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"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be mod ified as a result of changes by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".

C

77 11 206 372 SEPTEMBER 1999 Edition Anglaise

N.T. 3305A

XC0U - XB0U

Special features of the F9Q 780 engine

For the timing belt removal-refitting procedure, refer to Technical Note 3309A.

For parts not dealt with in this Technical Note refer to Workshop Repair Manuals

MR 325 and 337.

All copyrights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden w ithout the pr ior written authority of Renault.

RENAULT 1999

8/14/2019 Xc0u - Xb0u


Sump

Contents

07-1

07-2

07-3

07-4

07-5

07-7

07-9

07-12

07-14

Pages

Capacities - Grad es

Accessories belt tensioning

Cylinder h ead tightening

Tyres - Wheels

Brakes

Brake comp ensator

Und erbody height

Values for checking front axle

geometry

Values for checking rear axle

geometry

VALUES AND SETTINGS

Pages

07

Specifications

General

Location of compon ents

Injection w arning light

Engine imm obiliser functionInjection / air cond itioning strategy

Idle speed correction

Pre-post heating

Pre-post heating unit

Immersion heaters

Accelerator poten tiometer

Advance solenoid valve

Diesel temperatu re sensor

Pump

Pum p - Setting

Pum p - Setting check

Pump - Setting adjustment

Centralised Coolant Temperature

Management

Wiring diagram

Fault finding

Introduction

Interpretation of faults

Assistance

Conformity check

Customer comp laints

Fault finding charts

13-1

13-3

13-4

13-6

13-713-8

13-9

13-10

13-11

13-12

13-14

13-15

13-17

13-19

13-21

13-22

13-24

13-27

13-28

13-31

13-32

13-61

13-62

13-67

13-68

DIESEL EQUIPMENT13

10

Cylinder head gasket 11-1

TOP AND FRONT OF ENGINE11

Turbocharging

Turbocharger

Carbonised mixture

Air intake

Manifolds

12-1

12-4

12-5

TURBOCHARGING - CARBONISEDMIXTURE

12

Exhaust gas recirculation (EGR)

Oil vapours rebreathing

14-1

14-4

ANTIPOLLUTION14

10-1

ENGINE AND PERIPHERALS

ASSEMBLY

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Contents

Pages

Clutch p late - Disc 20-1

CLUTCH20

General

Connecting pipes

Wiring diagram

62-1

62-2

62-5

AIR CONDITIONING62

Identification

GearsGearbox (Removal - Refitting)

21-1

21-221-3

MANUAL GEARBOX21

Alternator

Starter

16-1

16-2

STARTING - CHARGING16

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VALUES AND SETTINGS

Capacities - Grades 07

Units

Capacity

in litres

(approx.) *

Diesel engine(oil)

F9Q

Grade

Whendraining

5

5.5 (1)

E. U. countries

Other countries

* Adjust using a d ipst ick

(1) Following replacement of the oil filter

UnitsCapacity

in litres

JC5

gearbox

Grade Special features

3.1

All cou ntries: TRANSELF TRX 75 W 80 W

(API GL5 or MIL-L 2105 G or D standard s)

F9Q

cooling

circuit

7.5 Glacéol RX

(type D)

Protection to - 20 °C ± 2 °C for hot, temperate and

cold climates.

Protection to - 37 °C ± 2 °C for very cold climates.

0 °C + 30 °C- 30 °C + 20 °C- 20 °C - 10 °C

- 15 °C

ACEA B2/B3

ACEA B2/B3

ACEA B2/B3

ACEA B2/B3

+ 10 °C

ACEA B1 oil must not be used for diesel engines in

any circumstan ces.

15W40-15W50

10W40-10W50

5W30

5W40-5W50

0°C + 30

°C- 30

°C + 10

°C + 20

°C- 20

°C - 10

°C

- 15 °C

API CF

API CF

API CF

API CF

15W40-15W50

10W40-10W50

10W30

5W40-5W50

07-1

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VALUES AND SETTINGS

Accessories belt tensioning 07

A Cran ksh aft

B Altern ator

C Power st eer ing pum p

E Coolant p um p

→ Tension checking p oint

98751R1

ALTERNATOR AND POWER STEERING

WITHOUT

AIRCONDITIONING

Tension

(US = SEEM unit)

Multi-tooth power

steering be lt

Fitting 97 ± 3

Minimu m op erating

tension67

07-2

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VALUES AND SETTINGS

Cylinder head tightening 07

Wait 3 minutes to allow the gasket to settle.

Cylinder h ead tightening:

- the cylinder head is tightened p rogressively,

the p rocedur e below is app lied successively to

bolts 1-2 then 3-4, 5-6, 7-8 and 9-10,

- slacken bolts 1-2 un til there are fully released,

- tighten bolts 1-2 to 2.5 daN.m, then turn them

through an angle of 213° ± 7°,

- repeat the slackening and re-tightening opera-

tion for bolts 3-4, 5-6, 7-8 and 9-10.

The cylinder head is not re-tightened.

CYLINDER HEAD TIGHTENING PROCEDURE

REMINDER: to obtain correct tightening of the

bolts, remove an y oil from the cylind er head secu-

ring holes using a syringe.

All of the cylind er head bolts must be changed fol-

lowing rem oval. The cylind er head is not re-

tightened.

Pre-seating of the gasket

Tighten all the bolts to 3 daN.m, then turn them

through an angle of 100° ± 4° in the order ind ica-

ted below.

27 6 10

18 5 94

3

07-3

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VALUES AND SETTINGS

Tyres - Wheels 07

(1) Fully laden and motorway use.

Wheel nuts tightening torque: 9 daN.m

Wheel rim run -out: 1.2 mm

CLIO II

Vehicle Wheel rim Tyres

Tyre inflation pressure

when cold (in bar) (1)

Front Rear

XB0U

5 B 13

5.5 J 14

6 J 14

165/ 70 R 13 T

165/ 65 R 14 T

175/ 65 R 14 T

2.3 2.1

XB0U5.5 J 14

6 J 14175/ 65 R 14 T 2.4 2.1

KANGOO

Vehicle Wheel rim Tyres

Tyre inflation pressure

when cold (in bar) (1)

Front Rear

FC0U

KC0U

5 B 13

5 B 13

5.5 J 14

165/ 70 R 13 C

165/ 70 R 13 (2)

165/ 70 R 14

2.8

2.6

2.4

3.6

2.9

3.0

(1) Fully laden and motorway use.

Wheel nuts tightening torque: 9 daN.m

Wheel rim run -out: 1.2 mm

(2) Strengthened suspension.

07-4

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VALUES AND SETTINGS

Brakes 07

Vehicle

Thickness of discs (in mm)

Front Front

Diameter of drums or Thickness of discs (in mm)

Rear

Normal Maximum (1)

FC0U

KC0U

20 17.7

normal load

203.2

increased load

228.3

normal load

204.45

increased load

229.5

(1) Drum: maximum w ear diameter.

Maximum disc run -out: 0.07 mm

Vehicle

Thickness of lin ings (in mm) (including support)

Front

New Minimum

Rear

New Minimum

Brake fluid

FC0U

KC0U

17.8 5.5

With ABS

4.6 (1)

3.15 (2)

Without

ABS

4.2 (1)

2.8 (2)

2SAE J1703

DOT 4

FC0U (3)

KC0U (3)

17.8 5.5

With ABS

4.8

Without

ABS

4.5

2SAE J1703

DOT 4

KANGOO

(1) Primary lining.

