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ENGINE CONTROL SYSTEM
SECTION
EC
CONTENTS
K9K APPLICATION NOTICE .......................................... 5 How to Check Vehicle Type ................................. 5 K9K-Type 1 DIESEL EQUIPMENT.............................................. 6 Cleanliness........................................................... 6 Special features ................................................... 9 Location of components ..................................... 16 Specifications ..................................................... 20 Diesel filter ......................................................... 23 High pressure pump........................................... 25 Flow actuator...................................................... 29 Fuel temperature sensor .................................... 32 Venturi ................................................................ 34 Injector rail.......................................................... 36 Pressure sensor ................................................. 41 Injectors.............................................................. 42 High pressure pipes ........................................... 46 ECM ................................................................... 50 DIESEL INJECTION .............................................. 52 Immobilizer function ........................................... 52 Idle speed adjustment ........................................ 53 Air conditioning control....................................... 55 Pre/postheating (glow plug) control.................... 57 DIESEL EQUIPMENT............................................ 58 Glow plugs ......................................................... 58 Engine coolant temperature ............................... 59 ANTI-POLLUTION ................................................. 60 Oil vapour rebreathing........................................60 Exhaust gas recirculation (EGR) ....................... 61 DIESEL INJECTION ..............................................62 System diagram ................................................. 62 Trouble diagnosis - Introduction .........................64 Trouble diagnosis - ECM terminal ......................75 Trouble diagnosis - Summary table of DTC .......77 Trouble diagnosis - Introduction .........................79 DTC P0089 Common rail fuel pressure regulation function ..............................................80 DTC P0087 Fuel flow capacity function .............82 DTC P0110 IAT sensor.......................................83 DTC P0115 ECT sensor.....................................84 DTC P0180 Fuel temperature sensor circuit ......85 DTC P0190 FRP sensor .................................... 86 DTC P0200 Injector control circuit .....................87 DTC P0201 Injector circuit cylinder 1 ................. 89 DTC P0202 Injector circuit cylinder 2 ................. 91 DTC P0203 Injector circuit cylinder 3 ................. 93 DTC P0204 Injector circuit cylinder 4 ................. 95 DTC P0225 APP senser 1 .................................97 DTC P0231 Low pressure control circuit............99 DTC P0235 TC boost pressure sensor ............100 DTC P0301 Cylinder 1 misfire..........................101 DTC P0302 Cylinder 2 misfire..........................102 DTC P0303 Cylinder 3 misfire..........................103 DTC P0304 Cylinder 4 misfire..........................104 DTC P0325 Knock sensor circuit ..................... 105
EC-K9K-1
DTC P0335 CKP sensor (POS) ....................... 106 DTC P0340 CMP sensor.................................. 107 DTC P0380 Glow plug diagnostic connection.. 108 DTC P0382 Glow plug relay control circuit ...... 109 DTC P0400 EGR volume control solenoid valve circuit ........................................ 110 DTC P0403 EGR control circuit ........................111 DTC P0409 EGR position sensor .................... 112 DTC P0500 VSS .............................................. 113 DTC P0513 Immobiliser ................................... 114 DTC P0530 Refrigerant pressure sensor......... 115 DTC P0560 ECM supply voltage ..................... 116 DTC P0571 Brake switch circuit....................... 117 DTC P0604 ECM memory ............................... 118 DTC P0606 ECM ............................................. 119 DTC P0608 Sensor supply voltage .................. 121 DTC P0609 Supply voltage APP sensor 2....... 122 DTC P0685 ECM relay control......................... 124 DTC P2120 APP sensor 2 ............................... 125 DTC P2226 Atmospheric pressure sensor circuit .................................................... 127 DTC C001 CAN communication line................ 128 Trouble diagnosis States and parameter summary table .............. 129 Trouble diagnosis States and data monitor summary table .......... 130 Trouble diagnosis - Conformity check .............. 131 Trouble diagnosis Interpretation of parameters............................. 163 Trouble diagnosis - Interpretation of states ...... 164 Trouble diagnosis - Tests ................................. 165 Trouble diagnosis - Customer complaints ........ 178 Trouble diagnosis - Symptoms......................... 180 K9K-Type 2 DIESEL EQUIPMENT.......................................... 225 Cleanliness....................................................... 225 Special features ............................................... 228 Location of components ................................... 235 Specifications ................................................... 238 Diesel filter ....................................................... 241
High pressure pump ......................................... 243 Flow actuator....................................................247 Fuel temperature sensor .................................. 250 Venturi ..............................................................252 Injector rail........................................................254 Pressure sensor ............................................... 259 Injectors............................................................ 260 High pressure pipes ......................................... 264 ECM .................................................................268 DIESEL INJECTION ............................................270 Immobilizer function ......................................... 270 Idle speed adjustment ......................................271 Air conditioning control .....................................273 Pre/postheating (glow plug) control..................275 DIESEL EQUIPMENT ..........................................276 Glow plugs .......................................................276 Engine coolant temperature .............................277 ANTI-POLLUTION ............................................... 278 Oil vapour rebreathing......................................278 Exhaust gas recirculation (EGR) ..................... 279 DIESEL INJECTION ............................................282 System diagram ............................................... 282 Trouble diagnosis - Introduction .......................284 Trouble diagnosis - System operation..............290 Trouble diagnosis - ECM terminal ....................297 Trouble diagnosis - Summary table of DTC .....299 Trouble diagnosis - Introduction .......................301 DTC P0016 CMP sensor.................................. 302 DTC P0045 TC boost control solenoid valve ...303 DTC P0070 Ambient air temperature ............... 304 DTC P0087 Fuel flow capacity function ...........305 DTC P0089 Common rail fuel pressure regulation function ............................................306 DTC P0100 Mass air flow sensor..................... 307 DTC P0115 Engine coolant temperature sensor ..............................................................308 DTC P0170 Insufficient individual injection adjusitng ...........................................................309 DTC P0180 Fuel temperature sensor circuit ....310 DTC P0190 FRP sensor .................................. 311
EC-K9K-2
