PROGRESS

ASSESSMENT
NAME OF TRAINEE:

WEEK:

GROUP:

TRAINER:

NETWORK TRAINING:

TRAINING CENTRE:

START RESULT:

END RESULT:

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

A : Euro 2000.

B : Euro 4.

C : Euro 3.

Start

End

Start

End

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

A : To reduce fuel consumption.

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

C : Improve the performance of exhaust gas recirculation.

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

A : 1,600 bar.

B : 1,450 bar.

C : 2,000 bar.

ASSESSMENT

Start

End

K9K Engine Developments

4. What is the main advantage of piezoelectric injectors?

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

Start

End

Start

End

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

A : Pneumatically by a solenoid valve.

B : By an electric motor.

C : By an electromagnet.

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

A : Variable geometry multi-vane.

B : Fixed geometry computer-controlled.

C : Fixed geometry with mechanical relief valve.

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

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

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

Start

End

ASSESSMENT

K9K Engine Developments

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

Start

End

A : High pressure is sent to the return line.

B : The volume of low pressure fuel entering the high pressure

C : Through dual regulation.

pump is controlled.

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

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

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

A : On the injection pump pulley.

B : On the camshaft.

C : On the crankshaft.

ASSESSMENT

Start

End

CONTENTS
2nd GENERATION K9K ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction

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

Lower Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Workshop sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

nd

2 GENERATION K9K
ENGINE

K9Keu4-D1104OP0004

Introduction

Engine type

Power in kW (bhp)

Torque (Nm)

K9K 764/732

80 (110)

240

From the beginning of 2005, new diesel vehicles must conform to the Euro 4 emissions
standard.
This standard will cut emissions by nearly 50 percent in comparison with the Euro 3
standard.
The K9K engine, also know as step 2, uses the new Siemens injection system in order
to meet the new emissions standards at the same time as maintaining a high level of
performance.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

Lower engine
The 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

K9Keu4-D1104OP0006

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

Dual-mass flywheel

K9Keu4-M0305OP0014

A dual-mass flywheel gives improved

acoustics and driving pleasure.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

Air supply/exhaust gas recirculation

Inlet flap
A computer-controlled air flap at the
inlet ensures damping when the engine
is switched off.

K9Keu4-D1104OP007b

The flap is controlled by an electric

motor and will allow air flow to be managed in order to control of the regeneration temperature on future models
equipped with a particle filter. Such a
system is also able to regulate the flow
of fresh air to the engine by opening/closing the flap.

Turbocharger
Nm
260
240
220
200

K9Keu4-D1104OP0008

160
K9K 74 kW Euro3

140

K9K 80 kW Euro4

120
100
1,000

2,000

3,000

K9Keu4-D1104OP0005

180

4,000 rpm

This engine uses a multi-vane variable geometry turbocharger to obtain the optimal
torque curve. The torque curve is controlled by a pneumatic solenoid valve.
An intercooler located behind the front bumper cools the air leaving the turbocharger
in order to improve the engine output.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

Exhaust gas recirculation (EGR)

K9Keu4-D1104OP0002

1 Intercooler.
2 Recirculation valve.

Exhaust gas recirculation is regulated by a flap which is controlled by the computer. A

device for cooling the gas improves the EGR potential and reduces nitrogen oxides
emissions (NOx). A decrease in temperature allows a greater mass of gas to be
admitted for a given volume.

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

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

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

K9Keu4-M0305OP0104

K9Keu4-M0305OP0103

K9Keu4-M0305OP0102

K9Keu4-M0305OP0101

Summary table of sensors

Water thermistor
It 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 sensor

It is located on the diesel return pipe at the highpressure pump outlet. It cannot be separated
from the injector return circuit.
Temperature range:
23 C/+ 120 C

Inlet pressure sensor

It 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 sensor

It is inductive and is attached to the rear section
of the clutch housing.
The target is built into the flywheel.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

K9Keu4-D1104OP0010

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

K9Keu4-M0305OP0106

K9Keu4-M0305OP0107

Fuel pressure sensor

It is attached to the rail and cannot be
dismantled.

