renault engine k9k gen4 siemens

ASSESSMENT 1

1. What emission standard does the step 2 K9K engine meet?

2. What is the function of the recirculated exhaust gas cooler?

3. What is the maximum injection pressure on the Siemens system?

NAME OF TRAINEE: WEEK:

GROUP: TRAINER:

NETWORK TRAINING: TRAINING CENTRE:

START RESULT: END RESULT:

Start End

■A :Euro 2000. ❏ ❏

■B :Euro 4. ❏ ❏

■C :Euro 3. ❏ ❏

Start End

■A :To reduce fuel consumption. ❏ ❏

■B :To increase the rate at which the engine heats up. ❏ ❏

■C : Improve the performance of exhaust gas recirculation. ❏ ❏

Start End

■A :1,600 bar. ❏ ❏

■B :1,450 bar. ❏ ❏

■C :2,000 bar. ❏ ❏

PROGRESSASSESSMENTPROGRESSASSESSMENT

K9K Engine Developments

2 ASSESSMENT

4. What is the main advantage of piezoelectric injectors?

5. How is the damping flap actuated on the step 2 K9K engine?

6. What type of turbocharger is used on the step 2 K9K engine?

7. What is the position of the fuel flow regulator when it is disconnected?

Start End

■A :They increase the injection pressure. ❏ ❏

■B :They improve fuel atomisation. ❏ ❏

■C :They allow the number of injections per cycle to be multiplied. ❏ ❏

Start End

■A :Pneumatically by a solenoid valve. ❏ ❏

■B :By an electric motor. ❏ ❏

■C :By an electromagnet. ❏ ❏

Start End

■A :Variable geometry multi-vane. ❏ ❏

■B :Fixed geometry computer-controlled. ❏ ❏

■C :Fixed geometry with mechanical relief valve. ❏ ❏

Start End

■A :Fully open (kept open by a return spring). ❏ ❏

■B :Fully closed (kept closed by a return spring). ❏ ❏

ASSESSMENT 3


8. How is the pressure regulated on a Siemens injection system?

9. Why must you never disconnect a piezoelectric injector when the engine is running?

10. Where is the cylinder position sensor located on a step 2 K9K engine?

Start End

■A :High pressure is sent to the return line. ❏ ❏

■B :The volume of low pressure fuel entering the high pressure pump is controlled.

❏ ❏

■C :Through dual regulation. ❏ ❏

Start End

■A :Because it may jam open and destroy the engine. ❏ ❏

■B :Because it can damage the piezoelectric component. ❏ ❏

■C :Because it may damage the computer's electronics. ❏ ❏

Start End

■A :On the injection pump pulley. ❏ ❏

■B :On the camshaft. ❏ ❏

■C :On the crankshaft. ❏ ❏

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS 1

CONTENTSCONTENTS2nd GENERATION K9K ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Lower Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Air supply/exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine monitoring/management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Workshop sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19


Introduction

From the beginning of 2005, new diesel vehicles must conform to the Euro 4 emissionsstandard.

This standard will cut emissions by nearly 50 percent in comparison with the Euro 3standard.

The K9K engine, also know as step 2, uses the new Siemens injection system in orderto meet the new emissions standards at the same time as maintaining a high level ofperformance.

Engine type Power in kW (bhp) Torque (Nm)

K9K 764/732 80 (110) 240

K9Keu4-D1104OP0004

2nd GENERATION K9K ENGINE2nd GENERATION K9K ENGINE

2nd generation K9K engine

4 TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

Lower engineThe general layout of the engine has not been modified in any notable way. However,the cylinder head has been redesigned in order to accommodate the new injectors.

Timing

A new camshaft pulley (1) is now in use. This is accompanied by a simpler adjustmentmethod for refitting purposes.

Dual-mass flywheel

K9Keu4-D1104OP0006

1

K9Keu4-M0305OP0014

A dual-mass flywheel gives improvedacoustics and driving pleasure.



Air supply/exhaust gas recirculation

Inlet flap

Turbocharger

This engine uses a multi-vane variable geometry turbocharger to obtain the optimaltorque curve. The torque curve is controlled by a pneumatic solenoid valve.

An intercooler located behind the front bumper cools the air leaving the turbochargerin order to improve the engine output.

