Technical Note Green Edition Anglaise

TECHNICAL NOTE GREEN EDITION ANGLAISESEPTEMBER 2001 77 11 307 842 Type 4131A Service 00429 MASTER 2 fitted with the G9T 720 engine 01 SUMMARY OF G9T 720 ENGINE FAULTS XDX G Other sub-section concerned: q q 08 09 10 11 12 13 14 16 19 Engine: Gearbox: G9T 720 XXX Basic manual: Workshop Repair Manual: Mot. G9T Technical Note: 3438A, 3450A, 3471A, 3502A, 3517A UNIT LAUNCH OPERATION APPRAISAL (OLO) G9T 720 CARRIED OUT IN FRANCE BETWEEN SEPTEMBER 2000 AND APRIL 2001. 1 2 3 Number of vehicles manufactured during this period – 23 493 MASTER 2 fitted with G9T 720 engine Number of calls recorded in the OLO period – 258 calls recorded Breakdown statement of the entire operation for the ESPACE and MASTER 2 vehicles. – An average of 15 calls received per 1000 vehicles sold, – 243 parts returned for analysis, – 34 operations carried out by analysts in the network. – 7 customer vehicles returned for analysis, – 80 % of calls concern vehicles with a mileage of less than 7,000 miles On the following page, you will find the main faults associated with the G9T 720 engine according to customer complaint, and their known remedies. 4 "The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed." All copyrights reserved by Renault. 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. © RENAULT 2001 ENGINES AND AUXILIARIES 101 Contents 01 01-03 01-04 01-05 01-06 – STARTING IMPOSSIBLE OR ENGINE UNSTABLE AT IDLE – DIESEL FUEL LEAKING FROM THE FUEL CIRCUIT – LACK OF POWER; INDICATOR LIGHT ON OR OFF – ENGINE IS UNUSUALLY NOISY – OTHER G9T 720 ENGINE FAULTS q INJECTION WARNING LIGHT COMES ON ENGINE JERKING ROUGH IDLING COOLANT LEAK ENGINE OVERHEATING OIL SEEPAGE CONDITION OF EGR VALVE PIPE 01-07 01-07 01-07 01-07 01-08 01-08 01-08 q q q q q q 4131A 01-2 ENGINES AND AUXILIARIES Starting is impossible and/or engine timing STARTING IS IMPOSSIBLE AND/OR ENGINE TIMING CUSTOMER COMPLAINT Impossible to start. Engine stalls. FAULT FINDING POSSIBLE CAUSE 01 AFTER-SALES SOLUTION Replace the accessories belt and the diesel fuel supply pipe. Clean the engine compartment. IMPORTANT: Check the condition of all rubber parts located underneath the vehicle, and replace if necessary. Replace the fuel pressure regulator. NOTE: Redesigned fuel pressure regulators have been fitted in engines later than G9T 720 C029629. Replace the fuel pressure regulator. If replacing the pressure regulator does not rectify the fault, replace the high pressure pump. The accessories belt Check whether the accessories belt is frayed. sections have split the The diesel fuel supply pipe diesel fuel supply pipe. is split. Engine stalls at idling speed. Engine stalls after heavy acceleration. Rough idle. Slow engine response. Impossible to start. Engine stalls. Rough idle. Ensure that there is no air leak in the fuel supply circuit. Normal operation may momentarily be resumed after a gentle tap on the pressure regulator. Fuel pressure regulator malfunction. Diagnostic tool displays the Faulty pressure or fuel regulator, or faulty high following faults: pressure pump. – DF072 05.DEF – DF072 06.DEF – DF072 07.DEF Ensure that there is fuel at the high pressure pump inlet. 4131A 01-3 ENGINES AND AUXILIARIES Diesel fuel leaking from the fuel circuit. DIESEL FUEL LEAKING FROM THE FUEL CIRCUIT CUSTOMER COMPLAINT Fuel odours. Fuel leaks. Traces of fuel on the ground. FAULT FINDING Fuel leak from the high pressure pump housing. POSSIBLE CAUSE Fuel leak from a plug in the high pressure pump. 01 AFTER-SALES SOLUTION Replace the high pressure pump. NOTE: Redesigned high pressure pumps have been fitted in engines later than G9T 720 C021130. Replace the high pressure pipes. Torque-tighten the high pressure pipe nuts to 3 daNm rather than 2.5 daNm IMPORTANT: Check the condition of all rubber parts located underneath the vehicle, and replace if necessary. Pay attention to the installation advice detailed in the Technical Notes. Badly positioned high pressure pipes can result in more seepage or leaks. Check the condition of the cylinder head cover shield and soundproofing. These may become soaked in diesel fuel, if there is a leak. Fuel seepage from the high pressure pipes. Run the engine under load to maximise the pressure in the high pressure rail. Fuel seepage from the high pressure pipe unions in the high pressure circuit. 4131A 01-4 ENGINES AND AUXILIARIES Lack of power output; indicator light on or off LACK OF POWER; INDICATOR LIGHT ON OR OFF CUSTOMER COMPLAINT Lack of power. The injection warning light comes on. FAULT FINDING Diagnostic tool may display the following faults: – DF019 04.DEF – DF077 01.DEF – DF078 01.DEF – DF084 02.DEF IMPORTANT: An external reason, such as air entering downstream of the air flowmeter can cause the diagnostic tool to display an EGR valve fault. Check that the turbocharger turbine can spin freely. POSSIBLE CAUSE EGR valve. 