Air mass flowmeter

It is located behind the computer and is
incorporated with the air temperature sensor
(NTC).

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

Fuel supply
Fuel filter
1

5
2
K9Keu4-D1104OP0011

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.

This is a metallic monobloc unit with click connections.

It comprises a thermostatic component which enables fuel from the return circuit to be
recirculated towards the high-pressure pump. During operating phases at low
temperatures, this component enables the compression of fuel hotter than that
contained in the tank.

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

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

High-pressure pump
1

Low-pressure transfer pump.

Flow regulator.
Pump cylinder.
Pressure regulator.
Fuel inlet.
High-pressure outlet.
Injector return line.

5
6

K9Keu4-M0305OP0001

1
2
3
4
5
6
7

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 the
tank.
The maximum injection pressure is 1 600 bar.

Pumping principle
5
1

2
b
7

c
3
6

10

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.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

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

formation.
The fuel is drawn up in the tank by an internal transfer pump (1) via the fuel filter. It is
then 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-pressure
pump via the valve (6) and then flows into the fuel return duct (c).
The flow regulator (2) which is controlled by the engine management computer
determines the amount of fuel delivered to the high-pressure pumping components (3).
The high-pressure outlets of the three pump components are collected together and
guided towards the high-pressure outlet (b).
The pressure regulator (4) lies between the high-pressure channel and the fuel return
line. It regulates the amount of fuel delivered towards the high-pressure outlet.
Details of pumping components
2

1
2
3
4

Piston.
Inlet valve.
Outlet valve.
Pump shaft with cam.

K9KEU4-M03050p0002

3
3
4
1
4

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

11

2nd generation K9K engine

Rail pressure check

A special feature of the Siemens high-pressure pump is that there are two ways of
regulating the rail pressure:
- Flow regulation.
- Regulation by bleeding.

Flow regulation method

Flow regulator
The purpose of the flow regulator
is to regulate the amount of fuel
delivered to the pumping
cylinders in order to obtain the
desired pressure in the rail.

K9Keu4-M0305OP0004

The injection computer controls the regulator.

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

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

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.

12

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

K9Keu4-M0305OP0010

The flow regulator is controlled by a

pulse-width modulated current of
12 V.

2nd generation K9K engine

Pressure regulation by bleeding method

Pressure regulator

1 High-pressure outlet.
2 Towards return circuit.

K9Keu4-M0305OP0005

The role of the pressure regulator is to bleed any excess high pressure into the return
line 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 quicker
and more accurate. It is however less efficient because of the needless pressurisation
of 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).

The pressure regulator is controlled by

a pulse-width modulated current of
12 V.

A
K9Keu4-M0305OP0011

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

Notes
- In the rest position, the pressure regulator is kept closed by a spring set to
50 bar.
- During pressure regulation by bleeding, the flow regulator is positioned at a value
defined by the computer which does not affect the rail pressure.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

13

2nd generation K9K engine

Pressure accumulator.
1 Rail.
2 Pressure sensor.
The pressure accumulator is in the form
of a cylindrical rail.
It includes a pressure sensor which
informs the computer of the pressure
available in the rail.

K9Keu4-D1104OP0013

Note

K9Keu4-D1104OP0014

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

14

A plastic cover fits over the highpressure rail. This safety component
prevents pressurised fuel spraying in
the event of a leak from one of the
connections.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

2nd generation K9K engine

Piezoelectric injectors
The switching time for piezoelectric
injectors is 4 times quicker than
conventional electromagnetic injectors.

k9keu4-M0305op0006

This makes it easier to multiply the

number of injections per cycle with the
aim of improving combustion and
reducing emissions.

Note
These Siemens injectors do not require individual calibration or injection
adjustment by accelerometer.

Internal operation of the injector

1
2

The principle of hydraulic opening is similar to that of

electromagnetic injectors.
The needle is caused to lift when the piezoelectric
component (1) dilates as a result of electric stimulation.

K9Keu4-M0305OP0007

When the component extends, it pushes back the valve

(3). The pressure above the needle drops and escapes
towards the return line (4). The injector needle (5) rises
under the action of high pressure.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

15

2nd generation K9K engine

Piezoelectric principle
1 Piling up of piezoelectric ceramic
layers.