DTC P0200 Injector control circuit ................... 312 DTC P0201 Injector circuit cylinder 1............... 314 DTC P0202 Injector circuit cylinder 2............... 316 DTC P0203 Injector circuit cylinder 3............... 318 DTC P0204 Injector circuit cylinder 4............... 320 DTC P0225 APP senser 1 ............................... 322 DTC P0231 Low pressure actuator circuit ....... 324 DTC P0235 TC boost pressure sensor ............ 325 DTC P0263 Cylinder 1 misfire.......................... 326 DTC P0266 Cylinder 2 misfire.......................... 327 DTC P0269 Cylinder 3 misfire.......................... 328 DTC P0272 Cylinder 4 misfire.......................... 329 DTC P0325 Knock sensor circuit ..................... 330 DTC P0335 CKP sensor (POS) ....................... 331 DTC P0340 CMP sensor.................................. 332 DTC P0380 Glow plug diagnostic connection.. 333 DTC P0382 Glow plug relay control circuit ...... 334 DTC P0400 EGR volume control solenoid valve circuit ........................................ 335 DTC P0403 EGR control circuit ....................... 336 DTC P0409 EGR position sensor .................... 337 DTC P0487 EGR position sensor .................... 338 DTC P0500 VSS .............................................. 339 DTC P0513 Immobiliser ................................... 340 DTC P0530 Refrigerant pressure sensor......... 341 DTC P0560 ECM supply voltage ..................... 342 DTC P0571 Brake switch circuit....................... 343 DTC P0604 ECM memory ............................... 344 DTC P0606 ECM ............................................. 345 DTC P0641 Sensor supply voltage .................. 347 DTC P0651 Supply voltage APP sensor 2....... 348 DTC P0685 ECM relay control......................... 349 DTC P0703 Brake switch circuit....................... 350 DTC P2120 APP sensor 2 ............................... 351 DTC P2226 Atmospheric pressure sensor circuit .................................................... 353 DTC P2264 Water in fuel sensor ..................... 354 DTC C001 CAN communication line................ 355 Trouble diagnosis States and parameter summary table .............. 356
Trouble diagnosis States and data monitor summary table ..........357 Trouble diagnosis - Conformity check ..............358 Trouble diagnosis Interpretation of parameters .............................390 Trouble diagnosis - Interpretation of states ......391 Trouble diagnosis - Tests .................................392 Trouble diagnosis - Customer complaints ........ 405 Trouble diagnosis - Symptoms.........................407 K9K DIESEL INJECTION ............................................450 Circuit diagram .................................................450 Wiring diagram Intake air temperature sensor ..........................454 Wiring diagram MAF sensor ...................................................... 456 Wiring diagram Engine coolant temperature sensor .................457 Wiring diagram - Fuel temperature sensor.......458 Wiring diagram Common rail fuel pressure sensor ...................459 Wiring diagram - Injector .................................. 460 Wiring diagram Accelerator pedal position sensor ....................462 Wiring diagram - Fuel flow actuator .................464 Wiring diagram TC boost pressure sensor ................................465 Wiring diagram Knock sensor (accelometer) ............................ 467 Wiring diagram Crankshaft position sensor...............................468 Wiring diagram Camshaft position sensor.................................469 Wiring diagram - Glow control system .............470 Wiring diagram - EGR control system ..............471 Wiring diagram Refrigerant pressure sensor.............................473 Wiring diagram Main power supply and ground circuit..............474 Wiring diagram - Brake switch .........................475 Wiring diagram - Temperature sensor ..............477 Wiring diagram - Cooling system ..................... 479
EC-K9K-3
Wiring diagram - Turbocharger boost control solenod valve ....................................... 482 Wiring diagram - CAN communication line ...... 483
Wiring diagram - MI & data link connectors .....484
EC-K9K-4
APPLICATION NOTICE 1K9K How to Check Vehicle Type
K9K
Confirm K9K engine type with model written on identification plate (refer to GI-44, "IDENTIFICATION INFORMATION"), then refer to service information in EC section. Vehicle type xTKxxxxK12Vxx xTKxxxxK12Yxx xTKxxxxK12Txx xTKxxxxK12Uxx Engine type Euro3 48 kW Euro3 60 kW Euro4 50 kW Euro4 63 kW Service information K9K-Type 1
K9K-Type 2
EC-K9K-5
DIESEL EQUIPMENT Cleanliness DIESEL EQUIPMENT1 1K9K-TYPE Cleanliness
K9K-Type 1
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks relating to contamination The system is very sensitive to contamination. The risks caused by the introduction of contamination are: damage or destruction of the high pressure injection system and the engine, seizing or leaking of a component. All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions. The cleanliness principle must be applied from the filter to the injectors. WHAT ARE THE SOURCES OF CONTAMINATION? Contamination is caused by: metal or plastic chips, paint, fibres: boxes, brushes, paper, clothing, cloths, foreign bodies such as hair, ambient air, etc. IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection problems. INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away. Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away. Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or paper for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be used once.
EC-K9K-6
DIESEL EQUIPMENT Cleanliness
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
K9K-Type 1
For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle. For each operation, use a clean brush which is in good condition (the brush must not shed its bristles). Use a brush and thinners to clean the connections to be opened. Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection system zone). Check that no bristles remain adhered. Wash your hands before and during the operation if necessary. When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206 804. They must not, under any circumstances, be reused. Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries contamination. All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted. The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. These items are likely to allow impurities to enter the system. A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
EC-K9K-7
DIESEL EQUIPMENT Cleanliness
Instructions For Fitting The Plugs Nissan part number: 16830 BN700 (Renault part number: 77 01 206 804)
K9K-Type 1
MBIB0321E
CAUTION: The engine must not run with: Diesel containing more than 10% diester Petrol, even in very small amounts. 2 The system can inject the diesel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428 kg/cm , 20,300 psi). Before carrying out any work, check that the injector rail is no longer pressurized and that the fuel temperature is not too high. You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system.
EC-K9K-8
DIESEL EQUIPMENT Special features
K9K-Type 1
The high pressure injection system is intended to deliver a specific quantity of diesel to the engine at a specific time. DESCRIPTION
DELPHI and type "DDCR" injection controlling 112 terminals ECM. The system consists of: a priming pump on the low pressure circuit, a diesel fuel filter, a high pressure pump incorporating a low pressure pump (transfer pump), a flow actuator attached to the pump, an injector rail, a pressure sensor located in the rail, four solenoid injectors, a fuel temperature sensor, an engine coolant temperature sensor, an intake (upstream) air temperature sensor, a camshaft position sensor (cylinder reference sensor), a turbocharger air pressure sensor, a knock sensor (accelerometer), an EGR solenoid valve, an accelerator pedal potentiometer, and an ECM. The "common rail" direct high pressure injection system works sequentially (based on the operation of multipoint injection for petrol engines). This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and produces high engine torque at low engine speeds thanks to a pre-injection procedure. The high pressure pump generates the high pressure sent to the injector rail. The flow actuator on the pump controls the quantity of diesel engine fuel supplied according to the demand determined by the ECM. The rail supplies each injector through a steel pipe.
EC-K9K-9
DIESEL EQUIPMENT Special features
K9K-Type 1
The ECM: determines the value of injection pressure necessary for the engine to operate well and then controls the pressure regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor located on the rail, determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should be started, controls each injector electrically and individually after determining these two values.
