Denny Schroeter Injectors / Removal / Fitting 25/01/23

Fuel injectors

It is strictly forbidden to work on the fuel injectors while the engine is running (high voltage).
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Denny Schroeter Injectors / Removal / Fitting 25/01/23

To remove and fit the other components quoted in the paragraph, refer to their respective chapters.
Removal
Remove the corresponding injector pipe gallery.
Remove the cylinder head cover.
Depending on the equipment, remove the Jake brake.
Remove union (1) to drain the fuel contained in the cylinder head.
Unscrew nuts (2).
Remove nut (3).
Blank off the ports.
Remove fuel delivery pipe (4) to the cylinder head
Remove bolt (5).
Save spherical washer (6).
Remove flange (7).
Withdraw injector (8).
Take off seal (9).
Put each part in a new watertight plastic bag immediately after its removal.
Fitting
Replace all seals and gaskets without fail.
Replace all removed fuel delivery pipes (4) without fail.
Fit injector (8).

It is essential to check for the presence of one single seal (9) to guarantee alignment of the fuel delivery pipe (4) with the injector (8), in order to
ensure a perfect seal.
Match the orientation (A).
Fit cylinder head fuel delivery pipe (4).
Match the orientation (B).
Wiggle the injector (8) and fuel delivery pipe (4) around to ensure their positioning.
Fit nut (3).
Fit flange (7).
Fit spherical washer (6).
Fit bolt (5).
Screw up nut (3) and bolt (5) without tightening.
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Denny Schroeter Injectors / Removal / Fitting 25/01/23

Preliminary tighten bolt (5) then nut (3) to a torque of 5 Nm.

Final tighten bolt (5) then nut (3) to a torque of 60 Nm.
For the rest of the fitting operations, proceed in the reverse sequence to removal.
Hold terminal lugs (10) of the wiring harness with pliers when tightening nuts (2) to torque.
Fuel-Injection
High pressure pipe gallery union nut (see page )
Cylinder head fuel delivery pipe nut (see page )
Injector nozzle-holder flange setscrew (see page )
High pressure pump securing nut 195 ± 20 Nm
High pressure pump securing stud (
FRENETANCH 242
)(+ Loctite Frenétanch) 20 ± 4 Nm
High pressure pump securing nut (tighten in diametrically 60 ± 12 Nm
opposed sequence, then retighten first nut only)
Booster pump securing bolts (tighten in diametrically opposed sequence) 8 ± 1 Nm
High pressure pump speed sensor setscrew 8 ± 1 Nm
Scavenge valve 30 + 10 Nm
Scavenge valve plug 15 + 5 Nm
Pressure and boost air sensor setscrew 6.5 ± 1.5 Nm
Flow limiter 85 ± 5 Nm
Pressure limiter to common rail 95 ± 5 Nm
Common rail pressure sensor 20 + 2 Nm
ECU cooler piping setscrew 8 ± 1.5 Nm
Injector supply wire securing nut 1.5 ± 3 Nm
Accelerator pedal sensor setscrew 10 ± 2 Nm
Pressure sensor to rail union 45 ± 5 Nm
Fuel leak-off return pipe to pressure limiter union 30 ± 3 Nm
Fuel leak-off return union setscrew 12 ± 2.4 Nm
Low pressure polyamide pipes securing clamp nut 15 ± 3 Nm
High pressure pump oil filler plug 35 ± 5 Nm
Polyamide pipe union nut 28 ± 2 Nm
Wiring harness to engine block attaching clamp screw 30 ± 6 Nm
Fuel low pressure and leak-off return pipes securing nut on clips 3.5 ± 0.7 Nm

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Denny Schroeter Cylinder head cover / Fitting 25/01/23

Fitting the cylinder head cover

The item numbers indicated in the text refer to the drawing on page .
Install seal (14).
Fit the rocker cover (8).
Fit the setbolts fitted with rubber sandwich mountings.

Tighten to torque.
* 1: preliminary tighten at 2 Nm Nm.
* 2: tighten at 20 ± 4 Nm Nm.