(2) Secondary lining.

(3) Increased payload option.

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VALUES AND SETTINGS

Brakes 07

VehicleThickness of discs (in mm)

Normal Minimum

Diameter of drums or Thickness of discs (in mm)

Rear

Normal Maximum (1)

XB0U

without ABS12 10.5 180.2 181.2

XB0U

with ABS20.6 17.6 203.2 204.2

(1) Drum: maximum w ear diameter.

Maximum disc run -out: 0.07 mm

(1) Primary lining.

(2) Secondary lining.

Vehicle

Thickness of lin ings (in mm) (including support)

Front

New Minimum

Rear

New Minimum

Brake fluid

XB0U 18.2 64.6 (1)

3.3 (2)2

SAE J1703

DOT 4

CLIO II

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VALUES AND SETTINGS

Brake compensator 07

BRAKING PRESSURE

Vehicle

Fuel level

status

(driver in vehicle)

Check pressure (1) (in bar)

Front Rear

FC0U

KC0U

normal p ayload

100 35.4

FC0U

KC0Uincreased p ayload 100 38

KANGOO

+ 80

90966S

+ 8

0

(1) The check is carried ou t using two p ressure gauges arranged in an X formation.

VehicleFuel level

status

(driver in vehicle)

Check pressure (1) (in bar)

Front Rear

XB0U 100 56

CLIO II

0- 18

90966S

(1) The check is carried ou t using two p ressure gauges arranged in an X formation.

07-7

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VALUES AND SETTINGS

Brake compensator 07

Tolerances : ± 7.5 mm

The difference between the right-hand sid e and the left-hand side of the same axle of a vehicle mu st not ex-

ceed 5 mm , the driver’s side always being the higher.

If the un derbody height is adjusted, the brake limiter and the headlights mu st be adjusted.

(1) Increased p ayload.

(2) Stand ard p ayload.

VehicleAt the front

H1 - H2 = ... mm

At the rear

H4 - H5 = ... mm

Dimension X (mm)

RH and LH

FC0U

KC0U73.5

- 60.5 (1)

- 54.1 (2)

402 (1)

430 (2) → 410

KANGOO

Tolerances : ± 10.5 mm

The difference between the right-hand sid e and the left-hand side of the same axle of a vehicle mu st not ex-

ceed 5 mm , the driver’s side always being the higher.

If the un derbody height is adjusted, the brake limiter and the headlights mu st be adjusted.

VehicleAt the front

H1 - H2 = ... mm

At the rear

H4 - H5 = ... mm

Dimension X (mm)

RH and LH

XB0U 96 - 23 -

CLIO

07-8

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VALUES AND SETTINGS

Underbody height 07

12333R3

The dimension H 5 is measured at the centreline of

the suspension bar.

88636-4R

MEASURING POINTS

KANGOO

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VALUES AND SETTINGS

Underbody height 07

88637R

88576R

KANGOO

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VALUES AND SETTINGS

Underbody height 07

13491R4

NOTE: the d imension H5 is measured at the centreline of the rubber bu sh.H2 = dim ension measu red betw een the lower surface of the sub-frame to the right of the wheel

centreline and the ground .

MEASURING POINTS

CLIO II

88636-4R

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H1 - H2 = 7 mm

H1 - H2 = 74 mm

H1 - H2 = 98 mm

H1 - H2 = 164 mm

H1 - H2 = 7 mm

H1 - H2 = 74 mm

H1 - H2 = 98 mm

H1 - H2 = 164 mm

H5 - H2 = 97 mm

H5 - H2 = 117 mm

H5 - H2 = 137 mm

H5 - H2 = 157 mm

81603S1

93011-1S

93014-1S

93013-1S

93012-1S

VALUES AND SETTINGS

Values for checking front axle geometry 07

UNLADEN

NOT ADJUSTABLE

NOT ADJUSTABLE

NOT ADJUSTABLE

CAMBER

VALUES

CASTOR

3°55’

3°25’

2°55’

2°25’

Maximu m right/

left d ifference= 1°

1°12’

- 0°15’

- 0°29’

- 0°13’

Maximu m right/


ADJUSTMENTPOSITION OF

FRONT AXLE

KING PIN INCLINATION

8°05’

10°25’

11°00’

11°56’

Maximu m right/


PARALLELISM

IMMOBILISATION OF RUBBER BUSHES

Adjustable by

rotating track

rod sleeves

1 revolution =

30’

(3 mm )

(For 2 wh eels)

toe-out

+ 0°10’ ± 10’

+ 1 mm ± 1 mm

ANGLES

UNLADEN- -

± 30’

± 30’

± 30’

KANGOO

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H1-H2 = 96 mmH1-H2 = 104 mm

H1-H2 = 121 mm

H5-H2 = 89 mm

H5-H2 = 109 mm

H5-H2 = 129 mm

10°50’

11°00’

11°22’

Maximu m right/

left difference= 1°

2°36’

2°06’

1°36’

Maximu m right/


H1-H2 = 96 mm

H1-H2 = 104 mm

H1-H2 = 121 mm

81603S1

93011-1S

93014-1S

93013-1S

93012-1S

VALUES AND SETTINGS

Values for checking front axle geometry 07

UNLADEN

CAMBER

VALUES

CASTOR

ADJUSTMENTPOSITION OF

FRONT AXLE

KING PIN INCLINATION

PARALLELISM

IMMOBILISATION OF RUBBER BUSH ES

Adjustable by

rotating track

rod sleeves

1 revolution

= 30’

(3 mm )

(For 2 wh eels)

toe-out

+ 0°16’ ± 20’

+ 1.6 mm ± 2 mm

ANGLES

UNLADEN- -

±30’

±30’

CLIO II

- 1°10’

- 1°15’

- 1°18’

Maximu m right/


±30’

NOT

ADJUSTABLE

NOT

ADJUSTABLE

NOTADJUSTABLE

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(For tw o wheels)

Toe-in

- 15’ ± 10’

- 1.5 mm ± 1 mm

- 0°50’ ± 15’

NOT ADJUSTABLE

93013-2S

93011-2S

81603S1

VALUES AND SETTINGS

Values for checking rear axle geometry 07

UNLADEN

CAMBER

VALUES

PARALLELISM

ANGLES

UNLADEN NOT ADJUSTABLE

UNLADEN- -

IMMOBILISATION OF

RUBBER BUSHES

POSITION OF

REAR AXLEADJUSTMENT

KANGOO

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(For 2 wh eels)

Toe-in

- 30’ ± 30’

- 3 mm ± 3 mm

- 0°42’ ± 20’

NOT ADJUSTABLE

93013-2S

93011-2S

81603S1

VALUES AND SETTINGS

Values for checking rear axle geometry 07

UNLADEN

CAMBER

VALUES

PARALLELISM

ANGLES

UNLADEN NOT ADJUSTABLE

UNLADEN- -

IMMOBILISATION OF

RUBBER BUSHES

POSITION OF

REAR AXLEADJUSTMENT

CLIO II

07-15

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ENGINE AND PERIPHERALS ASSEMBLY

Sump

- the gearbox - sub-frame tie-rod,

- th e tie-rod s (3),

- the sub-frame mounting bolts and fit the

threaded rods Mot. 1233-01 one by one.