The injected flow to the engine is determined by: the duration of injector control, the injector opening and closing speed, the needle travel (determined by a constant for the type of injector), the nominal hydraulic flow of the injector (unique to each injector), the high pressure rail pressure controlled by the ECM. The ECM controls: the idle speed adjustment, the exhaust gas flow reinjected into the inlet, the fuel supply control (advance, flow and rail pressure), the cooling fan control, the heat adjustment of the coolant circuit (thermoplungers), the glow plug (pre/post heating) control. The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump). It supplies the rail whose pressure is controlled for charge by the flow actuator and for discharging by the injector valves. Falls in pressure can be compensated for in this way. The flow actuator allows the high pressure pump to provide just the amount of diesel fuel necessary to maintain the pressure in the rail. Thanks to this element, heat generation is minimised and engine output improved. In order to discharge the rail using the injector valves, the valves are controlled by short electrical impulses: short enough not to open the injector, (through the return circuit from the injectors), long enough to open the valves and discharge the rail. The ECM controls the cooling fans and the coolant temperature warning light on the instrument panel.
EC-K9K-10
DIESEL EQUIPMENT Special features
IMPORTANT The engine must not operate with: diesel engine fuel containing more than 10% diester, petrol, even in tiny quantities.
K9K-Type 1
The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out any work, check that the injector rail is not under pressure and that the fuel temperature is not too high. You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system. Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel temperature sensor and the venturi can be replaced. For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is running. It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit contamination problems. If the pressure sensor fails, the pressure sensor, the rail and the five high pressure pipes must be replaced. It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being replaced, the pulley must be replaced. It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor (engine speed sensor). If the wiring should fail, it has to be replaced with new wiring. Applying 12 volts directly to any component in the system is prohibited. Ultrasonic carbon removal and cleaning are prohibited. Never start the engine without the battery being connected correctly. Disconnect the injection system ECM when carrying out any welding work on the vehicle. It is essential to replace all the disconnected air inlet plastic pipes.
EC-K9K-11
DIESEL EQUIPMENT Special features
K9K-Type 1
There is a 16 digit code on the injectors called individual injector correction. This code is specific to each injector, and takes into account differences in manufacture and specifies the flow injected by each of them. When an injector is replaced, it is necessary to program the code of the new injector into the ECM. When an ECM is replaced, it is necessary to program the codes of the four injectors. There are two possibilities: If it is possible to communicate with the ECM: read out the data from the ECM using the "SAVE DATA FOR REPLACE" in "WORK SUPPORT" mode with CONSULT-II turn ignition switch OFF. remove battery negative cable. change the ECM reprogram the data from the "WRITE DATA AFTER REPLACE" in "WORK SUPPORT" mode with CONSULTII to the replaced ECM after replacement, ensure that the ECM has not detected malfunctions relating to the injector codes and check that the instrument panel warning light is off.
If it is not possible to communicate with the ECM: turn ignition switch OFF. remove battery negative cable. change the ECM read the data on the injectors Refer to EC-K9K-44 for individual injector correction value location. enter the data in the ECM using the "ENTER INJCTR CALIB DATA" in "WORK SUPPORT" mode with CONSULT-II manually reconfigure the different elements such as the power-assisted steering pump assembly and the thermoplungers etc. using CONSULT-II, ensure that the ECM has not detected malfunctions relating to the injector codes and check that the instrument panel warning light is off.
EC-K9K-12
DIESEL EQUIPMENT Special features
All the high pressure pipe removed must be systematically replaced along with the clips. TIGHTENING THE HIGH PRESSURE PIPES NOTE: fit the pump/rail pipe before the rail/injector pipes. Rail-pump pipe Undo the rail, Grease the threads of the high pressure pipe nuts, Insert the high pressure pipe olive into the taper of the high pressure pump outlet, Insert the high pressure pipe olive into the taper of the high pressure rail inlet. Move the nut into position by hand, on the rail side then the pump side, Tighten the rail, Tighten the high pressure pipe nuts on the rail side then on the pump side. Rail/injector pipes
K9K-Type 1
Undo the rail, Grease the threads of the high pressure pipe nuts, Insert the high pressure pipe olive into the taper of the high pressure injector inlet, Insert the high pressure pipe olive into the taper of the high pressure rail outlet, Move the nuts into position by hand, on the injector side then the rail side, Tighten the rail, Ensure that the new clip, supplied with the new high pressure pipe, is fitted, Tighten the nuts of the high pressure pipes on the injector side first and then on the fuel rail side. NOTE: Before fitting a new high pressure pipe, move back the nuts on the pipe then lightly lubricate the nut threads with the oil from the sachet (1) provided in the parts kit.
EC-K9K-13
DIESEL EQUIPMENT Special features
CHECKING SEALING AFTER REPAIR After any operation, check that there are no diesel leaks. Reprime the circuit using the priming pump. Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks. Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
K9K-Type 1
Once the engine coolant temperature is above 50°C and provided there are no malfunctions present, carry out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no leaks. Perform a visual inspection after the road test to make sure that there are no high pressure leaks. Clean off the tracing fluid.
EC-K9K-14
DIESEL EQUIPMENT Special features
REPLACING THE ECM The system can be reprogrammed using CONSULT-II. Before an ECM is replaced in after-sales, the following must be done.
K9K-Type 1
Check the individual correction value from "WORK SUPPORT" mode using print out function of CONSULT-II. After replacing ECM, enter each injector's individual correction value using "WORK SUPPORT" mode with CONSULT-II. Also set the system configuration using "CONFIGURATION" mode with CONSULT-II.
REPLACING THE INJECTORS NOTE: Individual injector correction is a factory calibration carried out on each injector to adjust the flow of each one precisely, taking into account differences in manufacture. The correction values are written on a label affixed to each injector then entered in the ECM which can then control each injector by taking account of their differences in manufacture. The system can be programmed "WORK SUPPORT" mode with CONSULT-II. The correction values (16 digit code) must be replaced after replacing an injector. (Refer to special features)
Entering each injector's individual correction value, when replacing the ECM.