Cylinder head exploded view

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Denny Schroeter Cylinder head cover / Fitting 25/01/23

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Denny Schroeter Cylinder head cover / Fitting 25/01/23

** With Jake brake

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Denny Schroeter Common rail return pipe / Removal / Fitting 25/01/23

Fuel-Injection
High pressure pipe gallery union nut (see page )
Cylinder head fuel delivery pipe nut (see page )
Injector nozzle-holder flange setscrew (see page )
High pressure pump securing nut 195 ± 20 Nm
High pressure pump securing stud (
FRENETANCH 242
)(+ Loctite Frenétanch) 20 ± 4 Nm
High pressure pump securing nut (tighten in diametrically 60 ± 12 Nm
opposed sequence, then retighten first nut only)
Booster pump securing bolts (tighten in diametrically opposed sequence) 8 ± 1 Nm
High pressure pump speed sensor setscrew 8 ± 1 Nm
Scavenge valve 30 + 10 Nm
Scavenge valve plug 15 + 5 Nm
Pressure and boost air sensor setscrew 6.5 ± 1.5 Nm
Flow limiter 85 ± 5 Nm
Pressure limiter to common rail 95 ± 5 Nm
Common rail pressure sensor 20 + 2 Nm
ECU cooler piping setscrew 8 ± 1.5 Nm
Injector supply wire securing nut 1.5 ± 3 Nm
Accelerator pedal sensor setscrew 10 ± 2 Nm
Pressure sensor to rail union 45 ± 5 Nm
Fuel leak-off return pipe to pressure limiter union 30 ± 3 Nm
Fuel leak-off return union setscrew 12 ± 2.4 Nm
Low pressure polyamide pipes securing clamp nut 15 ± 3 Nm
High pressure pump oil filler plug 35 ± 5 Nm
Polyamide pipe union nut 28 ± 2 Nm
Wiring harness to engine block attaching clamp screw 30 ± 6 Nm
Fuel low pressure and leak-off return pipes securing nut on clips 3.5 ± 0.7 Nm

Consumables
Automotive part N° Industrial reference N°
50 01 857 701 Loctite 242 threadlocking compound
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Denny Schroeter Common rail return pipe / Removal / Fitting 25/01/23

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Denny Schroeter Injector pipe bundle / Removal / Fitting 25/01/23

Injector pipe gallery

To remove and fit the other components quoted in the paragraph, refer to their respective chapters.
Removal
Remove hand priming pump and prefilter (1)*.
See page
Remove centrifugal filter (2).
See page
Loosen unions (3).
Check that the cylinder head fuel delivery pipes remain fastened during the unions (3) tightening phase. If they turn around, it is essential to replace them.
While loosening the rail end unions, hold the flow limiters (4) to prevent them from working loose.
Remove pipes gallery.
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Denny Schroeter Injector pipe bundle / Removal / Fitting 25/01/23

Blank off the ports.

Put each part in a new watertight plastic bag immediately after its removal.
Fitting
For fitting, proceed in the reverse sequence to removal.
Tighten pipe unions (3) to a torque of 40 Nm, without holding flow limiters (4).
Use tool 2565.
In the event of leakage at a nut, loosen the nut in question by 1/4 of a turn, then retighten at a maximum torque of 50 Nm. If the leak persists, the pipe
gallery must be replaced.
Check that the cylinder head fuel delivery pipes remain fastened during the unions (3) tightening phase. If they turn around, it is essential to replace them.

It is essential to replace the complete pipe gallery. Under no circumstance should the flanges connecting the pipes in the same gallery be dismantled.

Tools
General purpose tools
Illustration RENAULT Designation Manufacturer's Manufacturer's code N° Scale Qty
TRUCKS part N° reference N°
2565 WRENCH AB 1 1

AB FACOM
6 et 8, rue Gustave Eiffel
BP 99
FRANCE
01 64 54 45 45 - 01 69 09 60 93 -

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Denny Schroeter Fuel circuit / Bleeding 25/01/23

Bleeding the fuel system

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Denny Schroeter Fuel circuit / Bleeding 25/01/23

Open bleed screw (1), then unscrew and actuate hand pump (2) until the fuel flows without air bubbles. Close the bleed screw and actuate the hand pump
until it hardens. Screw up the hand pump control before starting the engine.
Actuate the starter until the engine fires.

It is forbidden to bleed the low pressure circuit using the starter.

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Denny Schroeter Cylinder head / Removal 25/01/23

Removal
The item numbers indicated in the text refer to the drawing on page .

Remove the cylinder head cover (1).

Remove seal (16).
Disconnect wires (A).
Withdraw the wiring harness from clips (B).
Tighten nuts (C).
Move aside the wiring harness complete with bracket (D).
Tighten nuts (5 - 6).
Remove mechanisms (14 - 15).
Save spacers (7).
Tighten nuts (8).
Disconnect the wiring harness from injectors.
Withdraw spacer (9).
Remove seal (10).

Exploded view
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Denny Schroeter Cylinder head / Removal 25/01/23

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