K9Keu4-D1104OP007b

A computer-controlled air flap at theinlet ensures damping when the engineis switched off.

The flap is controlled by an electricmotor and will allow air flow to be mana-ged in order to control of the regenera-tion temperature on future modelsequipped with a particle filter. Such asystem is also able to regulate the flowof fresh air to the engine by opening/clo-sing the flap.

K9Keu4-D1104OP0008

K9Keu4-D1104OP0005

260

240

220

200

180

160

140

120

100

Nm

1,000 2,000 3,000 4,000 rpm

K9K 74 kW Euro3

K9K 80 kW Euro4



Exhaust gas recirculation (EGR)

Exhaust gas recirculation is regulated by a flap which is controlled by the computer. Adevice for cooling the gas improves the EGR potential and reduces nitrogen oxidesemissions (NOx). A decrease in temperature allows a greater mass of gas to beadmitted for a given volume.

Note

The step 2 K9K engine is not equipped with a bypass canal on the exhaust gascooler.

K9Keu4-D1104OP0002

12

1 Intercooler.2 Recirculation valve.



Engine monitoring/management Signals from various sensors are sent to the computer so that it can control the injectorsystem actuators.

Summary table of sensors

Water thermistorIt is attached to the cooling circuit which is located at the end of the cylinder head on the clutch side.Type: Negative Temperature Coefficient (NTC).

Fuel temperature sensorIt is located on the diesel return pipe at the high-pressure pump outlet. It cannot be separated from the injector return circuit.Temperature range:– 23 °C/+ 120 °C

Inlet pressure sensorIt is attached to the intercooler outlet duct.It is supplied with 5 V from the computer and its range allows measurements from 0.2 to 3 bar.

TDC and engine speed sensorIt is inductive and is attached to the rear section of the clutch housing.The target is built into the flywheel.

K9Ke

u4-M

0305

OP0

101

K9Ke

u4-M

0305

OP0

102

K9Ke

u4-M

0305

OP0

103

K9Ke

u4-M

0305

OP0

104



Camshaft sensorIt is a Hall effect sensor and is attached to the flywheel end of the rocker cover. The target is mounted on the camshaft.

Fuel pressure sensorIt is attached to the rail and cannot be dismantled.

Air mass flowmeterIt is located behind the computer and is incorporated with the air temperature sensor (NTC).

K9Ke

u4-D

1104

OP00

10K9

Keu4

-D11

04OP

0010

K9Ke

u4-D

1104

OP00

10K9

Keu4

-M03

05O

P010

7K9

Keu4

-M03

05O

P010

6



Fuel supply

Fuel filter

This is a metallic monobloc unit with click connections.

It comprises a thermostatic component which enables fuel from the return circuit to berecirculated towards the high-pressure pump. During operating phases at lowtemperatures, this component enables the compression of fuel hotter than thatcontained in the tank.

Notes

- The thermostatic section can be separated from the filter unit.- This type of unit is fitted to Mégane II models. A conventional plastic unit is

fitted to the Modus.

K9Keu4-D1104OP0011

2

5

14

3

1 Inlet from tank.2 Tank return line.3 High-pressure pipe and injector

return line.4 High-pressure pump supply.5 Thermostatic component for

recirculation.



High-pressure pump

The high-pressure pump is a rotary type and is driven by the timing belt.

It incorporates an internal low-pressure pump (5 bar) in order to draw up fuel from thetank.

The maximum injection pressure is 1 600 bar.

Pumping principle

K9Keu4-M0305OP0001

4

7321

56

1 Low-pressure transfer pump.2 Flow regulator.3 Pump cylinder.4 Pressure regulator.5 Fuel inlet.6 High-pressure outlet.7 Injector return line.

3

3

3

a c

b

47

21

5

6

K9KEU4-M03050p0003

1 Internal fuel transfer pump.2 Flow regulator.3 High-pressure pumping

component.4 Pressure regulator.5 Low-pressure regulator valve.6 Valve.7 Filter. a Fuel inlet.b High-pressure outlet. c Fuel return line.



The high-pressure pump has 3 pumping components arranged in a 3-sided starformation.