EC-K9K-15
DIESEL EQUIPMENT Location of components
K9K-Type 1
YEC670E
1. Fuel filter (LHD models) 2. Venturi 3. Fuel temperature sensor 4. EGR control solenoid valve 5. Injector 6. Turbocharger air temperature sensor 7. Turbocharger boost pressure sensor 8. Fuel filter (RHD models) 9. Priming pump (RHD models) 10. Air cleaner 11. ECM
12. Camshaft position sensor 13. High pressure pump 14. Fuel flow actuator 15. Knock sensor (Accelerometer) 16. Spherical injector rail 17. Common rail fuel pressure sensor 18. Engine coolant temperature sensor 19. Intake air temperature sensor 20. Crankshaft position sensor 21. Glow relay (control) unit 22. IPDM E/R
EC-K9K-16
DIESEL EQUIPMENT Location of components
K9K-Type 1
YEC671E
1. Fuel filter (LHD models) 2. Venturi 3. Fuel temperature sensor 4. EGR control solenoid valve 5. Injector 6. Turbocharger air temperature sensor 7. Turbocharger boost pressure sensor 8. Fuel filter (RHD models) 9. Priming pump (LHD models) 10. Air cleaner 11. ECM
12. Camshaft position sensor 13. High pressure pump 14. Fuel flow actuator 15. Knock sensor (Accelerometer) 16. Spherical injector rail 17. Common rail fuel pressure sensor 18. Engine coolant temperature sensor 19. Intake air temperature sensor 20. Crankshaft position sensor 21. Glow relay (control) unit 22. IPDM E/R
EC-K9K-17
DIESEL EQUIPMENT Location of components
1 Camshaft position sensor 6 7 8 9 Injector Injector rail Rail pressure sensor Knock sensor (Accelerometer)
K9K-Type 1
YEC630A
2 3 4 5
Fuel flow actuator Fuel temperature sensor High pressure pump Venturi
Models without intercooler
YEC631A
Models with intercooler
YEC672E
EC-K9K-18
DIESEL EQUIPMENT Location of components
10 11 12 13 14 Intake air temperature sensor Turbocharger boost pressure sensor Turbocharger air temperature sensor EGR control solenoid valve Priming bulb (RHD models) 15 Fuel filter (RHD models) 16 Fuel filter (LHD models)
K9K-Type 1
Models without intercooler
YEC633A
YEC632A
Models with intercooler
YEC634A
17 Engine coolant temperature sensor
YEC673E
YEC635A
18 IPDM E/R 19 ECM
YEC636A
EC-K9K-19
DIESEL EQUIPMENT 1K9K-TYPE 1 Specifications
K9K-Type 1
Engines Vehicles Type Suffix Bore (mm, in) Stroke (mm, in) Displacement cm3 (cu in) Emission control standard
Compressi on ratio
Catalytic converter
K12
K9K
750 752
76 (2.99)
80.5 (3.17)
1,461 (89.15)
18.25/1
228
EU 00 Euro 2
ENGINE SPEED (rpm) IDLE SPEED 800 ± 50 900 or more* : without intercooler 875 or more* : with intercooler *: A/C ON Max. - no load Max. - under load
SMOKE OPACITY Homologation value Max. - legal
5000 ± 100
4800 ± 100
1.5 m-1 (46%)
3 m-1 (70%)
DESCRIPTION High pressure pump Fuel pump Common rail fuel pressure sensor Injectors
MARQUE/TYPE DELPHI DELPHI DELPHI DELPHI
SPECIAL NOTES 0 to 1400 bars continuous pressure Incorporated into the high pressure pump Incorporated into the rail Non measurable resistance Solenoid injector Maximum pressure 1400 bar Non measurable resistance Located on the high pressure pump Resistance: 5.3 ± 0.5 at 20ºC ECM (computer) (112 terminals) With pre-postheating function controlled by the ECM (computer) Resistance: Less than 1 connector disconnected Double track potentiometer Resistance: terminals 1: 4 (earth) and 6 (+5 V): 1.7 ± 0.9 k terminals 2: 5 (earth) and 3 (+5 V): 2.85 ± 2.05 k CTN thermistor Resistance: 5000 ± 6800 at - 40°C 9500 ± 900 at - 10°C 2051 ± 120 at 25°C 810 ± 47 at 50°C 310 ± 17 at 80°C
Diesel flow actuator ECM Pre/postheating unit (glow) Pre-heater plugs (glow) Accelerator pedal potentiometer (APP sensor)
DELPHI DELPHI NAGARES BED 7-12
BERU CTS
Intake air temperature sensors
JAEGER
EC-K9K-20
DIESEL EQUIPMENT Specifications
DESCRIPTION Fuel temperature sensor MARQUE/TYPE DELPHI SPECIAL NOTES
K9K-Type 1
Located on the high pressure pump CTN thermistor Resistance: 2.2 k at 25°C CTN thermistor Resistance: 76000 ± 7000 at - 40°C 12500 ± 1130 at - 10°C 2252 ± 112 at 25°C 810 ± 40 at 50°C 280 ± 8 at 80°C 115 ± 3 at 110°C 88 ± 2 at 120°C Variable reluctance sensor Resistance: 760 Built into the computer Resistance: terminals A and B: 9 k terminals A and C: 4 k terminals B and C: 5 k
Engine coolant temperature sensor
ELTH
Crankshaft position (Engine speed) sensor Atmospheric pressure sensor Turbocharger boost pressure sensor
MGI DELPHI DELCO ELECTRONICS
Camshaft position sensor Knock sensor (accelerometer) Turbocharger air temperature and turbocharger boost pressure sensor
SAGEM SAGEM BOSCH / LDF6T 20250
Hall effect sensor Non measurable resistance Pressure sensor with a negative temperature coefficient thermistor Supply voltage +5V Resistance between terminals 1 and 2: 20,376 ± 1110.5 at -25°C 15,614 ± 829 at -20°C 9426 ± 475 at -10°C 5887 ± 281.5 at 0°C 3791 ± 172.5 at 10°C 2511 ± 109 at 20°C 1715.5 ± 71 at 30°C 1200 ± 47 at 40°C 851 ± 32 at 50°C 612 ± 22 at 60°C 446 ± 15 at 70°C 330 ± 11 at 80°C 4-track connector: 1: earth 2: air temperature sensor signal 3: +5V supply 4: pressure sensor signal
EC-K9K-21
DIESEL EQUIPMENT 1K9K-TYPE 1 Specifications
DESCRIPTION EGR solenoid valve EGR valve position potentiometer MARQUE/TYPE PIERBURG SPECIAL NOTES
K9K-Type 1
Resistance: terminals 4 and 6: 8 ± 0.5 at 25°C Incorporated into the EGR solenoid valve Resistance: terminals 2 and 3: 1 ± 0.5 k at 20°C terminals 1 and 2: 4 ± 1.6 k at 20°C
EC-K9K-22
DIESEL EQUIPMENT Diesel filter
IMPORTANT: Before carrying out any work, wait for the fuel temperature to drop.
K9K-Type 1
REMOVAL - REFITTING Disconnect the battery. Remove fuel filter: RHD models After removing battery and air cleaner 15Fuel filter (RHD models)
MYEC633A
LHD models After removing front wipers, cowl top cover, front wiper motor assembly and cowl top panel/tray. Release the diesel fuel filter from its support. Fit the new diesel fuel filter (do not remove the plugs until the last moment). Disconnect all the snap fasteners beginning with the three vertical snap fasteners. Prevent the snap fasteners from coming into contact with the environment. Disconnect the pump outlet snap fastener last of all; reconnect it immediately when the new filter is installed. Reconnect the other snap fasteners. Prime the system using the priming bulb (automatic degassing). Reconnect the battery.
EC-K9K-23
DIESEL EQUIPMENT Diesel filter
16Fuel filter (LHD models)
K9K-Type 1
MYEC634A
EC-K9K-24
DIESEL EQUIPMENT High pressure pump
IMPORTANT: It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being replaced, the pulley must be replaced.