10

REMOVAL

Place the vehicle on a tw o post lift.

Disconnect the battery.

Remove the engine u nd ertray.

Drain the eng ine oil.

Remove:

- the front wheels and the r ight-hand mud

shield,

- the steering shaft yoke nut and eccentric bolt

after first pu shing back the p rotector,

- the sub-frame - body tie-rods,

- the bolt (1) and unscrew the engine tie-bar

bolt (2) without r emoving it,

- the bumper lower fastener ,

13359R1

Mot. 1233 -01 Threaded rods for lowering

the sub-frame

TIGHTENING TORQUES (in daN.m)

14175R

ESSENTIAL SPECIAL TOOLS

Sub-frame front mounting bolt 6.2

Sub-frame rear mounting bolt 10.5

Sump bolt 1.5

Steering shaft yoke mounting bolt 3

Engine tie-bar bolt 6.2

Wheel bolt 9

10-1

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ENGINE AND PERIPHERALS ASSEMBLY

Sump 10

Gradually lower the sub-frame u sing th e threaded

rods Mot. 1233-01 un til approximately dimension

X is reached .

14264R

X1 = 5 cm

X2 = 6 cm

Remove the sump .

REFITTING

Fit the new after sales service seal.

Refit in the reverse order to remova l.

10-2

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TOP AND FRONT OF ENGINE

Cylinder head gasket 11


REMOVAL



Remove the engine undertray and th e sound-

deadening cover.

Drain the cooling circuit via the lower hose on the

radiator.

Mot. 251-01 Gauge stand

Mot. 252-01 Bearing plate for measuring theprotrusion of the pistons

Mot. 1054 Top dead centre pin

Mot. 1159 Tool for supporting the engine on

the sub-frame

Mot. 1453 Engine support tool

Mot. 1505 Tool for tensioning the belt

Mot 1543 -03 Belt preload tool

Tensioner nut 5Crankshaft pulley bolt 2 + 115° ± 15°

Suspended engine mounting bolt 6.2

Wheel bolt 9

TIGHTENING TORQUES (in daN.m or/and °)

99024R2

Remove the tim ing belt (refer to Technical Note

3309A).

ESSENTIAL EQUIPMENT

Angular tightening wrench

Cylinder head testing equipment

11-1

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Remove:

- the air filter unit (1),- th e u nit su p port (2),

NOTE: take care with seals (3) and

(4). Chan ge them if necessary.

Remove:

- the EGR valve p ipes and

connectors,

- th e vacu u m p ip e on th e v a-

cuum pum p,

- the hose on the coolant hou-

sing (cylinder h ead ou tlet),

- the ear th str ap on the bul-

khead,

- the a ir p ipes on the manifo ld

and the turbo,

- th e oil sep arator.

15826R1

99310R

Fit Mot. 1159 between the sub-frame and the cy-

lind er block and on the coolant pipe mou nting

bolt.

11-2

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- the exhaust downp ipe (1),

- the m an ifold s tr ut (3),

12416R2

12412-1R

Disconnect:

- the coolant temperature sensor connector,

- the calibrated injector, heater plugs and injec-

tion pu mp connectors,

- the fu el p ip es.

- the oil feed (5) and return (7) pipes on the tur-

bo.

12415R5

Unclip the engine harness and m ove it aside.

Slacken the inner tim ing cover moun ting bolts wi-

thout removing them.

12521-1R1

Remove the cylinder h ead bolts.

11-3

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12516S

NOTE: all measu rements m ust be taken in the lon-

gitud inal centreline of the engine to p revent er-

rors du e to tilting of the piston.

CALCULATION OF THE THICKNESS OF THE

CYLINDER HEAD GASKET

Check of the protrusion of the pistons

Clean the piston crowns to remove the carbon

deposits.

Turn th e crankshaft one revolution in the direc-

tion of operation to bring piston n° 1 close to Top

Dead Centre.

Fit tool Mot. 252-01 on the piston.

Fit Mot. 251-01 together w ith a dial gauge on

bearing plate Mot. 252-01. With the dial gauge

anvil in contact with the cylind er block, find thepiston Top Dead Centre.

Cleaning

It is very important that the mating surfaces of

the aluminium parts are not scratched.

Use the produ ct Décapjoint to dissolve the part of

the gasket which remains attached .

App ly the prod uct to the section to be cleaned;

wait app roximately ten minu tes, then remove it

using a wooden spatu la.

It is advisable to wear gloves du ring this

operation.

Do not allow any of the prod uct to come into

contact with the p aintwork.

Your attention is drawn to the care which must

be taken w hen carrying out this operation to

prevent the introduction of foreign bodies into

the pressurised oil feed pipes leading to the

camshafts (pipes located both in the cylinder

block and in the cylinder head) and into the oil

return pipe .

CHECKING THE MATING SURFACE

Check whether the mating su rface is deformed

using a r uler and a set of feeler gauges.

Maximu m deformation: 0.05 mm .

Grinding of the cylinder head is prohibited.

Test the cylinder h ead to detect any cracks.

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Measure the protru sion of the pistons.

ONLY CONSIDER THE SIDE OF THE PISTON

WHICH HAS THE GREATEST PROTRUSION.

For a m aximu m engine p iston p rotrusion:

- less th an 0.653 (exclusive), use a gasket identi-

fied by a tab w hich has two holes (thickness

1.35),

- betw een 0.653 (inclusive) an d 0.786 (inclusive),

use a gasket identified by a tab w hich has one

hole (thickness 1.45),

- m ore than 0.786 (exclusive), use a gasket id enti-

fied by a tab w hich has three holes (thickness

1.55).

REFITTING

Fit the cylind er head gasket selected beforehand .

This is positioned by tw o centring p ins.

Position the pistons at mid -travel to prevent an y

contact w ith the valves when the cylind er head is

tightened.

Align the cylinder head on the centring pins.

Tighten the cylind er head using an angular

wr ench for cylinder head tightening (see section

07 "Cylinder head tightening").

Proceed in th e reverse order to removal.

Refit the tim ing belt (refer to Technical Note

3309A).

Fill and bleed th e cooling circuit (see section 19

"Filling - Bleeding" of Workshop Repair Manu al

M.R. 337).

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TURBOCHARGING

Turbocharger 12

Turbo mounting nuts 2.4

Oil feed union (female) 2.3

Oil feed union (male) 2.6

Oil return union bolt 1.2

Mounting nut securing the intermediate

exhaust downpipe to the turbo 2.6

Lower strut fastener 3.5

Upper strut fastener 2.3


DI1215

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TURBOCHARGING

Turbocharger 12

14731R1

REMOVAL

COMMENT: to slacken the m ounting n uts secu-

ring the turbocharger to the exhau st manifold

more easily, it is useful to spr ay a releasing pr o-du ct onto these nuts w hile they are still warm and

then just before removal.


Remove the engine cover.

From underneath

Remove:

- the protector und erneath the vehicle,- the exhaust downpipe,

- the mounting plate (3); use a tool made on site

to remove bolt (4), otherw ise remove the upper

bolt (10),

- the two bolts securing the turbo oil return pipe

(5) to the engine,

- the lower mounting nut securing the turbo to

the exhau st man ifold (6).

