in size) have penetrated 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 chips, - paint, - fibres: • cardboard, • brushes, • paper, • clothing, • cloth, - foreign bodies such as hair, - ambient atmosphere, - etc. a - Cleaning cloths Use lint free cleaning cloths (part number 77 11 211 707 ). The use of rags or ordinary paper towels is prohibited: these produce lint and lose fibres, which then contami- nate the fuel circuit. Each cloth must only be used once. b - Blanking plugs The blanking plugs are used to cap the fuel circuit once it is opened and to therefore prevent contaminants from entering. A set of blanking plugs should be used once only and used plugs must be discarded after use: once used, the plugs are soiled and cleaning them is not sufficient to make them reusable. Unused plugs must also be discarded and not used again for any other operation on an injection system. Blanking plug kit part number: - K9K ( DELPHI injection): 77 01 206 804 - K9K ( SIEMENS injection): 77 01 476 857 c - Protective bags Use hermetically resealable plastic bags, using adhesive tape, for example, to store components which will be refitted and reused. Stored parts will therefore be less subject to the risk of contamination. These bags must be used once only: once they have been used, they are to be discarded. d - Cleaning products Two cleaning products can be used: - an aerosol spray brake cleaner (part number 77 11 226 128 ). - an injector cleaner (part number 77 11 224 188 ), To use the injector cleaner, be sure to have a clean brush in good condition (the brush must not lose any bristles) as well as a clean container which has no impurities in it. WARNING Cleaning the engine using a high-pressure washer is prohibited because of the risk of damaging con- nections. In addition, moisture may collect in the connectors and create electrical connection faults. Note: Use a new injector cleaner each time work is carried out (a used cleaning agent will contain impurities).

10A- 6 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair 10A III - GENERAL RECOMMENDATIONS 1 - Advice to be followed before any operation 1) Carry out the work in a clean working area and take care to protect removed components from dust using plastic bags which are hermetically resealable, for example. 2) Always order the following from the Parts Depart- ment before carrying out work: - a new blanking plug kit ; these are specific to the engine - a sufficient number of lint free cleaning cloths . - one of the two cleaning products for fuel pipe unions, - the parts always to be replaced after each removal operation mentioned in the operational procedures specific to the vehicle. 3) Wear safety goggles fitted with side shields to prevent the cleaning product from splashing the eyes. 4) Wear latex safety gloves to avoid prolonged contact with the skin. 5) Before any operation on the injection system, using plastic bags or clean cloths, protect: - the accessories and timing belts, - the electrical accessories (starter, alternator, power- assisted steering pump, sensors and electrical connectors), - the flywheel face. 2 - Instructions to be followed during the operation Wash your hands before and while carrying out the work. Change the latex safety gloves if they become soiled or damaged. All components removed from the injection system must be stored in a hermetically sealed plastic bag once they have been capped. Reseal the bag hermetically using adhesive tape, for example, even if the bag must be opened shortly afte- rwards: ambient air can be a source of pollution. After opening the fuel circuit, the use of brushes, cleaning agents, air blow guns, rifle-type brushes or standard cloths is strictly prohibited: These items are likely to allow impurities to enter the system. When replacing a component with a new one or when refitting it after storing it in a plastic bag, do not unpack it until it is time to fit it on the vehicle. 3 - Cleaning There are currently two procedures for cleaning the fuel circuit before opening it in order to carry out work in the workshop. These procedures enable the fuel circuit to be cleaned to prevent contamination from entering: they both have the same end result and neither is preferred over the other. a - Using the injector cleaning agent Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks. Pour the injector cleaning agent into a container which is free from impurities. Dip a clean brush, which is not shedding bristles, into the container of injector cleaning agent. Clean the unions carefully using the brush and the injector cleaning agent. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system). Make sure there are no brush bristles remaining and that the area is clean. Wipe the sections that were cleaned with fresh cleaning cloths. Open the circuit at the unions and immediately fit the relevant blanking plugs. Note: If wearing leather protective gloves, cover these with latex gloves. IMPORTANT Wear latex safety gloves when using the cleaning agent. IMPORTANT Wear safety goggles fitted with side shields during this operation.

10A- 7 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair 10A b - Using the brake cleaning agent Clear the access to the unions that need opening, following the work procedures specific to the vehicle (see the relevant Workshop Repair Manual). Protect sections which are sensitive to fuel leaks. Spray the brake cleaning agent onto the unions to be opened. Clean the unions carefully using fresh cleaning cloths. Blast the components that have been cleaned with compressed air (tools, workbench, and also parts, unions and around the injection system). Make sure there are no brush bristles remaining and that the area is clean. Open the circuit at the unions and immediately fit the relevant blanking plugs. WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary. IMPORTANT Wear latex safety gloves when using the cleaning agent. IMPORTANT Wear safety goggles fitted with side shields during this operation. WARNING Do not blast with compressed air once the fuel circuit is open, otherwise impurities may enter the system. Use cleaning cloths only, if necessary.

10A- 8 ENGINE AND LOWER ENGINE ASSEMBLY Engine: Precautions for repair 10A 4 - Instructions for fitting the plugs K9K, and 732 or 764

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Renault K9K 1.5L DCI Engine Service & Repair Manual

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