K9K-Type 1
SPECIAL TOOLING REQUIRED Nissan No. Tool for removing and refitting high KV113E0010 pressure pipes (Mot. 1566) EQUIPMENT REQUIRED Low torque wrench High pressure pipe wrench (for example, Facom "DM19" wrench). Pipe socket for tightening the injector-rail high pressure pipes (for example, Facom Crowfoot 18-17 wrench). Pipe socket for tightening the pump-rail high pressure pipe (for example, Facom Crowfoot 19-17 wrench). TIGHTENING TORQUES (in daNm) High pressure pipe nuts Rail nuts Filler neck nut on the rail High pressure pump mounting bolts 3.8 2.8 ± 0.3 2.1 2.1 ± 2
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit.
EC-K9K-25
DIESEL EQUIPMENT High pressure pump
REMOVAL YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY It is strictly forbidden to remove any injection pump pulley marked number 070 575 (see diagram). If the pump is being replaced, the pulley must be replaced.
K9K-Type 1
The high pressure pump may be removed after having first removed the timing belt Disconnect the battery. Remove: the neck (1) located on the fuel rail, the dipstick guide and plug the hole. Undo the mounting nuts of the rail (2) a few turns.
EC-K9K-26
DIESEL EQUIPMENT High pressure pump
Carefully disconnect: the connectors from the flow actuator (3) and fuel temperature sensor (4), the pre-heater (glow) plugs and the injectors (5), the return pipe (8) connecting the injector with the pump.
K9K-Type 1
EC-K9K-27
DIESEL EQUIPMENT High pressure pump
Remove the high pressure pipe (9) connecting the pump to the rail. To do this: undo the nut on the pump side then the nut on the rail side, Move the nut along the tube keeping the olive in contact with the taper. Plug all the holes of the injection circuit. Remove the three mounting bolts (10) from the injection pump then remove it.
K9K-Type 1
Refit the high pressure pipe, to do this: remove the protective plugs, insert the high pressure pipe olive into the taper of the high pressure pump outlet, insert the high pressure pipe olive into the taper of the high pressure rail inlet. Finger tighten the nuts of the high pressure pipe starting with the one located on the rail side. Tighten the mounting bolts (10) on the high pressure pump to a torque of 2.1 daN.m. IMPORTANT: Do not touch the pipes with the wrench when torque tightening. Using the recommended tools, tighten the following in the order and to the torques shown: the nut on the rail side to 3.8 daN.m, the nut on the pump side to 3.8 daN.m, Tighten the rail mounting nuts to a torque setting of 2.8 daNm.
REFITTING Fit the pump then position the mounting bolts without tightening them. IMPORTANT: All the high pressure pipes removed must be systematically replaced. Before fitting the new high pressure pipe, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit. Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure after it has been repaired (refer to "Special features").
EC-K9K-28
DIESEL EQUIPMENT Flow actuator
EQUIPMENT REQUIRED Low torque wrench Pipe socket for tightening the high pressure pipe (for example, Facom Crowfoot 18-17 wrench).
K9K-Type 1
TIGHTENING TORQUES (in daNm) Flow actuator mounting bolt 0.55 ± 0.06
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit.
EC-K9K-29
DIESEL EQUIPMENT Flow actuator
REMOVAL YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect the battery. Remove the engine cover. Disconnect the connector from the flow actuator (1) and from the fuel temperature sensor carefully (2).
With air cleaner removed
K9K-Type 1
Unscrew the two retaining bolts from the bracket (4). Withdraw the flow actuator (by hand using small successive turns. Do not use the electrical connector as a lever arm). REFITTING Remove the new component from its packaging just before fitting it. NOTE: Do not lubricate the seals with grease or used diesel oil. Use the applicator provided in the kit for the new part. Position the actuator. (Important: when fitting the regulator, do not mark the seal.) Position the two mounting bolts then tighten them. Fit a new high pressure pipe to injector no. 4 plus a new clip (refer to high pressure pipes). Reconnect: the diesel return pipe, the electrical connectors.
YEC637A
Disconnect the fuel return pipe (3). Remove the high pressure pipe from injector no. 4 (refer to high pressure pipes). Plug the holes in the injection circuit. Disconnect the pre-heater plug and the injectors from cylinders 3 and 4.
EC-K9K-30
DIESEL EQUIPMENT Flow actuator
Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure circuit after it has been repaired (refer to "Special features").
K9K-Type 1
EC-K9K-31
DIESEL EQUIPMENT Fuel temperature sensor
EQUIPMENT REQUIRED Low torque wrench
K9K-Type 1
TIGHTENING TORQUES (in daNm) Fuel temperature sensor 1.5 ± 0.15
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit.
EC-K9K-32
DIESEL EQUIPMENT Fuel temperature sensor
REMOVAL YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect the battery. Remove the engine cover. Disconnect the connector from the fuel temperature sensor carefully (1). Undo then remove the fuel temperature sensor. REFITTING
K9K-Type 1
Grease the O-ring with the lubricant from the sachet provided with the new part. Take care not to damage the O-ring when installing the sensor. Position the fuel temperature sensor then tighten to torque. Reconnect: the electrical connector. the battery. Test the sealing of the high pressure after it has been repaired (refer to "Special features").
EC-K9K-33
DIESEL EQUIPMENT Venturi
EQUIPMENT REQUIRED Low torque wrench
K9K-Type 1
TIGHTENING TORQUES (in daNm) Venturi mounting bolts 0.55 ± 0.06
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit.
EC-K9K-34
DIESEL EQUIPMENT Venturi
REMOVAL YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect the battery. Remove the engine cover. Disconnect: the fuel return pipe on the pump (1). the return pipe (2) connecting the injector with the pump. Remove the venturi mounting bolts (3) then take it out. REFITTING
K9K-Type 1
Grease the O-ring with the lubricant from the sachet provided with the new part. Take care not to damage the O-ring when installing the venturi. Position the venturi then tighten it to torque. Reconnect the different pipes. Test the sealing of the high pressure circuit after it has been repaired (refer to "Special features").
EC-K9K-35
DIESEL EQUIPMENT Injector rail
SPECIAL TOOLING REQUIRED Nissan No. Tool for removing and refitting high KV113E0010 pressure pipes (Mot. 1566) EQUIPMENT REQUIRED Low torque wrench High pressure pipe wrench (for example, Facom "DM19" wrench). Pipe socket for tightening the injector-rail high pressure pipes (for example, Facom Crowfoot 18-17 wrench). Pipe socket for tightening the pump-rail high pressure pipe (for example, Facom Crowfoot 19-17 wrench).
K9K-Type 1
TIGHTENING TORQUES (in daNm) High pressure pipe nuts Rail nuts Filler neck nut on the rail 3.8 2.8 ± 0.3 2.1
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit. IMPORTANT: The pressure sensor cannot be separated from the rail.
EC-K9K-36
DIESEL EQUIPMENT Injector rail
REMOVAL YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect the battery. Remove the engine cover. Carefully disconnect: the connectors from the flow actuator (1), the connectors from the fuel temperature sensor (2), the injector connectors (3), the glow (heater) plugs, on the pump, the fuel supply (4) and return (5) pipes. the return pipe (6) connecting the injectors with the pump.