From above

Remove:

- the turbo oil feed u nion bolt (7),

- the two intake air feed and outlet pipesconnected to the turbo,

- the two upper mounting nuts securing the tur-

bo to th e man ifold (8).

Disconnect the ru bber p ipe (9) (connected to the

Wastegate).

12415R3

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TURBOCHARGING

Turbocharger 12

REFITTING

Refit in the reverse order to removal.

WARNING: it is essential to change the copp erseal at the tu rbo oil feed u nion or the O-rings de-

pend ing on the removal procedu re.

IMPORTANT:

Before starting the engine, leave the fuel shut-off

connector on the injection pu mp d isconnected.

Then operate the starter until the oil pressu re

war ning light goes ou t (persist for a few seconds).

Reconnect the fuel shu t-off, pre-heat an d start

the engine.

Run the engine at id le speed and check that there

are no leaks at the oil unions.

Special precautions

• Before refitting, check that the turbo bearings

are lubricated correctly. To do th is, operate the

starter after first having disconnected the fuelshu t-off connector (proh ibiting starting of the

engine) (clear the computer m emory).

The oil must be fed in abu nd ance via the oil

feed p ipes (place a receptacle un dern eath).

Otherw ise, change the lubrication pipe.

• On refitting, ensure that no foreign bodies en-

ter the turbine or the turbocharger.

• Ensure that the turbocharger oil return pipe is

not p artially or comp letely blocked by carbon

deposits.Also ensure that it is sealed correctly.

Otherw ise, change it.

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CARBONISED MIXTURE

Air intake 12

AIR INTAKE CIRCUIT DIAGRAM

16010R

1 Air filter

2 Flowmeter

3 In let m an ifold

4 Tu rbocharger

A Air inlet

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CARBONISED MIXTURE

Manifolds 12

REMOVAL

COMMENT: removal of the man ifolds requ ires re-

moval of the tu rbocharger (refer to the

"Turbocharging" section). The two manifolds can-

not be removed separately.

Disconnect:

- the bat ter y,

- the inlet manifold air feed pipe (11),

- on the manifold, the rubber pipe (9) leading to

th e Wastegate.

Remove th e lifting eye. To gain access to the bolts

securing it, the fuel p ipes mou nting plate (12)

mu st be detached.

Manifold mounting stud 0.8

Manifold mounting nut 2.8

EGR valve mounting bolt 2.7

EGR circuit pipe nut 2.7


12415R4

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CARBONISED MIXTURE

Manifolds 12

Remove the two nu ts (5) securing the EGR pipe from the exhaust m anifold.

DI1216

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CARBONISED MIXTURE

Manifolds 12

Remove the nuts securing the man ifolds.

If the inlet man ifold is to be changed, remove the EGR valve.

REFITTING

Refit in the reverse order to removal.

Change the manifold seals and ensur e that they are fitted correctly.

It is essential to change the oil seals on the tu rbo.

DI1217

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DIESEL EQUIPMENT

Specifications 13

Vehicle Gearbox

Engine

Type IndexBore

(mm)

Stroke

(mm)

Cubic

capacity

(cm3)

Compression

ratio

Catalytic

converter

Emission

control

standard

XB0U

XC0U

JB3

JC5F9Q 780 80 93 1870 18.3/ 1

◊ C99

◊ C112Eu 96

ENGINE SPEED (rpm)

Idle speed Maximum unladen Maximum loaded

OPACITY OF SMOKE

Approval value Legal maximum

850 ± 25 4800 ± 250 4750 ± 250 1.3 m -1 (41 %) 3 m -1 (70 %)

DESCRIPTION BRAND/TYPE SPECIAL NOTES

Injection pump BOSCH

VE 4/ 11 E2000 R803

Rotary pu mp associated with a comp uter w hich

controls:

- the pump (advance and flow),

- the cold star t system,

- th e EGR,

- the fan assembly.

Pum p setting, obtaining of Top

Dead Centre by m eans of an 8

mm ∅ pin (Mot. 1054)

Pump piston lift: 0.32 ± 0.02 mm

Nozzle holder

BOSCH

Y431 K02431

(cylinders 1-2-3)

Y431 K02474

(cylind er 4)

Resistance of calibrated injector: 100 ± 10Ω at 20 °C

Injectors DSLA 145 P808

Opening pressure: 200 bars

Calibration impossible.

Fuel filter BOSCHSeparate priming unit.

The filter is fitted with an electric diesel heater.

Pre-heating unitNAGARES

BRE 6/ 12

With p re-post heating fun ction controlled by injec-

tion compu ter.

Heater p lugs BERU

Tightening torque: 1.5 daN.m

Voltage: 12 volts

Resistance: 0.6 ± 0.1Ω

Fuel shut-off Resistance: 0.8Ω

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DIESEL EQUIPMENT

General 13

The use of electronic injection on diesel engines has m ade it possible to optimise the op eration of these en-

gines and thus red uce the emission of pollutan t gases.

The system consists of a compu ter which receives information from:

- the coolant temperature sensor,- the flowm eter (with air temperature sensor),

- the engine speed sensor,

- the vehicle speed sensor,

- the accelerator pedal position sensor,

- the brake switch ,

- the injection start sensor (the sensor is part of the injector of cylind er n° 1),

- the diesel temperature sensor,

- the fuel flow slide valve position sensor,

- the atmospheric pressure sensor (located in the computer).

The comp uter controls:

- the inject ion pump:• fuel flow slide valve,

• advance solenoid valve,

- the cold start system (heater plugs and pre-post heating un it),

- the engine immobiliser system,

- the exhaust gas recirculation system (EGR),

- the injection fault/ pre-heating warning light,

- the fuel shut-off,

- the immersion heaters which heat the cooling circuit coolant (depend ing on vehicle),

- the fan assembly.

SPECIAL FEATURES

The accelerator cable only controls the load p otentiometer located in the engine compartm ent (single track

poten tiometer + no-load sw itch).

sensors located in th e pu mp

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DIESEL EQUIPMENT

Location of components 13

The injection p um p provides the compu ter with

information.

To do this, it has two sensors:

- a diesel temperature sensor,- a sensor providing information regarding the

position of the fuel flow slide valve.

Depending on the comm and s received from the

comp uter, the pum p supp lies each cylind er with a

defined quantity of diesel at a d etermined point.

To do this, it has two actuator s:

- an advance solenoid valve; this solenoid valve,

wh ich is controlled by the compu ter, perm its

constant alteration of the adv ance point (pu mp

2-way connector),- an electromagnet which permits alteration of

the p osition of the fuel flow slide valve.

Only the ad vance solenoid v alve and th e diesel

temp erature sensor can be removed. In the event

of failure of one of the other comp onents, send

the pum p to an in jection centre.

The compu ter controls the fuel shu t-off located

on the p um p an d th e engine imm obiliser.

98734R1

1 Advance so lenoid va lve

2 Flow control slide valve, flow slide valve posi-

tion information, diesel temp erature infor-

mation

3 Calibra ted in jector

14727R1

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DIESEL EQUIPMENT

Location of components 13

16686R

6 Coolant temperature sensor (CCTM and in-

jection)

3 EGR valve

4 Fu el filter

5 EGR solenoid valve

8 Air flow sensor with incorporated tempera-

ture sensor

14 Pr e-post hea ting unit

15 Computer (in which is located an atmosphe-ric pressu re sensor)

14733R

16 Oxid ising catalyst

14728R

14734-1R

17 Immersion heaters (depending on vehicle)

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DIESEL EQUIPMENT

Injection warning light 13

PRINCIPLE OF ILLUMINATION OF THE INJECTION WARNING LIGHT ON THE INSTRUMENT PANEL

The single injection w arning light is u sed for the p re-heating fun ction and for the injection fault function. It

is controlled by the comp uter via track 54 (preheating) or track 26 (fault).