The fuel is drawn up in the tank by an internal transfer pump (1) via the fuel filter. It isthen fed towards the valve (6) and towards the flow regulator (2).

A mechanical valve (5) maintains an inlet pressure of 5 bar.

In order to keep the system lubricated, the fuel reaches the inside of the high-pressurepump via the valve (6) and then flows into the fuel return duct (c).

The flow regulator (2) which is controlled by the engine management computerdetermines the amount of fuel delivered to the high-pressure pumping components (3).

The high-pressure outlets of the three pump components are collected together andguided towards the high-pressure outlet (b).

The pressure regulator (4) lies between the high-pressure channel and the fuel returnline. It regulates the amount of fuel delivered towards the high-pressure outlet.

Details of pumping components

K9KEU4-M03050p0002

4

4

2 2

3

3

1

1 Piston.2 Inlet valve.3 Outlet valve.4 Pump shaft with cam.



Rail pressure checkA special feature of the Siemens high-pressure pump is that there are two ways ofregulating the rail pressure:

- Flow regulation.- Regulation by bleeding.

• Flow regulation method

Flow regulator

The injection computer controls the regulator.

This method of regulation is efficient as only the necessary amount of fuel ispressurised. This method is therefore the most frequently used for engine operation.

Notes

- In the rest position, the flow regulator is kept closed by a return spring.- During flow regulation, the flow regulator is kept closed by the computer.

K9Keu4-M0305OP0004

The purpose of the flow regulatoris to regulate the amount of fueldelivered to the pumpingcylinders in order to obtain thedesired pressure in the rail.

K9Keu4-M0305OP0010

A

Scale:5 V/div.2 ms/div.

The flow regulator is controlled by apulse-width modulated current of12 V.



• Pressure regulation by bleeding methodPressure regulator

The role of the pressure regulator is to bleed any excess high pressure into the returnline in order to regulate the rail pressure. It is controlled by the injection computer.

Compared to the flow regulation method, the regulation by bleeding method is quickerand more accurate. It is however less efficient because of the needless pressurisationof fuel.

This method is therefore only used:

- when cold (temperature lower than 17 °C),- at idle speed,- in order to bleed the rail quickly if there is too much pressure (e.g. rapid

acceleration followed immediately by the release of the accelerator pedal).

Notes

- In the rest position, the pressure regulator is kept closed by a spring set to50 bar.

- During pressure regulation by bleeding, the flow regulator is positioned at a valuedefined by the computer which does not affect the rail pressure.

K9Keu4-M0305OP00051 High-pressure outlet.

2 Towards return circuit. 1

2

2

K9Keu4-M0305OP0011

A

Scale:5 V/div.500 us/div.

The pressure regulator is controlled bya pulse-width modulated current of12 V.



Pressure accumulator.

Note

To preserve a perfect seal, the pressure sensor must not be removed from theinjector rail.

K9Keu4-D1104OP0013

1

2

1 Rail.2 Pressure sensor.

The pressure accumulator is in the formof a cylindrical rail.

It includes a pressure sensor whichinforms the computer of the pressureavailable in the rail.

K9Keu4-D1104OP0014

A plastic cover fits over the high-pressure rail. This safety componentprevents pressurised fuel spraying inthe event of a leak from one of theconnections.



Piezoelectric injectors

Internal operation of the injector

Note

These Siemens injectors do not require individual calibration or injectionadjustment by accelerometer.

k9keu4-M0305op0006

The switching time for piezoelectricinjectors is 4 times quicker thanconventional electromagnetic injectors.

This makes it easier to multiply thenumber of injections per cycle with theaim of improving combustion andreducing emissions.

K9Keu4-M0305OP0007

5

2

1

4

3

The principle of hydraulic opening is similar to that ofelectromagnetic injectors.

The needle is caused to lift when the piezoelectriccomponent (1) dilates as a result of electric stimulation.

When the component extends, it pushes back the valve(3). The pressure above the needle drops and escapestowards the return line (4). The injector needle (5) risesunder the action of high pressure.



Piezoelectric principle

K9Keu4-M0305OP0008

1

1 Piling up of piezoelectric ceramic layers.

Piezoelectric components are madefrom ceramic material.

