here for some user wich can not download from MHH
GREEN TECHNICAL NOTE
FEBRUARY 2008
77 11 403 582
EDITION ANGLAISE
4737A
Service 00429
RENAULT CONFIDENTIAL
CLIO 2
Type
BB0 J
CB0 J
SB0 J
Mégane
Type
XA0 R
KANGOO
Type
XC0 J
XC0 N
Fitted with the EPIC diesel fuel injection pump
13B
DIFFICULT TO START, ENGINE HESITATION, WARNING LIGHT ILLUMINATION
Other sub-section concerned:
• Engine:
F8Q 622 - 632
• Gearbox:
01A
Basic manual:
XXX
Workshop Repair Manual:
Technical Note:
" The repair procedures given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The procedures may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which the vehicles
are constructed. "
312, 337, 380
3420A, 3682A
All rights reserved by RENAULT S.A.S.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
RENAULT S.A.S.
© RENAULT S.A.S. 2008
EPIC INJECTION PUMP
13B
Repairing the rotor sensor
TECHNICAL INFORMATION
Customer complaint
In order of appearance:
– Difficult to start.
– Accelerator pedal has no effect.
– Lack of power.
– Engine hesitation.
– Injection warning light comes on.
– Impossible to start.
1
Possible cause
– Faulty rotor sensor inside the EPIC pump.
Fault finding
– Confirm the customer complaint.
– The diagnostic tool displays DF066, 2 or 3 DEF.
– Apply the fault finding procedure for DF066
according to Technical Note 3420A.
• If the result is correct:
– Apply this Technical Note.
1 - Bonnet bolt
Operation to be carried out
– Addition of a shim between the rotor sensor core
and the pump casing to compensate for the
deviation in reading the rotor sensor position.
– Remove the mounting bolts (1) from the bonnet.
– Remove the bonnet.
Description of the operation
– Disconnect the battery.
All vehicles
REMOVAL
IMPORTANT
Please observe the recommendations when
disconnecting and reconnecting the battery (see
Electrical equipment, Battery: Removal –
Refitting) (MR 380, 80A, Battery).
Special notes for Kangoo
Note
The following operation requires two people.
– Protect areas sensitive to leaking fuel (alternator
and air conditioning compressor).
– Clean the exterior of the rotor sensor and the high
pressure pipe unions:
– Spray brake cleaner, part number:
77 11 226 128 on the edges of the sensor and
the high pressure pipe unions,
– Wipe using lint-free cloths, part number:
77 11 211 707,
– Blow compressed air over the cleaned parts.
13B -2
EPIC INJECTION PUMP
13B
Repairing the rotor sensor
– Remove:
– the injector return pipes,
– the oil vapour recirculation pipe,
– the high pressure pipes.
Note
For the operation to be a success, it is ESSENTIAL
to observe the procedure described below.
– Plug the unions:
– 8 yellow blanking covers for the pump and
injectors,
– 8 red flexible blanking covers for the high
pressure pipes.
– While keeping the rotor sensor pressed against the
pump:
– undo the mounting bolts,
– remove the two bolts.
– Remove the sensor.
– Disconnect the wiring harness from the pump (2).
– Move the wiring harness away from the pump (2).
IMPORTANT
Ensure that the sensor does not touch the core.
2
2 – Pump wiring harness
4
– Unclip the rotor sensor wiring harness (3) from its
support on the pump side.
4 – Rotor sensor
– Fit the blanking plug on the sensor.
– Fit the sensor on the engine.
Note
Do not disconnect the sensor wiring harness on
the pump.
3 – Rotor sensor wiring harness
13B -3
EPIC INJECTION PUMP
13B
Repairing the rotor sensor
4
4 – Rotor sensor
6
– Remove the O-ring from the rotor sensor.
– Using the special socket supplied in the repair kit:
6 – Special socket
– undo the core (5) of the rotor sensor.
IMPORTANT
1 or 2 shims are positioned between the core of the
rotor sensor and the rotor.