If a fault is present w hen th e ignition is switched on, the ind icator light remains illum inated at the end of the

pre-heating p hase. The coolant temperature w arning light is controlled by the injection comp uter (see sec-

tion 13 "CCTM")

• Failure of a component of the injection system

Faults which result in illum ination of the warning light:

- accelerator pedal position p otentiometer,

- calibrated injector,

- advance solenoid valve (and regulator),

- engine speed sensor,- fuel shut-off,

- computer fau lt ,

- flow slide valve (actuator and potentiometer),

- m ain relay.

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DIESEL EQUIPMENT

Engine immobiliser function 13

This vehicle is fitted w ith a 2nd generation engine imm obiliser system. It is ESSENTIAL to progr amm e the injec-

tion compu ter with the engine imm obiliser code for it to be able to operate.

REPLACEMENT OF AN INJECTION COMPUTER

The injection compu ters are sup plied w ithout a code.

When a comp uter is replaced, it mu st be program med with th e code of the vehicle and th e correct operation

of the engine immobiliser fun ction m ust be checked.

To do th is, simply sw itch on the ignition for a few seconds th en switch it off.

CHECKING THE ENGINE IMMOBILISER FUNCTION

Remove the key from the ignition sw itch. After 10 seconds the red engine immobiliser war ning light shouldflash (to check that it is not possible to start the engine, refer to section 82 of Workshop Repair Manu als M.R.

325 an d 337.

TESTING AN INJECTION COMPUTER WITHOUT A CODE BORROWED FROM THE WAREHOUSE

(this operation is extremely inad visable)

WARNING: before testing an injection comp uter, it is essential to progr amm e it w ith the vehicle’s engine

immobiliser code for it to be able to operate. Following th e test, it is essential to erase the code from th e

compu ter before return ing it to the warehou se. If the code is not erased, the comp uter w ill be unusable. This

operation m ust be carried out by su itably trained personnel. To erase the code from th e comp uter, refer to

section 82 of Workshop Repair Manual M.R. 325 or 337.

IT IS NOT POSSIBLE TO BORROW A CODED COMPUTER FROM ANOTHER VEHICLE TO CARRY OUT A TEST.

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DIESEL EQUIPMENT

Injection/Air conditioning strategy 13

AIR CONDITIONING/INJECTION COMPUTER CONNECTION

The electrical connection:

- from the air conditioning compu ter to the injection comp uter is via a wire (track n° 37). In fact, only the

compressor power absorbed information is transmitted along this wire.- from the injection compu ter to the air cond itioning comp uter is via a wire (track n° 28). The compressor

operation authorisation or prohibition information is transmitted along this wire.

AIR CONDITIONING COMPRESSOR OPERATION STRATEGY

During certain p hases of operation, the injection compu ter proh ibits operation of the comp ressor.

Engine starting strategy

Comp ressor operation is pr ohibited for 5 seconds after the engine is started.

Overheating protection strategy

The comp ressor is not engaged if the coolant temperature is above or equ al to: +105 °C.

Strategy for release of pow er on heavy acceleration

The compr essor is cut off on h eavy acceleration if the vehicle speed is below 68 mph (110 km/h), if the engine

speed is below 3600 rpm.

Strategy for release of power at start of movement of vehicle

The comp ressor is cut off wh en the v ehicle starts to move if the vehicle speed is below 15 mph (25 km/h), if 1st

gear or reverse is engaged and if the accelerator p edal position is greater than 35 %. The comp ressor is enga-

ged im med iately on exit from on e of the ranges of use.

Engine stalling prevention strategy

The compressor is cut off if the engine speed is below 625 rpm.

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DIESEL EQUIPMENT

Idle speed correction 13

IDLE SPEED CORRECTION IN LINE WITH AIR CONDITIONING SELECTION

If the air conditioning is selected by the d river, the idle speed is changed to 875 rpm.

IDLE SPEED CORRECTION DURING OPERATION OF THE IMMERSION HEATERS

While the imm ersion heaters are supp lied (see section 13 "Immersion heaters"), the id le speed is fixed at 875

rpm.

IDLE SPEED CORRECTION IN THE EVENT OF ACCELERATOR/BRAKE INCONSISTENCY

In the event of an inconsistency fault or a load p otentiometer fault, the engine speed is maintained at

1300 rpm.

IDLE SPEED CORRECTION DURING OPERATION OF THE HEATED WINDSCREEN

While the electric wind screen is selected, th e idle sp eed is fixed at 1000 rpm. At - 30°C, it decreases to 850

rpm.

IDLE SPEED CORRECTION IN LINE WITH TEMPERATURE

Engine speed

in rpm

Temperature

in °C

- 30° 0°

850

1000

In no circumstan ces can the idle speed be maintained at 1000 rpm for a d uration of 11 minutes irrespective of

the engine coolant temperatu re.

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DIESEL EQUIPMENT

Pre-post heating 13

LOCATION

16603R3

98366R3

2 Heater plug (their tightening torque is 1.5

daN.m).

12412R1

WARNING: the tightening torque of the nut secu-

ring the electric lead on the heater plug is

0.2 daN.m.

1 Pr e-post heating un it

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DIESEL EQUIPMENT

Pre-post heating unit 13

16270S

PRINCIPLE OF OPERATION OF THE PRE-POST

HEATING

1. On switching on the ignition "pre-heating"

a) Variable pre-heating

The time for which the w arning light is illu-

minated and the heater plugs are sup plied

depend s on the coolant temperature.

If the coolant temp eratur e sensor is faulty,

the heater plugs are supplied autom atically

for 10 seconds.

b) Fixed pre-heating

When the pre-heating warn ing light goes

out (variable pre-heating), the heater p lugs

remain sup plied for 8 seconds .

2. Starting

While the starter is operating, the heater plu gs

remain supp lied for a maximum du ration of

20 seconds , if the coolant temp erature is be-

low 60 °C.

3. Engine running "post-heating"

During this ph ase, the heater plugs are sup -

plied continuou sly d epending on the coolant

temperature.

12526-1S

The post-heating is interru pted if the engine

speed is > 2500 rpm.

If the coolant temp erature sensor is faulty, the

heater plugs are supp lied au tomatically for 30

seconds .

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DIESEL EQUIPMENT

Immersion heaters 13

The three immersion h eaters (heater p lugs) are

located on a coolant housing secured un der the

man ifold at th e engine - gearbox connection.

The pu rpose of the system is to heat the coolant.

The imm ersion heaters are supp lied w ith 12 volts

by tw o relays. One relay controls two imm ersion

heaters, the other relay controls one imm ersion

heater. This makes it possible to control a choice

of one, two or th ree immersion heaters.

The resistance of the imm ersion heaters is:

0.6 ± 0.1 Ω at 20 °C, connector removed.

16269S

Control strategy

The imm ersion heaters are supp lied:

- if the engine speed is greater than 650 rpm,

- if the post-heating is complete.

