TECHNICAL NOTE -
REPAIR
Standard 23520 Date 05-2011 EN R0039/2
Document reserved exclusively for the RENAULT TRUCKS network.
It must not be communicated to third parties without written authorization from RENAULT TRUCKS.
Supersedes & replaces MAGNUM / PREMIUM / KERAX / MIDLUM
R0039/1 dated 02/2009 DXi Euro 4 / Euro 5 Incentive / Euro 5 / Euro 5 EVV
Modifications to the SCR SYSTEM
previous versions are
highlighted by two
Concerns: Workshop – Reception – Stores
vertical lines
I – SUBJECT: REPLACEMENT OF INTERNAL ADBLUE PUMP
COMPONENTS
It is now possible to replace certain internal components
on AdBlue pumps that are out of warranty: 2 3
– Vent valve (1). 1 5
– Pressure sensor (2). 4
– Temperature sensor (3).
– Cooling valve (CCV) (4).
– Pumping element (5) (with the renovation kit).
This Technical Note explains the methods to be used when
replacing these parts.
II – TOOLING
REFERENCE DESIGNATION QUANTITY
74 88 890 102 Pump 1
74 88 890 104 Adapter 1
© RENAULT TRUCKS 1/8 Direction Customer Technical Support R0039/2
III – METHOD
All work on the AdBlue pump requires a clean working environment.
III – 1. Preparation for the replacement of internal AdBlue pump components
REFERENCE DESIGNATION QUANTITY
74 20 993 004 Vent valve 1
– Clean the pump to stop dirt getting in during
disassembly.
– Attach 4 x M8x100 bolts, without tightening, into
each of the four mounting holes under the pump to
provide a stand.
1
– Using a screwdriver, remove the breather valve (1)
(this must be replaced whenever work is carried out
on the pump).
– Remove the pump cover.
– Remove any pieces of the breather valve that may
have fallen off during its removal.
© RENAULT TRUCKS 2/8 Direction Customer Technical Support R0039/2
III – 2. Replacing the pressure sensor
REFERENCE DESIGNATION QUANTITY
74 21 390 067 Pressure sensor 1
– Disconnect the connector (6).
– Remove the sensor (7).
– Fit the new sensor by twisting it slightly to help it into
the hole.
– Connect the connector (6).
– Refit the cover, being careful to ensure it is correctly
positioned to provide a good seal.
© RENAULT TRUCKS 3/8 Direction Customer Technical Support R0039/2
III – 3. Replacing the temperature sensor
REFERENCE DESIGNATION QUANTITY
74 21 390 063 Temperature sensor 1
– Disconnect the connector (8), noting its orientation.
9
– Replace the sensor (9).
When fitting, turn the sensor so that the connector
locking tab is away from the pressure sensor.
– Reconnect the connector (8).
© RENAULT TRUCKS 4/8 Direction Customer Technical Support R0039/2
III – 4. Replacing the cooling valve (CCV)
Only fitted on vehicles manufactured before CAM 08M8 (08/12/2008).
REFERENCE DESIGNATION QUANTITY
74 21 390 062 Cooling valve (CCV) 1
10
– Disconnect the connector (10).
– Remove the valve (4).
11
– Carefully remove the heating components (11) on the
right and left hand sides of the valve using a
screwdriver.
– Remove the heating components from their holders to
replace the holders.
12
– Replace the seal (12).
– Fit the heating components onto the new valve.
10
Fit the protective covers onto the valve connectors
to stop impurities entering the system.
– Fit the new valve.
– Connect the connector (10).
© RENAULT TRUCKS 5/8 Direction Customer Technical Support R0039/2
III – 5. Replacing the internal pumping element with the renovation kit
The following method is to be applied in the event of:
– AdBlue pump oil or fuel contamination.
– Failure of the internal pumping element.
In the event of oil or fuel contamination, drain the whole of the AdBlue circuit and clean all
the parts with lukewarm water. Replace them if necessary (significant contamination in the
circuit).
QUANTITY
REFERENCE DESIGNATION ==> 08M8 08M8 ==>
(08/12/2008) (08/12/2008)
74 85 130 513 Renovation kit with CCV 1
74 85 130 514 Renovation kit without CCV 1
– Disconnect all the electrical connectors, noting their
position and their orientation for easy reassembly.
– Remove the filter element (from underneath the
pump).
13
– Remove the 3 bolts (13) securing the filter holder.
– Remove the 3 bolts (14) securing the pumping
element (5). 5 14
© RENAULT TRUCKS 6/8 Direction Customer Technical Support R0039/2
4
– Remove the cooling valve (CCV) (4) if the vehicle
has one (see § III-4).
– Remove the filter holder + pumping element
assembly from the top.
15
– Separate them by removing the hose (15).
– Refit in the reverse order of removal, replacing the
following components included in the renovation kit:
• Pumping element: 5 Nm.
• Prefilter.
• Hose.
• Filter holder: 5 Nm.
• Cooling valve (CCV) (if the vehicle has one).
• Vent valve.
• Cowl fixing bolts.
• Filter: 23 Nm.
Coat the hose seals with soapy water for easy reassembly.
© RENAULT TRUCKS 7/8 Direction Customer Technical Support R0039/2
III – 6. Seal test
16
17
– Fit the adapter 74 88 890 104 (16) to the vent valve
hole (17).
18
– Connect the pump 74 88 890 102 (18) to the adapter.
– Pump until a pressure of 0.3 bar is obtained.
– Wait between 45 seconds and 1 minute.
– Check that the pressure has not dropped.
– Remove the test tools.
– If the pressure drops, check that the newly-replaced
components have been correctly fitted.
– Fit a new vent valve
– Remove the M8x100 bolts being used as a base.
© RENAULT TRUCKS 8/8 Direction Customer Technical Support R0039/2