During the removal operation, these shims can be
found:
- either at the base of the pump,
- or on the core.
5
IMPORTANT
Ensure that the shims do not fall into the engine or
pump.
– Remove the core of the rotor sensor by hand.
5 – Core
ADDITION OF THE SPECIAL SHIM
– Remove the 2 original shims from the core.
– Fit the special 0.25 mm shim.
– Refit the original shim(s).
13B -4
EPIC INJECTION PUMP
Repairing the rotor sensor
13B
– torque tighten the mounting bolts to 6 N.m.
REFITTING
– Clip on the electrical sheath of the rotor sensor.
– After having removed the blanking plugs, refit the
high pressure pipes:
– torque tighten to 25 N.m on the pump side only.
– Refit the injector return and oil vapour recirculation
pipes.
– Protect the area around the high pressure pipes
(from splashes during the bleed operation).
– Connect the battery.
8
Note
7
It is ESSENTIAL to carry out the necessary
programming (see Battery: Advice) (Technical
Note 3682A, 80A, Battery) or (Electrical
equipment, Battery: Removal - Refitting)
(MR for the vehicle, 80A, Battery).
7 – Original shim(s)
8 – Special shim
– Refit the core of the rotor sensor whilst holding the
shims.
IMPORTANT
Do not mark or cover the core of the sensor.
– Bleed the injection system:
– engage the starter for 5 seconds,
– prime the circuit using the priming bulb,
– repeat the operation until air is released from
the diesel circuit.
– Torque tighten the high pressure pipes on the
injector side to 25 N.m.
– Screw in the core of the rotor sensor completely by
hand.
– Tighten it a quarter of a turn using the tool.
Special notes for Kangoo
– Refit the bonnet.
– Tighten the bolts to a torque of 8 N.m.
Note
Tightening torque of the core: 1.6 N.m
– Clear the fault codes using the diagnostic tool.
–
–
–
–
Lubricate the new O-ring.
Remove the blanking plug from the rotor sensor.
Fit the O-ring on the sensor body.
Refit the rotor sensor, without putting the core under
any strain.
– While keeping the rotor sensor pressed against the
pump:
– fit the sensor mounting bolts,
– tighten the bolts by hand until contact is made,
Note
The fault code must not reappear after having run
the flow actuator and advance actuator tests on
the pump.
– Carry out an operational test.
Marking the vehicle after work has been carried
out:
– Add the red CLIP (supplied in the kit) to the wiring
harness of the rotor sensor.
IMPORTANT
Do not exceed this value as this may damage the
injection pump.
13B -5
EPIC INJECTION PUMP
13B
Repairing the rotor sensor
CLAIM COMPLETION AND CODING
Destination of removed parts
– In accordance with warranty directives.
When to take action
– Upon receipt of a customer complaint.
Parts required
Quantity and description of parts
Codification items
Part number
1 Brake cleaner
77 11 226 128
1 Special injection cloths
77 11 211 707
1 EPIC pump repair kit
composed of:
– 8 yellow blanking covers
– 8 red blanking covers
– 1 white blanking cover
– 1 sensor seal
– 1 shim
– 1 disposable tool for removing
the rotor core
– 1 clip
77 01 478 776
Tooling required
– Conventional.
Time required
Clio 2
Code
Description
Time
7697
Repair of the EPIC pump
0.8
0331
Vehicle programming
0.2
0145
Operational test
0.3
TOTAL
1.3
Mégane
Code
Description
Time
7697
Repair of the EPIC pump
0.8
0331
Vehicle programming
0.2
0145
Operational test
0.3
TOTAL
1.3
Kangoo
Code
Description
Time
4191
Remove and refit bonnet
0.5
7697
Repair of the EPIC pump
0.8
0331
Vehicle programming
0.2
0145
Operational test
0.3
TOTAL
1.8
13B -6
• With PGCS
– Cause Opecode:
7608
• Without PGCS
– NITG code:
M4C1
• With or without PGCS
– Supplier code:
– Customer complaint code:
153
7ML, 7C