If the cond itions above are met, the imm ersion

heaters are controlled in line w ith a pa ttern rela-

ted to the air and coolant temp erature.

Unshaded area: immersion heater not sup plied

Shaded area: immersion heater sup plied

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DIESEL EQUIPMENT

Immersion heaters 13

If the conditions stated above are met, the imm ersion heaters are supp lied on e by one in line with th e battery

voltage.

No Yes

If the battery voltage is > 13.5 volts

No immersion h eaters are

supplied

One imm ersion heater is

supplied

If after 20 seconds the ba ttery

voltage is

> 13.5 volt s

No Yes


supplied

Two imm ersion heaters are

supplied

If after 20 seconds the ba ttery

voltage is> 13.5 volts

No Yes

Three imm ersion heaters are

sup plied for as long as the

batter y voltage is > 13.5 voltsand the conditions stated above

are met


supplied

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DIESEL EQUIPMENT

Accelerator potentiometer 13

No-load value ≈ 0 %

Full-load value ≈ 100 %

Allocation of tracks:

1 N o-load sw itch

2 Not used

3 Track signal

4 Earth5 5 V supply

6 N o-load sw itch

REMOVAL OF THE POTENTIOMETER

Remove the h ousing located u nd er the master

cylinder.

Unh ook the accelerator cable from th e housing.

The potentiometer is sup plied by the Parts

Department with the hou sing.

REFITTING

Refit in the reverse ord er to remov al.

It is essential to validate the rep air using the

diagnostic equipm ent.

15759R1

15760S

NOTE: an accelerator pedal p osition

poten tiometer fault or No-load switch fault willresult in a modified idle speed or op erating speed

(see section 13 "Idle speed correction").

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Clean the area where the advance solenoid valve

is secured to the pu mp .

Remove the ad vance solenoid valve (6).

DIESEL EQUIPMENT

Advance solenoid valve 13

Hydraulic head bolt 1.2

Advance solenoid valve bolt 1

High pressure pipes 2.5


The operator is requested to carry out the

advance solenoid valve removal operation in

conditions of extreme cleanliness.

REMOVAL

Remove the high p ressure p ipes (1).

Disconnect conn ectors (2) and (3).

12412R3

Remove:

- the plate (4) securing the pum p to the engine,

- the steel plate (5) (this plate is secured by a bolt

securing the hydraulic head).

12569R

12568R

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DIESEL EQUIPMENT

Advance solenoid valve 13

WARNING: check that the O-ring (7) has not

remained attached in the pum p body.

12559R

REFITTING

Refit in the reverse order to remova l.

Observe the tighten ing torqu e of the bolt secu-

ring the hyd raulic head a nd of the bolts secur ing

the adv ance solenoid valve.

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DIESEL EQUIPMENT

Diesel temperature sensor 13

Bolt securing the pump cover 0.7

TIGHTENING TORQUE (in daN.m)

The operator is requested to carry out the diesel

temperature sensor removal operation in

conditions of extreme cleanliness.

REMOVAL

Clean the u pp er section of the pu mp very ca-

refully (pu mp cover).

Place a cloth un derneath the p um p an d on the al-

ternator to soak up th e diesel wh ich w ill flow ou t

of the pump .

Remove the three bolts (1) securing the p um p co-

ver.

ESSENTIAL SPECIAL EQUIPMENT

0986 612 605 Socket for removing bolts with a

BOSCH imprint

This equipment must be obtained from the

BOSCH network.

12571R

To remove the fourth bolt (2) securing the pu mp

cover, use th e BOSCH tool (5).

12570R

WARNING: take care not to let any impu rities

enter the pump .

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DIESEL EQUIPMENT

Diesel temperature sensor 13

Clean the su rfaces (4) of the diesel temperature

sensor electrical connections.

12567R

REFITTING

Position the sensor and tigh ten it.

Clean the sealing surface of the u pp er section of the pum p and the cover.

Position the cover and th e bolts, then tigh ten

them observing their tightening torqu es. Tighten

in a cross formation.

12566R

Remove the d iesel temp erature sensor (3). It is

secur ed by tw o Torx bolts.

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DIESEL EQUIPMENT

Pump 13


Mot. 1054 Top D ead Centre pin

Mot. 1200-01 Pulley - pump support tool

Mot. 1383 Tool for removing diesel pipes

Nut securing the pump shaft to the

RAM pulley 4.5

Pump mounting bolt (front) 2.5±0.5

Pump mounting bolt (rear) 2.6±0.3

Front support / cylinder headmounting bolt 3,3± 0,3

Rear support / cylinder head

mounting bolt 2.6±0.3

High pressure pipes 2.5±0.3


NOTE: the veh icles are fitted w ith a RAM pulley.

It is not necessary to rem ove the tim ing belt to

remove the pump .

REMOVAL


Remove th e computer (remove th e computer

connector (1), then the bolt secur ing the comp u-

ter).

Disconnect the electrical un ion connected to the

pump.

Remove the cover (A) protecting the RAM pulley

(on certain vehicles, it is necessary to remove the

suspend ed engine mou nting).

Turn th e engine so that the index on the camsha ft

notched w heel is aligned with th e mark (5) on the

timing cover.

DI1303-1R1

12419R

Remove the bolt protecting the setting hole and

engage tool Mot. 1054 in its place.

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DIESEL EQUIPMENT

Pump 13

Fit the p ulley sup port tool Mot. 1200-01.

12410R2

Disconnect:

- the diesel return quick release union (6),

- the rubber pipe (7) for diesel return from the

injectors,- the connectors (8).

Remove:

- the four high pressure pipes (9),

- the bolts securing the pump support on the cy-

linder block.

12412R4

Slacken:

- by passing a Torx screwdriver into the slots of

th e RAM pu lley, the three bolts securing the

pump,

- the central nut securing the pump shaft to theRAM pulley.

Unscrew alternately the central nu t and all three

bolts securing the pu mp un til they are comp letely

released.

Remove the pump .

REFITTING

Refit the p um p.

Carry ou t the setting operations (refer to the

"Pump - Setting" section).

Carry ou t the other refitting operations in the re-

verse order to removal.

Reprime the pu mp bleeding the high p ressure

pipes un der the starter.

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Mot. 856-02 Gauge holder plus gauge exten-

sion lead (Bosch electronic

pump)Mot. 1054 TDC pin

Mot. 1079 Pump setting gauge

Mot. 1200-01 Pulley - pump support tool

Mot. 1358-01

Mot. 1359

Mot. 1383 Tool for removing diesel pipe

DIESEL EQUIPMENT

Pump - Setting 13

WARNING:

- it is essential to use tool Mot. 1358-01 (tool

Mot. 1358 does not w ork for HTD2 pulleys),

- the engine should only turn when the wheel is

turned, 5th gear engaged, (turn slowly and

smoothly to prevent return du e to the passage

of the compression),- the engine should only turn in its direction of

rotation. If it is turned in the op posite d irection

to the d irection of rotation, repeat the setting

checking or adjustmen t procedu re from zero.

NOTE: the setting value is 0.32 ± 0.02 mm.

Fit an 8.4 mm spacer on tool Mot. 856-02 as

described in Technical Note 3121A.