K9K-Type 1
Remove: the neck (7) located on the fuel rail, the dipstick guide and plug the hole. Disconnect the pressure sensor connector from the rail (8).
EC-K9K-37
DIESEL EQUIPMENT Injector rail
Remove the clips connecting the high pressure pipes. IMPORTANT: When undoing the high pressure pipes, it is essential to maintain the central union of the injector (9).
K9K-Type 1
Remove all the high pressure pipes (12). Plug all the holes in the injection circuit. Remove the rail (13).
IMPORTANT: Do not damage the injector's leak return duct (10).
Undo the mounting nuts of the rail (11) a few turns. NOTE: Undo the nut on the pump side or the injector side, then the nut located on the rail side. Undo the nuts for each pipe in turn. Move the nut along the pipe keeping the olive in contact with the taper.
EC-K9K-38
DIESEL EQUIPMENT Injector rail
REFITTING IMPORTANT: All the high pressure pipes removed must be replaced as a matter of course. Fit a new high pressure rail on the studs. Finger tighten the nuts. Before fitting the new high pressure pipes, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit. NOTE: Fit the pump/rail pipe before the rail/injector pipes. Fit the pump-rail high pressure pipe: remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the pipe. insert the high pressure pipe olive into the taper of the high pressure pump outlet, insert the high pressure pipe olive into the taper of the high pressure rail inlet. finger tighten the nuts of the high pressure pipe starting with the one located on the rail side. Fit the rail-injector high pressure pipe: IMPORTANT: When tightening the high pressure pipes, it is essential to maintain the central union of the injector (10).
K9K-Type 1
remove the protective plugs from the high pressure rail outlet, the injector high pressure inlet and the pipe. insert the high pressure pipe olive into the taper of the high pressure injector inlet, insert the high pressure pipe olive into the taper of the high pressure rail outlet. finger tighten the nuts of the high pressure pipe starting with the one located on the injector side. Fit the remaining high pressure pipes as you did previously. NOTE: The order in which the pipes are installed is not important. Fit the clips supplied with the new pipes onto the high pressure pipes: Insert the first half of the clip using adjustable pliers, Insert the second half of the clip using adjustable pliers. IMPORTANT: Pay attention to the direction of installation of the second clip. The tabs located in the centre of the clip will only fit together in one position.
EC-K9K-39
DIESEL EQUIPMENT Injector rail
Tighten the rail nuts to a torque of 2.8 daNm. IMPORTANT: Do not touch the pipes with the wrench when torque tightening. IMPORTANT: Follow the order and tightening torque of the high pressure pipes. Using the recommended tools, tighten the nuts on the rail - pump high pressure pipe: tighten the nut on the rail side to a torque of 3.8 daN.m. tighten the nut on the pump side to a torque of 3.8 daN.m.
K9K-Type 1
Using the recommended tools, tighten the nuts on the rail - injector high pressure pipes: tighten the nut on the injector side to a torque of 3.8 daN.m. tighten the nut on the rail side to a torque of 3.8 daN.m. NOTE: Tighten one pipe fully before moving on to the next pipe.
Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure after it has been repaired (refer to "Special features").
EC-K9K-40
DIESEL EQUIPMENT Pressure sensor
The pressure sensor (1) cannot be separated from the fuel rail. If the pressure sensor malfunctions, the pressure sensor assembly - rail and high pressure pipes - must be replaced (refer to fuel rail section).
K9K-Type 1
EC-K9K-41
DIESEL EQUIPMENT Injectors
SPECIAL TOOLING REQUIRED Nissan No. Tool for removing and refitting high KV113E0010 pressure pipes (Mot. 1566) EQUIPMENT REQUIRED Low torque wrench High pressure pipe wrench (for example, Facom DM19 wrench). Pipe socket for tightening the injector-rail high pressure pipes (for example, Facom Crowfoot 18-17 wrench). Pipe socket for tightening the pump-rail high pressure pipe (for example, Facom Crowfoot 19-17 wrench).
K9K-Type 1
TIGHTENING TORQUES (in daNm) High pressure pipe nuts Rail nuts Injector mounting Filler neck nut on the rail 3.8 2.8 ± 0.3 2.8 ± 0.3 2.1
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit. IMPORTANT: It is forbidden to open an injector. If you open an injector by mistake, you will have to change it. This is because of the manufacturing and installation tolerances and because there is a risk of contaminating the inside of the injector. The rod filter of the injector must not be removed.
EC-K9K-42
DIESEL EQUIPMENT Injectors
REMOVAL NOTE: It is possible to replace a single high pressure pipe. YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect the battery. Remove: the engine cover, the neck (1) located on the high pressure rail, the dipstick guide then plug the hole. Undo the mounting nuts of the rail (2) a few turns. Disconnect: the fuel return pipe (3), the injector electrical connector.
K9K-Type 1
Remove the clip (4) connecting the high pressure pipes.
IMPORTANT: When undoing the high pressure pipes, it is essential to maintain the central union of the injector (5).
Undo the nut on the injector side, then the nut located on the rail side of the high pressure pipe. Move the nut along the tube keeping the olive in contact with the taper.
IMPORTANT: Do not damage the injector's leak return duct (6).
EC-K9K-43
DIESEL EQUIPMENT Injectors
REFITTING
K9K-Type 1
NOTE: Read the 16 digit code on the new injector before refitting it and programming the code into the ECM using the CONSULT-II (see section "Special features, Replacing injectors"). The code is unique to each injector, it specifies the flow. Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the wipes recommended for this purpose, dipped in clean solvent. Dry off using a different new wipe. Replace the flameshield washer with a new one. Position the injector. Tighten its mounting clamp to a torque of 2.8 daN.m. * 16 digit code Remove the high pressure pipe (7). Disconnect the diesel return pipe on the injector. Plug all the holes of the injection circuit. Unscrew the injector bracket (8). Remove the injector. Pull off the flameshield washer. IMPORTANT: All the high pressure pipes removed must be systematically replaced.
Before fitting the new high pressure pipe, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit.
EC-K9K-44
DIESEL EQUIPMENT Injectors
Fit the high pressure pipe: remove the protective plugs from the rail, the injector inlet and the pipe. insert the high pressure pipe olive into the taper of the injector inlet, insert the high pressure pipe olive into the taper of the rail outlet. Move the nut into position by hand, injector side first then the rail side. Fit a new clip supplied with the new pipes onto the high pressure pipes: Insert the first half of the clip using adjustable pliers, Insert the second half of the clip using adjustable pliers. IMPORTANT: Pay attention to the direction of installation of the second clip. The tabs located in the centre of the clip will only fit together in one position.
K9K-Type 1
Tighten the rail nuts to a torque of 2.8 daNm. IMPORTANT: Do not touch the pipes with the wrench when torque tightening.
IMPORTANT: When tightening the high pressure pipes, it is essential to maintain the central union of the injector.