The component within an injector ismade up of ceramic layers.

k9keu4-M0305op0009

The piezoelectric principle has alreadybeen applied to some types of sensor(pressure, noise, etc.). When a force isapplied to a piezoelectric component, avoltage proportional to this force (1) canbe measured across its terminals.

Conversely, the piezoelectric componentextends when a voltage is applied acrossits terminals (2).

The extension of the actuator in theinjector (approximately 40 micrometres)enables it to open.

V

1 2



Injector controlA piezoelectric injector is electrically comparable to a capacitor. It accumulates currentand then gives it back.

- A piezoelectric injector must never be disconnected when the engine isrunning.

- The piezoelectric component maintains its position when the supply iscut. There is therefore a risk that the injector could jam open. This woulddestroy the engine.

K9Keu4-M0305OP0014b

K9Keu4-M0305OP0014a

T1

T2

I

I

T1

T2

Opening phase:

The computer closes contact T1 (with T2open), the piezoelectric componentextends and at the same time charges itscapacity. The injector opens. The injectorwould remain open if you disconnected itduring this phase. This is why an injectorshould not be disconnected when theengine is running.

Closing phase:

The computer closes contact T2 andopens T1. The capacity discharges, theinjector becomes a generator and thecurrent direction is reversed. Thepiezoelectric component goes back to itsoriginal position and the injector closes.



Controlling injection

The computer orders between 1 and 3 injections per cycle. This number of injectionsis the best compromise in terms of noise, emission and performance.

The number of injections differs depending on the engine speed and load.

Strength of controlled injection

MaintenanceThere are no special notes concerning general maintenance.

Refer to the vehicle maintenance schedule.

Fault findingIn order to check the return flow of injectors, use a conversion kit of the existing tool(MOT 1711 for the Delphi injection system on K9K engines) known as MOT 1771.

1 2 3

K9Keu4-M0305OP0013

A

1 Pre-injection 1.2 Pre-injection 2.3 Main Injection.

Scale:50 V/div.500 us/div.

K9Keu4-M0305OP0012

A

1 2

1 Pre- injection.2 Main Injection.

Scale:5 mV/div.500 us/div.

MECHANICAL AND ELECTRONIC SYSTEMS 19


During the workshop practicals, you will see the following symbols. They will help youto complete the work.

Refer to the technical documentation.

Carry out the practical work indicated.

Answer the question.

An important point is highlighted.

Check your objective with your trainer.

End of workshop practical.

STOP


K9K ENGINESIEMENS INJECTION

OBJECTIVE: To find out about performing fault finding on a Siemens diesel injection system

WORKSHOP PRACTICALWORKSHOP PRACTICAL



VIN and vehicle type:

Documents used: Special tooling:

Find out about the removal procedure for the injection rail protector.

Remove the injection rail protector in accordance with the recommendedprocedure.

Disconnect the cylinder marking sensor and attempt to start the engine.

Does the engine start? What conclusions can you draw?

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

Attempt to start the engine with the flow regulator on the high-pressurepump disconnected.



Does the engine start?

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

What is the position of the flow regulator when it is disconnected?

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

Attempt to start the engine with the pressure regulator on the high-pressure pump disconnected.

Does the engine start? What rail pressure value is read on the diagnostictool?

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

Display the injector control signal using an oscilloscope and note that thenumber of injections changes when the engine speed varies.

Find the procedure for hydraulically checking the high-pressure pump inthe documentation.



Note the procedure and carry out the checks:

Find the exact procedures for checking injectors in the documentation.

Note the procedures and carry out the checks:



Check Value measured

Check Value measured

STOP


K9K ENGINESIEMENS INJECTION

OBJECTIVE: To find out about the technical features of a Siemens Diesel injection system and how to perform fault finding on it.

WORKSHOP FAULT FINDINGWORKSHOP FAULT FINDING



VIN and vehicle type:

Customer complaint:

Documents used: Special tooling:

Apply the RENAULT fault finding procedure.

Note down the fault finding steps.

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.....................................................................................................................

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.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

.....................................................................................................................

What is the origin and the cause of the fault?

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STOP

renault engine k9k gen4 siemens

Documents

k9k engine meet

engine monitoringmanagement

engine heats

engine type power

new siemens injection

maximum injection pressure

high pressure pump

new injectors