Left-hand torque setting wrench

ESSENTIAL EQUIPMENT

15508S

Set of tools for operating on a

RAM pulley

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DIESEL EQUIPMENT

Pump - Setting check 13

RAM pulley nut (locking of the adjustment) 9

TIGHTENING TORQUE (in daN.m)

CHECK OF THE SETTING OF INJECTION PUMPS

FITTED WITH A RAM PULLEY

Remove the oil separator (2) and the high p ressure

diesel pipes (3) Mot. 1383.

In place of plu g (4) screw in su pp ort Mot. 856-02

together w ith its spacer.

On the dial gauge, screw in the extension lead sup -

plied with tool Mot 856-02 then p osition it and se-

cure it to the d ial gauge sup port Mot. 856-02 .

12412R6

Set the d ial gauge to BDC of the injection p um p

piston.

Check that the dial gau ge pin slides correctly in

the pu mp body and that it always indicates thesame BDC value (check to be carried ou t every

time the engine is turn ed).

12413R2

Check that the p um p piston travel is less than th e

d ial gauge travel.

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DIESEL EQUIPMENT

Pump - Setting check 13

Pin the engine using tool Mot. 1054 (two opera-

tors). To do this:

- Turn the engine in its direction of rotation (clo-

ckwise on the timing sid e),

- Look out for the mark to appear on the cams-

haft pulley,

- Stop turning the engine a half-tooth before

the two marks align.

DI1303-1R

- Maintain a pressure on the pin.

- Turn the engine slowly until the pin enters the

crankshaft notch.

- Check the pump piston lift read on the dial

gauge, the setting valu e is 0.32 ± 0.02 mm.

If the value is not correct, correct the setting (see

below).

- Fit pin Mot. 1054.

12419R

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WARNING: slacken bolt (1) slightly using tool Mot.

1359 (WARNING: it is a left-hand thread) to allow

flange (B) to ro tate.

DIESEL EQUIPMENT

Pump - Setting adjustment 13

ADJUSTMENT OF THE SETTING OF INJECTION

PUMPS FITTED WITH RAM PULLEYS (to be carried

out following a setting check, see above).

Remove:- the p in Mot. 1054,

- the cover protecting the RAM pu lley. It is

necessary, on certain vehicles, to remove the

suspend ed engine mounting.

Fit p ulley imm obilising tool Mot. 1200-01.

10311R1

98694R2

12411R

Engage tool Mot. 1358-01 in the three openings

of flange (B).

Turn th e tool - clamp assembly so that the three

lugs of the tool engage in the th ree recesses of

the ann ular ad justing bolt.

12312R4

Turn th e clamp - tool Mot. 1358-01 assembly

clockwise un til the pu lley reaches its stop. This

makes it possible to place the pu lley in the start of adjustment position.

Remove imm obilisation tool Mot. 1200-01.

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DIESEL EQUIPMENT


DI1303-1R

- Maintain a pressure on the pin.

- Turn the engine slowly until the pin enters the

crankshaft notch.

- Usin g tool Mot. 1358-01, set the pum p turn ing

the tool an ti-clockwise to the setting value.

If the value is not correct, correct the setting (see

below).

NOTE: if the setting value is exceeded on

adjustment, move back two revolutions to take

up the clearances using tool Mot. 1358-01 then

start the adjustment again at the previous

operation.

Leave pin Mot. 1054 in place.

Lightly p re-tighten bolt (1) using tool Mot. 1359

and not exceeding 2 daN.m (a step to the left, the

dial gauge needle should n ot move).

- Fit pin Mot. 1054.

12419R

Pin the engine using tool Mot. 1054 (two opera-

tors). To do this:

- Turn the engine in its direction of rotation (clo-

ckwise on the timing sid e),

- Look out for the mark to appear on the cams-

haft pulley,

- Stop turning the engine a half-tooth before

the two marks align.

WARNING: it is essential that the torque setting

wrench used sets to the left.

Remove pin Mot. 1054.

Fit pulley imm obilising tool Mot. 1200-01.

Tighten bolt (1) to 9 daN.m, tool Mot. 1359.

Turn the engine through tw o revolutions and

check the p um p setting again.

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DIESEL EQUIPMENT


92600R3

X = 30 teeth

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DIESEL EQUIPMENT

Centralised coolant temperature management 13

244 Coolant temperature sensor (inject ion and

coolant temp erature ind ication on the

instrument panel).

3-way sensor, 2 tracks for the coolant

temp erature information and 1 track forthe indication on the instrument p anel.

This system enables the injection comp uter to

control th e cooling fan . It consists of a single

coolant temp erature sensor which is used by the

injection, the fan, the temp eratur e indicator and

the temperature warn ing light on the instrum ent

panel.

CCTM

98904R2

OPERATION

Sensor 244 enables:

- the coolant temperature to be indicated on

the instrument p anel,- the injection computer to be informed of the

engine coolant temperature.

Depending on the coolant temp erature, the

injection comp uter controls:

- the injection system,

- the E.G.R.,

- the fan relays:

• the fan assembly is operated at low speed if

the coolant temp eratur e exceeds 99 °C an d

stops when the temp erature falls below

96 °C,• the fan assembly is operated at high speed if

the coolant temp eratur e exceeds 102 °C an d

stops when the temp erature falls below

99 °C,

• the fan assembly may be operated for the

AC.

For vehicles which are not fitted w ith AC, only the

fan low speed is operationa l.

COOLANT TEMPERATURE WARNING LIGHT

The warning light is controlled by the compu ter.

It is operated w hen the temp erature exceeds

110 °C.

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DIESEL EQUIPMENT

Wiring diagram 13

16317G

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DIESEL EQUIPMENT

Wiring diagram 13

16317D

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DIESEL EQUIPMENT

Wiring diagram 13

PARTS LIST

104 Engine immobiliser system

107 Battery

120 Injection computer160 Brake switch

225 Diagnostic socket

234 High speed fan assembly relay

244 Coolant temperature sensor

247 Inst rument panel

250 Vehicle speed sensor

257 Pre-heating unit

273 Speed threshold sensor


419 AC management unit

597 Engine compartment fuse box

645 Passenger compartment connection unit680-681

682-683

711 Diesel pum p

738 Needle lift sensor

777 Power supply fuse board

799 Injection air flow meter

898 Immersion heater

921 Accelerator potentiometer

927 Impact sensor

952 Fuel shut-off and adv ance actuator electronics

1049 Immersion heater relay

Heater plugs

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MSACD7801.0

CONDITIONS OF APPLICATION OF THE CHECKS DEFINED IN THIS FAULT FINDING SECTION

In this fault find ing section, each fault is interp reted for a p articular type of storing (fault present, fault

memorised, fault present or memorised).

Therefore, the checks defined for dealing w ith each fault are only to be ap plied to th e vehicle if the fault is

interpreted for the type of fault declared by the diagnostic equipmen t.

If a fault is interp reted in this fault finding section only if it is declared "present", the ap plication of the

fault finding pr ocedu re wh en the fault is only "mem orised" will not enable the reason for the storing of

the fault to be identified. In this case, only a check of the wiring an d connections of the faulty comp onent

should be carried ou t.

If a fault is interpreted wh en it is declared "memorised", the cond itions for confirmation of the current

presence of the fault (and the necessity of app lying the fault finding procedu re) are given in the "NOTES"

box or at the beginning of the interp retation of the fault.

NOTE: The ignition must have been switched off before the diagnostic equipment is switched on.