01 AFTER-SALES SOLUTION Apply Technical Note 3502A. Replace the EGR valve if necessary. Significant lack of power. The injection warning light comes on. Lack of power and engine noise. Turbocharger is seized. Replace the turbocharger. Repair the engine. At a steady engine speed the Faulty rocker arm. noise is irregular and occurs The rocker arm has become dislocated and is intermittently. causing wear to the valve head and hydraulic stop. Replace the rocker arm. At a steady engine speed the Faulty rocker arm Check the condition of the noise is cyclic and constant. hydraulic tappet. The valve is not opening other rocker arms. completely, so play compensation is inefficient. Engine is running on 2 or 3 cylinders with exhaust noise. One or more injector flanges broken. Replace the flange and mounting bolts. Check the condition of the cylinder head and injector and repair if necessary. NOTE: Redesigned flanges have been fitted in engines later than G9T 720 C022085. 4131A 01-5 ENGINES AND AUXILIARIES Engine is unusually noisy ENGINE IS UNUSUALLY NOISY CUSTOMER COMPLAINT Engine rattle and exhaust smoke. FAULT FINDING Diagnostic tool displays fault DF072 stored. Disconnect each connector injector by injector to identify the cylinder at fault. POSSIBLE CAUSE Injector is remaining in open position. Contamination present in the injector port or injector is jammed. 01 AFTER-SALES SOLUTION Check the condition of the heater plug of the cylinder at fault. Check the compression if the heater plug is worn. Replace the faulty injector. Repair the engine if necessary. IMPORTANT: The flange and mounting screws for the injector must always be replaced when an injector is replaced. Replace the coolant pump and the worn sprockets. IMPORTANT: When replacing the coolant pump, remember to: Grease the seal Push down on the coolant pump Check that it is fitted flush with its sealing surface. Replace the engine. IMPORTANT: In engines later than the G9T 720 C026966, the lateral shims are checked when fitted. Approval is required for any acceptance of the cost of this operation. Ringing sound following operation on the coolant pump. Check for noise at the coolant The coolant pump is not pump closure panel. fitted flush with its sealing surface.The coolant pump gear is out of alignment and wearing the adjacent sprockets. Unusual noise when clutch There is more than 0.5 mm pedal is depressed. crankshaft side play and there are filings in the oil. Worn crankshaft lateral shims. 4131A 01-6 ENGINES AND AUXILIARIES Other G9T 720 engine faults THE INJECTION WARNING LIGHT COMES ON CUSTOMER COMPLAINT FAULT FINDING POSSIBLE CAUSE 01 AFTER-SALES SOLUTION Reset the high pressure pump sprocket according to the Workshop Repair Manual or Technical Note 3438A. Diagnostic tool displays fault Misalignment of the high Injection indicator light pressure pump gear by comes on in the absence of DF070 stored. Check the timing of the high one or two teeth. an operating fault. pressure pump gear. ENGINE JERKING CUSTOMER COMPLAINT Engine jerking or stalling. The injection warning light comes on. Unusual noise when clutch pedal is depressed. Engine jerking or stalling. The injection warning light comes on. FAULT FINDING POSSIBLE CAUSE AFTER-SALES SOLUTION See engine unusually noisy section page 01-06. Diagnostic tool displays fault Positioning or damage to the TDC sensor or to its DF070 03.DEF stored. Check the air gap between alignment. the TDC sensor and its target. Realign the TDC sensor to create an air gap of less than 2.6 mm. Apply the Technical Note 3502A. ROUGH IDLING CUSTOMER COMPLAINT Rough idle. FAULT FINDING POSSIBLE CAUSE AFTER-SALES SOLUTION Replace the flywheel. The engine speed stabilises Flywheel. when electrical consumers are switched on (e.g.: air conditioning, headlights, power assisted steering under load with the steering wheel on full lock). Ensure that the tooth of the flywheel target found next to TDC is wider than the others. COOLANT IS LEAKING CUSTOMER COMPLAINT Coolant is leaking. FAULT FINDING Coolant is leaking from the connection between the plenum chamber and the coolant pipe. POSSIBLE CAUSE Shifting or wear of the Oring found on the plenum chamber. AFTER-SALES SOLUTION Replace the O-ring. The joint must not slip or twist, as the two parts are connected. NOTE: Redesigned plenum chambers have been fitted in engines later than G9T 720 C025296. 4131A 01-7 ENGINES AND AUXILIARIES Other G9T 720 engine faults ENGINE OVERHEATING CUSTOMER COMPLAINT Coolant temperature warning light comes on. FAULT FINDING Poor coolant circulation in the coolant tank. The radiator stays warm. POSSIBLE CAUSE 01 AFTER-SALES SOLUTION The coolant pump impeller Replace the coolant pump. has become disconnected IMPORTANT: When replacing the coolant pump, from its driving shaft. remember to: Grease the seal Push down on the coolant pump Check that it is fitted flush with its sealing surface. OIL SEEPAGE CUSTOMER COMPLAINT Oil seepage. FAULT FINDING Oil seepage around the cylinder head cover bolts. POSSIBLE CAUSE Oil is following the thread of the mounting bolts and appears on the cylinder head cover. AFTER-SALES SOLUTION Do not replace the cylinder head cover. Clean the cylinder head cover bolts and refit using "Loctite Freinetanch" Part No.: 77 01 394 070. IMPORTANT: Cylinder head cover bolts have cement micro-encapsulated in the thread in engines later than G9T 720 C037707. CONDITION OF THE EGR VALVE PIPE CUSTOMER COMPLAINT EGR valve hose sleeve is deteriorated. Without malfunction. FAULT FINDING Concerns the EGR pipes with a silver-coloured sleeve. POSSIBLE CAUSE Crimping of the sleeve. AFTER-SALES SOLUTION Replace the EGR valve pipe. 4131A 01-8