The piezoelectric principle has already

been applied to some types of sensor
(pressure, noise, etc.). When a force is
applied to a piezoelectric component, a
voltage proportional to this force (1) can
be measured across its terminals.

Piezoelectric components are made

from ceramic material.
The component within an injector is
made up of ceramic layers.

Conversely, the piezoelectric component

extends when a voltage is applied across
its terminals (2).
The extension of the actuator in the
injector (approximately 40 micrometres)
enables it to open.

16

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

k9keu4-M0305op0009

K9Keu4-M0305OP0008

2nd generation K9K engine

Injector control
A piezoelectric injector is electrically comparable to a capacitor. It accumulates current
and then gives it back.
Opening phase:
T1

T2

Closing phase:

K9Keu4-M0305OP0014a

T1

T2

K9Keu4-M0305OP0014b

The computer closes contact T1 (with T2

open), the piezoelectric component
extends and at the same time charges its
capacity. The injector opens. The injector
would remain open if you disconnected it
during this phase. This is why an injector
should not be disconnected when the
engine is running.

The computer closes contact T2 and

opens T1. The capacity discharges, the
injector becomes a generator and the
current direction is reversed. The
piezoelectric component goes back to its
original position and the injector closes.

- A piezoelectric injector must never be disconnected when the engine is

running.
- The piezoelectric component maintains its position when the supply is
cut. There is therefore a risk that the injector could jam open. This would
destroy the engine.

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

17

2nd generation K9K engine

Controlling injection
1

1 Pre-injection 1.
2 Pre-injection 2.
3 Main Injection.
A
K9Keu4-M0305OP0013

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

The computer orders between 1 and 3 injections per cycle. This number of injections
is 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
1

1 Pre- injection.
2 Main Injection.

K9Keu4-M0305OP0012

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

Maintenance
There are no special notes concerning general maintenance.
Refer to the vehicle maintenance schedule.

Fault finding
In 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.

18

TECHNICAL TRAINING CONCERNING K9K ENGINE DEVELOPMENTS

K9K Engine Developments

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

Refer to the technical documentation.

Carry out the practical work indicated.

Answer the question.

An important point is highlighted.

STOP

Check your objective with your trainer.

End of workshop practical.

MECHANICAL AND ELECTRONIC SYSTEMS

19

WORKSHOP PRACTICAL
K9K ENGINE
SIEMENS INJECTION

OBJECTIVE: To find out about performing fault finding on

a Siemens diesel injection system

MECHANICAL AND ELECTRONIC SYSTEMS

20

K9K Engine Developments

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 recommended

procedure.

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-pressure
pump disconnected.

MECHANICAL AND ELECTRONIC SYSTEMS

21

K9K Engine Developments

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 highpressure pump disconnected.

Does the engine start? What rail pressure value is read on the diagnostic
tool?
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................

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

Find the procedure for hydraulically checking the high-pressure pump in

the documentation.

MECHANICAL AND ELECTRONIC SYSTEMS

22

K9K Engine Developments

Note the procedure and carry out the checks:

Check

Value measured

Find the exact procedures for checking injectors in the documentation.

Note the procedures and carry out the checks:

Check

STOP

Value measured

Check your objective with your trainer.

End of workshop practical.

MECHANICAL AND ELECTRONIC SYSTEMS

23

WORKSHOP FAULT FINDING

K9K ENGINE
SIEMENS INJECTION

OBJECTIVE: To find out about the technical features of a

Siemens Diesel injection system and how
to perform fault finding on it.

MECHANICAL AND ELECTRONIC SYSTEMS

24

K9K Engine Developments

VIN and vehicle type:

Customer complaint:
Documents used:

Special tooling:

Apply the RENAULT fault finding procedure.

Note down the fault finding steps.

.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
.....................................................................................................................
What is the origin and the cause of the fault?
....................................................................................................................
....................................................................................................................

STOP

Check your objective with your trainer.

End of workshop practical.

MECHANICAL AND ELECTRONIC SYSTEMS

25