RENAULT KERAX Premium Truck Engine DCI 11 Workshop Manual

RENAULT V.I. 20 094 – AN – 11.2001 ENGINE ENGINE FAMILY VEHICLE DCI 11 EQUIPMENT 2152 RENAULT KERAX RENAULT PREMIUM NOTE The above information may change in the course of time. Only the “Consult” section of the workshop manuals repertory in standard N° 10320 serves as reference. 20.0 20 094 50 21 002 910 20.0 20.0

1 20 094 RENAULT V.I. 11 / 01 – Imprimé en France – 50 21 002 910 CONTENTS VOLUMES DESIGNATION PAGES A Technical data A1 → A3 B Engine B1 → B9 C Air compressor C1 → C4 D Steering hydraulic pump D1 → D3 E Coolant pump E1 → E4 F Radiator F1 → F6 G Turbocharger G1 → G4 H Tools H1 → H2

A1 20 094 RENAULT V.I. 11 / 01 TECHNICAL DATA

A2 20 094 RENAULT V.I. 11 / 01 Tightening torques There are several types of tightening – Tightening to torque (in Nm.) – Tightening to angle (in °) – Tightening to torque–angle (in Nm. + °) Torques given in Nm. are nominal torques (average value calculated on the basis of the minimum torque and the maximum torque). The tightening accuracy class defines the tolerance of this torque in percent as a function of the nominal torque applied. Tightening accuracy classes – Class I: Special threaded hardware (tolerance ± 10% of the final torque) – Class II: Reserved for precise tightening (tolerance ± 10% of the nominal torque) – Class III: Reserved for normal standard tightening (tolerance ± 20% of the nominal torque) For standard threaded hardware indicated in the table below, use tightening class III. For other torques, see page A3. Tightening torques for conventional nut and bolt hardware to “METRIC system” standard 01.50.4002 Dia. and pitch of nuts and bolts (in mm) Quality class 8.8 Quality class 10.9 bolts (in mm) Tightening class III (± 20 %) Tightening class III (± 20 %) 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 10 x 1.00 10 x 1.25 10 x 1.50 12 x 1.25 12 x 1.50 12 x 1.75 14 x 1.50 14 x 2.00 16 x 1.50 16 x 2.00 18 x 1.50 18 x 2.50 20 x 1.50 20 x 2.50 22 x 1.50 22 x 2.50 7.4 12.1 19.2 17.9 39.4 37.4 35.4 67 64 61 105 98 161 151 235 210 328 296 444 406 10.8 17.8 28.2 26.3 58 55 52 98 94 90 155 143 237 222 346 308 481 435 652 596

A3 20 094 RENAULT V.I. 11 / 01 Kerax engine Nuts securing engine rear brackets to chassis 340 ± 68 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuts securing engine front brackets to chassis 237 ± 46 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium engine Nuts securing engine rear brackets to chassis 340 ± 68 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine front brackets to chassis setscrews 155 ± 30 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Engine aspiration hose spring clamp 5 ± 0.5 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat exchanger tube coolant drain plug 40 ± 5 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor Air compressor pinion securing nut 137 ± 30 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant pipe union nut 25 ± 5 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor securing nut 40 ± 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor securing stud (+ Loctite Frenétanch) 20 ± 4 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air compressor attaching screw (+ Loctite Frenétanch) 40 ± 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic pump Hydraulic pump pinion securing nut 60 ± 12 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water pump Water pump setscrew (+ Loctite Frenétanch) 20 ± 4 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Exhaust brake to turbocharger securing nut (+ GRIPCOTT N.F.) 20 ± 4 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust brake to turbocharger securing stud (+ GRIPCOTT N.F.) 10 ± 2 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger lubrication pipe union 24 ± 4.8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger to exhaust manifold setscrew 60 ± 12 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consumables Fixing, locking and sealing products Industrial reference Automotive reference Loctite 542 Frenétanch High temperature grease GRIPCOTT NF Consumables and oil capacity (see servicing handbook). Weight: – Undressed engine ]1000 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVENTIONAL SYMBOLS Depending on versions or options Mark – Assemble as per marking