Using the recommended tools, tighten the following in the order and to the torques shown: the nut on the injector side to a torque of 3.8 daN.m. the nut on the rail side to a torque of 3.8 daN.m.
Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure after it has been repaired (refer to "Special features").
EC-K9K-45
DIESEL EQUIPMENT High pressure pipes
SPECIAL TOOLING REQUIRED Nissan No. Tool for removing and refitting high KV113E0010 pressure pipes (Mot. 1566) EQUIPMENT REQUIRED Low torque wrench High pressure pipe wrench (for example, Facom DM19 wrench). Pipe socket for tightening the injector-rail high pressure pipes (for example, Facom Crowfoot 18-17 wrench). Pipe socket for tightening the pump-rail high pressure pipe (for example, Facom Crowfoot 19-17 wrench).
K9K-Type 1
TIGHTENING TORQUES (in daNm) High pressure pipe nuts Rail nuts Filler neck nut on the rail 3.8 2.8 ± 0.3 2.1
IMPORTANT: Before carrying out any work, connect the CONSULT-II, set up communication with the ECM and check that the injection rail is not under pressure. Wait until the fuel temperature drops. Order the special high pressure injection circuit plug kit.
EC-K9K-46
DIESEL EQUIPMENT High pressure pipes
REMOVAL NOTE: It is possible to replace a single high pressure pipe. YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect the battery. Remove: the engine cover, the neck (1) located on the high pressure rail, the dipstick guide then plug the hole. Undo the mounting nuts of the rail (2) a few turns.
K9K-Type 1
Undo the nut on the pump side or the injector side, then the nut located on the rail side. Move the nut along the tube keeping the olive in contact with the taper. IMPORTANT: Do not damage the injector's leak return duct (5).
Remove the clip (3) connecting the high pressure pipes. IMPORTANT: When undoing the high pressure pipes, it is essential to maintain the central union of the injector (4).
EC-K9K-47
DIESEL EQUIPMENT High pressure pipes
Remove the high pressure pipe(s). Plug all the holes of the injection circuit. REFITTING NOTE: Fit the pump/rail pipe before the rail/injector pipes. Before fitting the new high pressure pipes, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit. Fit the pump-rail high pressure pipe: remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the pipe. insert the high pressure pipe olive into the taper of the high pressure pump outlet, insert the high pressure pipe olive into the taper of the high pressure rail inlet. finger tighten the nuts of the high pressure pipe starting with the one located on the rail side. Fit the rail-injector high pressure pipe: remove the protective plugs from the high pressure rail outlet, the injector high pressure inlet and the pipe. insert the high pressure pipe olive into the taper of the high pressure injector inlet, insert the high pressure pipe olive into the taper of the high pressure rail outlet, finger tighten the nuts of the high pressure pipe starting with the one located on the injector side.
K9K-Type 1
Fit the remaining high pressure pipes as you did previously.
IMPORTANT: All the high pressure pipes removed must be systematically replaced.
Fit a new clip supplied with the new pipes onto the high pressure pipes: insert the first half of the clip using adjustable pliers, insert the second half of the clip using adjustable pliers.
IMPORTANT: Pay attention to the direction of installation of the second clip. The tabs located in the centre of the clip will only fit together in one position.
EC-K9K-48
DIESEL EQUIPMENT High pressure pipes
Tighten the rail nuts to a torque of 2.8 daN.m.
K9K-Type 1
NOTE: Tighten one pipe fully before moving on to the next pipe.
IMPORTANT: Do not touch the pipes with the wrench when torque tightening.
Using the recommended tools, tighten the following in the order and to the torques shown: the nut on the pump - rail high pressure pipe starting with the one located on the rail side to a torque of 3.8 daN.m. the nut on the pump side to a torque of 3.8 daN.m.
Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure after it has been repaired (refer to "Special features").
IMPORTANT: When tightening the high pressure pipes, it is essential to maintain the central union of the injector (4). Using the recommended tools, tighten the following in the order and to the torques shown: the nut on the injector side to a torque of 3.8 daN.m. the nut on the rail side to a torque of 3.8 daN.m.
EC-K9K-49
DIESEL EQUIPMENT ECM
K9K-Type 1
NOTE: When replacing an ECM, it is necessary to program the individual injector correction and the other vehicle configurations using CONSULT-II. REPLACING THE ECM Before an ECM is replaced in after-sales, the following must be checked using CONSULT-II:
Injectors individual correction value (16 digit code) System configulation
EC-K9K-50
DIESEL EQUIPMENT ECM
REMOVAL Disconnect: the battery, the ECM harness connectors. Remove the mounting nuts from the ECM (19). Reconnect the ECM. Connect the battery. REFITTING
K9K-Type 1
Fit the new ECM, taking care to engage the positioning tab, then fit the ECM on its mounting studs. Tighten the ECM mounting nuts.
Turn the engine on and read the DTC using the CONSULT-II. If necessary repair the DTC that appear then clear them. Check that the vehicle is operating correctly.
YEC636A
EC-K9K-51
DIESEL INJECTION Immobilizer function
K9K-Type 1
This vehicle is fitted with an engine immobilizer system which is controlled by a key recognition system. REPLACING THE ECM The ECM are supplied without a code but they must all be programmed with one. If an ECM is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine immobilizer function must be checked. (Refer to BL section.)
WARNING: These vehicles have a special ECM which does not function unless it is coded. Consequently, it is strongly recommended that you do not carry out tests using ECMs borrowed from the warehouse or on another vehicle to prevent coding and uncoding problems which may leave the ECM useless.
UNCODING PROCEDURE If the ECM has learnt a code and must be returned to the workshop it is imperative that you uncode it before removing it. (See the repair manual or the engine immobilizer TSB).
EC-K9K-52
DIESEL INJECTION Idle speed adjustment
K9K-Type 1
The ECM takes over calculation of the idle speed to maintain the idle speed at the recommended level and to compensate for any variation in the mechanical or electrical couple as regards: the engine coolant temperature, battery voltage, the gear selected on the transmission, the electrical consumers (climate control system, cooling fan assembly etc.), any malfunctions found. At the engine operating temperature, without high electrical consumer, the idle speed is 800 ± 50 rpm. IDLE SPEED CORRECTION ACCORDING TO ENGINE COOLANT TEMPERATURE
X. Engine speed in rpm Y. Temperature in °C
SPEED ADJUSTMENT WHEN THERE IS AN ACCELERATOR PEDAL POSITION SENSOR (POTENTIOMETER) MALFUNCTION
If one or both terminals of the accelerator pedal position sensor (potentiometer) are suspected, the ECM overrides the idle speed to maintain it at 1300 rpm. This defect mode limits performance. The orange injection warning light lights up and flashes. If the accelerator pedal position sensor (potentiometer) is blocked, is no longer being supplied, or is not transmitting an output signal, the ECM overrides the idle speed to maintain it at 1300 rpm. This mode limits performance. The orange injection warning light lights up and flashes. In both cases, when the brake pedal is depressed, the idle speed is stabilised at the recommended speed. If the information from the accelerator pedal position sensor (potentiometer) and the brake switch information does not correspond, the speed is changed to 1300 rpm.
