Attention:
- When working on the fuel tank or fuel lines, smoking or using open flames in the workplace is not permitted.
- Be careful not to spill fuel when disconnecting the fuel connectors.
- When performing work, use leak-resistant nitrile gloves and goggles with side protection.
- To prevent contaminants from entering the fuel system circuit, use plugs to seal the openings of disconnected components.
- To avoid corrosion or damage, measures must be taken to protect surfaces that may come into contact with leaking fuel.
Due to the high operating pressure, the diesel engine injection system is extremely sensitive to various contaminants, which can cause:
- damage or destruction of injection system components;
- increased wear of components;
- inadequate tightness of components.
All maintenance procedures must be carried out in conditions of perfect cleanliness. The work must be carried out in such a way that no particles (up to several microns in size) did not penetrate the system during disassembly.
Cleanliness principles must be followed for components from filters to fuel injectors.
Sources of pollution may be:
- metal or plastic filings;
- dye;
- foreign bodies (for example, hair);
- atmospheric air;
- fibers of cardboard, bristles, paper, fabric, etc.
Warning: Cleaning the engine with a high-pressure washer is prohibited, as there is a risk of damage to the connections. In addition, moisture can collect in the connectors and cause short circuits in the wiring.
Use only lint-free cloths for cleaning (catalog number 77 11 211 707). Do not use regular cloth or paper towels as these materials may release lint or fibres that may contaminate the fuel injection system circuit.
Cleaning cloths can only be used once.
When disconnecting fuel system components, plugs must be used to prevent contaminants from entering the fuel circuit.
The set of plugs should be used only once. Used plugs must be disposed of: when used, the plugs become dirty, and cleaning them makes their further use impossible.
Note:
Part numbers of plug kits for the K9K engine according to the spare parts catalog:
- DELPHI injection system: 77 01 206 804
- SIEMENS injection system: 77 01 476 857
To store the removed components that are planned to be reused, it is necessary to use sealed plastic bags and adhesive tape to prevent contamination from entering them. These packages must be disposed of after use.
To clean the components of the diesel engine injection system, two types of cleaning agents can be used:
- fuel injector cleaner (catalog number 77 11 224 188);
- brake cleaning aerosol (catalog number 77 11 226 128).
To use fuel injector cleaner you will need a clean brush in good condition (the bristles should not fall out of the brush), and a clean tank.
Note: Use only new cleaning agent to clean the injectors (the previously used cleaning agent contains contaminants).
Before performing work on the components of the diesel engine injection system, it is necessary to prepare:
- a set of new plugs corresponding to the engine model;
- sufficient quantity of lint-free cloth napkins;
- fuel line connector cleaners;
- consumables that must be replaced with new ones after each removal (to do this, you must first familiarize yourself with the repair procedure described in this manual).
Use goggles with side protection to prevent cleaning agent splashes into your eyes.
Use latex work gloves to prevent prolonged contact of diesel fuel with the skin of your hands.
Note: When using leather work gloves, it is recommended to wear a pair of latex gloves over them.
Before working on the injection system, use plastic bags or a clean cloth to protect:
- drive belts;
- electrical components (starter, generator, power steering pump, sensors and electrical connectors);
- flywheel surfaces.
Before starting and during work, it is necessary to wash your hands thoroughly.
If latex gloves become dirty or damaged, they must be replaced with new ones.
All removed components must be placed in sealed plastic bags immediately after removal. Use tape to seal the bags, even if the bag needs to be opened soon: atmospheric air can become a source of contamination.
After opening the fuel circuit, the use of brushes, cleaning agents, compressed air or ordinary rags for cleaning is strictly prohibited: all this can cause contamination of the system.
When replacing components with new ones or reinstalling components from plastic bags, they must be removed from the packaging immediately before installation.
There are two methods for cleaning injection system components before depressurization during any repair work. These procedures allow you to clean the outer surfaces of the components to prevent contaminants from entering the system: ultimately, both procedures lead to the same result, so both methods are equally effective.
Cleaning with fuel injector cleaner
1. Clean the surfaces around the connections to be opened (see the relevant section of this manual).
2. Take measures to protect areas that may be exposed to leaking fuel.
3. Fill a suitable clean container with fuel injector cleaner.
Caution: Use latex gloves when handling the cleaning agent.
4. Place a clean brush, free of loose bristles, into the container with the cleaning agent.
Caution: Use goggles with side protection to perform the following procedure.
5. Clean the connections thoroughly with a brush soaked in cleaning agent.
6. Use compressed air to blow off surfaces that must be clean when performing repair work (tools, workbench and other work area surfaces, joints and surfaces around injection system components). Make sure there are no bristles left from the brush and all surfaces are clean.
7. Wipe the cleaned surfaces with a clean, lint-free cloth.
8. Open the system at the connection and immediately install the appropriate plugs.
Caution: To prevent contamination from entering, do not use compressed air when opening the fuel system circuit. If necessary, use only lint-free cleaning cloths.
Cleaning with brake cleaner aerosol
1. Clean the surfaces around the connections to be opened (see the relevant section of this manual).
2. Take measures to protect areas that may be exposed to leaking fuel.
(Information is located on the website RENAULTBOOK.ru)
Caution: Use latex gloves when handling the cleaning agent.
Caution: Use goggles with side protection to perform the following procedure.
3. Spray brake cleaner onto the connections to be opened.
4. Clean the connections thoroughly with a clean, lint-free cloth.
5 Using compressed air, blow off the surfaces that must be clean when performing repair work (tools, workbench and other work area surfaces, joints and surfaces around injection system components). Make sure there are no bristles left from the brush and all surfaces are clean.
6. Open the system at the connection and immediately install the appropriate plugs.
Caution: To prevent contamination from entering the fuel system circuit, do not use compressed air. If necessary, use only lint-free cleaning cloths.