B1 20 094 RENAULT V.I. 11 / 01 ENGINE

B2 20 094 RENAULT V.I. 11 / 01 Practical advice Before commencing any work – Clean the major unit and its surrounds (see “Washing the vehicle” in the servicing handbook). – Ensure the batteries are disconnected. – Bleed the gas supply system. – Mark the pipes and wiring harnesses, where applicable. – Protect all ports and openings to prevent the ingress of foreign matter. – Before disconnecting an air pipe, drop the circuit pressure. – In the event of fluid splashing onto the bodywork, quickly clean using a cleaning product recommended by RENAULT V.I. The “COMMON RAIL” system is a high–performance fuel–injection system Since this system is more sensitive to cleanliness than in–line injection pump systems, risks of damage are all the more important. Hence, it is essential to comply with the fitting of genuine spare parts guaranteed by the manufacturer and observe operating, maintenance and repair instructions for the system. Work on the “COMMON RAIL” system The system works with very high injection pressures (up to 1400 bars) and with medium voltage current (control of injectors by discharge of capacitors). Prior to disassembly, carefully clean the surrounds then take all necessary precautions to prevent the ingress of foreign matter. Use a clean thinner then blow through with compressed air. Using the RENAULT V.I. test tool, ensure that the circuit pressure has dropped completely. In fact, under normal operating conditions, the pressure drops rapidly in the high pressure circuit after the vehicle has stopped (between 1 & 3 minutes). In extreme cases of malfunction (several or all the flow limiters jammed), high pressure may prevail for a long time, even not drop. In such case, create a fuel leak by loosening an injector pipe union while protecting your hand and keeping it as far away as possible from the point of leak. Any work on the fuel–injection system must be carried out with the engine shut–down (check: injectors, voltage, resistance, tightening, etc...). Upon disassembly Repairs must be carried out in a clean room, free from dust and using suitable tools. The wearing of gloves made from fibrous material is to be banned. Carefully clean the parts with a clean solvent, then inspect. Use top quality small brushes that are perfectly clean and in very good condition. Use unsoiled lint–free cloths. The spare parts department supplies cleaning cloths, blanking plugs and storage bags suitable for one–way use. Blank off the ports with plugs as soon as the pipes are dismantled. Avoid using compressed air. Cleaned components must be protected to avoid any trace of corrosion in the circuit. The injector nozzle–holder cannot be repaired. Systematically replace the unit in the event of malfunction. Do not expose yourself to sprayed fuel when testing injector sprays or high pressure circuit dribble. Observe the chronological disassembly / assembly sequence outlined in the workshop manual. Reassembly must be carried out without any modification or stress (torsion, welding, distortion, connecting arrange- ment, fastening, routing, etc...). Replace the part, if necessary. Tighten to the recommended torque. Circuits are to bled without using the starter. All these recommendations guarantee you “COMMON RAIL” system quality and reliability.

B3 20 094 RENAULT V.I. 11 / 01 To remove NOTE The method below applies to all power units. It principally covers important engine removal / fitting points. Disconnect the set of batteries. Always commence with the negative (–) terminal. Place the vehicle over a pit or on elevators. Over a pit, chock the roadwheels. On elevators, release the parking brake, raise the vehicle and install axle stands. IMPORTANT With air suspension: Move the suspension to the “down” position. Open the front grille. Tilt the cab. Remove the gearbox. (See MR : 32 065) Remove the soundproofing (1–2). Drain the cooling system. Remove drain plugs (3–4).

B4 20 094 RENAULT V.I. 11 / 01 Disconnect hoses (1–2). Disconnect oil filler spout (3) . Remove the screws (4). Remove the steering pump. Dislodge seal (5) from radiator cowl.

B5 20 094 RENAULT V.I. 11 / 01 Remove air aspiration pipe (1). Disconnect flexible air pipe (3). Withdraw clamps (2). Withdraw the clamps and disengage the hoses (4). Remove air aspiration tube (5). Remove the turbo heat shield. Withdraw the clamps (6). Disconnect hoses (7). Disconnect hose (8). Disconnect hose (9). Remove guards (1–2).

RENAULT KERAX Premium Truck Engine DCI 11 Workshop Manual

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