EC-K9K-53
DIESEL INJECTION Idle speed adjustment
IDLE SPEED ADJUSTMENT WHEN THERE IS AN INJECTOR CODE MALFUNCTION
K9K-Type 1
When there is an injector code malfunction, the ECM overrides the idle speed to maintain it at 1300 rpm. This mode limits performance. The orange injection warning light lights up and flashes. CORRECTION OF THE IDLING SPEED ACCORDING TO THE GEAR RATIOS The idling speed is modified according to the gear selected in the transmission: in neutral, 1st and 2nd gear, the speed is (at the engine operating temperature) 850 rpm (graph A), for the other gears, the speed is (at the engine operating temperature) 900 rpm (graph B).
X. Engine speed in rpm Y. Temperature in °C
EC-K9K-54
DIESEL INJECTION Air conditioning control
AIR CONDITIONING CONTROL The compressor is a variable displacement type. The air conditioning relays are controlled by wires: COMPRESSOR OPERATION PROGRAMMING During certain stages of operation, the ECM stops the compressor from functioning. Engine starting program The compressor is prevented from operating for 4 seconds after the engien has started. Thermal protection program
K9K-Type 1
The compressor is not engaged when the engine temperature is higher than 115 °C or from 110 °C at high speed, 4500 rpm for more than 3 seconds. Fan assembly control programming At idling speed and also when driving, with the air conditioning activated, the speed of the fan assembly is determined according to the refrigerant fluid pressure and the vehicle speed.
EC-K9K-55
DIESEL INJECTION Air conditioning control
Recovery of performance
K9K-Type 1
When pressure is applied to the accelerator pedal above 70%, the compressor is disengaged for 5 seconds. Recovery of output when the vehicle starts moving In order to help the vehicle move off, the air conditioning compressor is disengaged if the position of the accelerator pedal is above 35 % and the idling speed less than 1250 rpm. Anti-stall protection The compressor is disengaged if the engine speed is lower than 750 rpm. Engine overspeed timed protection program The compressor is disengaged when the speed reaches 4500 rpm for more than 3 seconds. NOTE: The time between the compressor being disengaged twice is always greater than 10 seconds.
EC-K9K-56
DIESEL INJECTION Pre/postheating (glow plug) control
The pre/postheating function is controlled by the preheating unit. PRE/POSTHEATING (glow plug) OPERATING PRINCIPLE 1) Ignition on "preheating" a) Variable preheating The time period for the warning light to light up and the feed to heater plugs depends on the coolant temperature and the battery voltage. 2)
K9K-Type 1
"Post heating" with the engine running
During this phase the plugs are supplied continuously according to engine coolant temperature.
X. Time in seconds Y. Temperature in °C For idle speed without pressing the accelerator pedal. X. Time in seconds Y. Temperature in °C Whatever the situation, the preheating warning light cannot be lit for more than 15 seconds (except in the event of an engine coolant temperature sensor malfunction). b) Fixed preheating After the warning light goes out the plugs remain supplied for a fixed period of 5 seconds.
EC-K9K-57
DIESEL EQUIPMENT Glow plugs
The resistance of a glow plug is 0.6 . TIGHTENING TORQUE (in daNm) Glow plug 1.5
K9K-Type 1
Plugs may be removed without having to open the high pressure circuit. REMOVAL Disconnect the battery. Unclip the plug connector. Clean the outside of the plug to avoid any dirt entering the cylinder. Loosen and remove the plugs.
To undo the plug on cylinder 4 use a 10 mm long radio socket attached to a universal joint. Once the plug is loosened use a hose to unscrew it completely. REFITTING Proceed in the reverse order to removal.
EC-K9K-58
DIESEL EQUIPMENT Engine coolant temperature
The cooling fan unit is controlled by the ECM. COOLING FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING The cooling fan assembly is controlled:
K9K-Type 1
at slow speed if the engine coolant temperature exceeds 99°C or if there is an engine coolant temperature sensor malfunction, and is switched off when the temperature falls below 96°C. at high speed if the engine coolant temperature exceeds 102°C or if there is a low speed malfunction, and is switched off when the temperature falls below 99°C.
The cooling fan assembly low and high speeds are controlled when the air conditioning function is selected on the instrument panel. If the low speed setting is suspected, the high speed setting operates under the low speed conditions. OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT The engine coolant temperature warning light remains lit if the engine coolant temperature exceeds 114°C. It goes out when the temperature falls below 111°C.
EC-K9K-59
ANTI-POLLUTION 1 1K9K-TYPE Oil vapour rebreathing
CIRCUIT DIAGRAM A.
K9K-Type 1
When there is a low charge, the vacuum in the air intake duct is below the spring set point. The oil vapours are extensively rebreathed by the vacuum in the air intake duct. When there is a medium or high charge, the pressure in the air intake duct exhausts the valve diaphragm, the oil vapours are breathed in small quantities via a calibrated hole.
B.
CHECKING To ensure the correct operation of the anti-pollution system, the oil vapour rebreathing circuit must be kept clean and in good condition.
1 2 3 4 5 Pa
Cylinder head cover Oil vapour rebreathing duct Oil vapour recirculation valve Air inlet duct Turbocharger Atmospheric pressure
EC-K9K-60
ANTI-POLLUTION Exhaust gas recirculation (EGR)
CIRCUIT DIAGRAM
K9K-Type 1
1 2 3 4 5 6 7 A B
Engine Air filter unit Air distributor Exhaust manifold EGR unit with solenoid valve Turbocharger ECM Air inlet Exhaust gas outlet
PURPOSE OF THE EGR SYSTEM Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases. The ECM authorises gas to pass by controlling a solenoid valve.
EC-K9K-61
DIESEL INJECTION 2K9K-TYPE 1 System Diagram
K9K-Type 1
YEC860A
EC-K9K-62
2K9K-TYPE 1
DIESEL INJECTION System Diagram
16. Accelerator pedal position sensor 17. Turbocharger 18. Glow relay unit 19. Catalyst 20. Camshaft position sensor 21. Battery 22. Ignition switch 23. Malfunction indicator 24. Glow lamp 25. Glow plug 26. Fuel injector 27. CAN communication 28. Fuel return 29. Intake manifold
K9K-Type 1
1. ECM 2. EGR control solenoid valve 3. Fuel rail pressure sensor 4. Fuel rail 5. Fuel temperature sensor 6. Fuel flow actuator (Fuel pressure regulator) 7. Turbocharger boost pressure sensor (60 kW engine models) 8. Turbocharger air cooler (60 kW engine models) 9. Fuel pump 10. Engine coolant temperature sensor 11. Crankshaft position sensor 12. Clutch switch 13. Intake air temperature sensor 1