The characterisation of a m emorised fault is always limited to d EF even if the failure is present but

the conditions un der w hich it is taken into accoun t are not met (it is not possible to obtain a 1.dEF

or a co.0 mem orised).

ESSENTIAL EQUIPMENT FOR OPERATING ON THE BOSCH ELECTRONIC INJECTION SYSTEM

- Diagnostic equipment (except XR25).

DIESEL EQUIPMENT

Fault finding - Introduction 13

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MSACD7801.0

Clear the comp uter m emory, switch off the ignition and then carry out a road test.

Comp lete the operation by carrying out a check using the d iagnostic equipment .AFTER

REPAIR

NoneNOTES

Computer faultDF001

present

or

memorised

If the fault is only m emorised, clear the comp uter m emory. Switch off, then sw itch on the ignition to

reinitialise the compu ter.

Change the comp uter if the fault appears again.

If the fault is present, change the computer.

DIESEL EQUIPMENT

Fault finding - Interpretation of faults 13

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Start the engine and allow it to warm u p to try to confirm the pr esence of a fault.

If the bargrap h then registers pr esent, app ly the fault finding p rocedur e associated w ith the type of faultdeclared.

MSACD7801.0

AFTER

REPAIR

NoneNOTES

Coolant temperature sensor circuit

dEF : Fault memorised

co.1 : Open circuit or shor t circu it to 12 volt scc.0 : Short circu it to earth1.dEF : Operating temperature consistency

DF002

present

or

memorised

NOTES

NoneNOTES dEF

If fault DF021 co.1 is declared also, look for an open circuit of the

sensors earth (track 33 of the compu ter connector).Also check the condition and secur ing of the engine earth strap

and th e MH engine earth.

co.1

Ensure the continuity and insulation from + 12 volts of the connection between track 14 of the compu ter

connector and track 3 of the coolant temp eratur e sensor connector.

Ensure the continu ity of the connection between track 33 of the comp uter connector and track 2 of the

coolant temp eratur e sensor connector.

Check the connections on the 2 connectors of the connection.

If the fault p ersists following these checks, change the coolant tem peratu re sensor.

DIESEL EQUIPMENT



Comp lete the operation by carrying out a check using the d iagnostic equipment .

If it is not p ossible to confirm the presence of a fault on the veh icle, check the coolant t emp erature sensor

circuits as a p recaution.

Investigate the reason for a possible increase in the engine coolant temperature ou tside the norm al

operating ranges (cooling circuit fault, temp erature sensor conformity, engine compartmen t cooling, ...).

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MSACD7801.0

AFTER

REPAIR

DF002

CONT

cc.0 NoneNOTES

Ensure the insulation from earth of the connection between track 14 of the comp uter connector and

track 3 of the coolant temp erature sensor connector.

Check wh ether there is short circuit on the sensor circuit (or the sensor) (resistance app roximately 300 to

450 ohm s at 80 °C / 2400 to 2600 ohm s at 20 °C).



1.dEF NoneNOTES

Measure the line resistances of the following connections:

- Betw een track 14 of the comp uter connector and track 3 of the coolant temp erature sensor connector.

- Betw een track 33 of the comp uter connector and track 2 of the coolant temp erature sensor connector.Carry ou t any op erations necessary in the event of an abnorm ally high resistance.

DIESEL EQUIPMENT





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MSACD7801.0

AFTER

REPAIR

DF003

present

or

memorised

NoneNOTES

Load potentiometer circuit


1.dEF : Gener al consist ency1.cc.1 : Short circuit to 12 volts of the 5 volts supply1.co.0 : Open circuit or short circuit to earth of the 5 volts supply2.cc.1 : Sensor short circuit or short circuit to 12 volts of the signal

NoneNOTES dEF

Press the accelerator ped al to Full-load to try to confirm the p resence of a fault.

If the fault is then registered p resent, apply th e fault finding procedu re associated w ith the typ e of fault

declared.

NoneNOTES 1.dEF

Ensure that the "pedal not p ressed" position recognition switch is operating correctly by means of status

ET016 "No-load switch information" (Switch op en betw een tracks 1 and 6 of the load poten tiometerconnector). Ensu re that earth is present on track 6.

Ensure the continu ity and in sulation from earth of the connection between track 65 of the compu ter

connector and track 1 of the load poten tiometer connector.


If the fault p ersists following these checks, change the load p otentiometer.

NoneNOTES 1.cc.1 / 1.co.0



Ensure the continuity and insulation from +12 volts of the connection between track 57 of the compu ter



If the fault p ersists following these checks, change the load p otentiometer. If the "load poten tiometer

circuit" fault app ears again, change the computer.

DIESEL EQUIPMENT




If it is not p ossible to confirm the presence of a fault on the veh icle, check the load poten tiometer circuits

as a precaution.

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MSACD7801.0

AFTER

REPAIR

DF003

CONT

2.cc.1 NoneNOTES


load potentiometer connector.

Ensure the insu lation from 12 volts of the connection between track 15 of the comp uter connector and

track 3 of the load potentiometer connector. Also ensure the insu lation of this connection from th e

connection betw een track 57 of the comp uter connector and track 5 of the load p otentiometer connector

(+5 volts p otentiometer ).

Look for a p ossible short circuit of the p otentiometer (between tracks 4 and 5 of the 6-way connector) or

of its sup ply.



2.co.0 NoneNOTES





DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

Vehicle speed sensor circuit


1.dEF : Signa l frequency too h igh

2.dEF : Maxim um speed exceeded

3.dEF : Consistency between flow and vehicle speed

DF004

memorised

NOTES None

NoneNOTES dEF

Carry ou t a road test to try to confirm th e presence of a fault.

If the fault is then registered p resent, apply th e fault finding procedu re associated w ith the typ e of faultdeclared.

NOTES None1.dEF / 2.dEF

3.dEF

Is the vehicle speed information present on the instrument panel?

NOA : Vehicle speed information from the ABS computer.

Check the connections at th e ABS comp uter connector.

Ensure the continu ity of the connection between track 43 of the engine

man agement comp uter connector and th e ABS compu ter connector.Ensure th e insulation of all the connections concerned w ith receiving th e vehicle

speed information.

B : Vehicle speed information from the tachometer sensor.

Check the veh icle speed sensor connections.

Ensure that th e speed sensor is sup plied correctly.

Ensure the continu ity and in sulation of the connection between track 43 of the

engine management compu ter connector and track B1 of the sensor connector.

If the fault p ersists following these checks, change the vehicle speed sensor.

Check the connections at the engine managem ent compu ter.

Ensure the continuity between track 43 of the engine man agement comp uter

connector and the sou rce of the veh icle speed informa tion (tachom eter sensor or ABS

computer).

YES

DIESEL EQUIPMENT




If it is not p ossible to confirm the presence of a fault on the veh icle, check the vehicle speed sensor circuits

as a precaution (signal int erference).

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MSACD7801.0

AFTER

REPAIR

NOTES None

NoneNOTES

Start the en gine to try to confirm th e presence of a fault.

If the bargrap h then registers pr esent, app ly the fault finding p rocedur e associated w ith the type of fault

declared.

If it is not possible to confirm the p resence of a fault with th e engine run ning, carry out a road test to

confirm a p ossible signal consistency fault.

dEF

NoneNOTES 1.dEF / 2.dEF

Measure th e resistance of the n eedle lift sensor at its connector.

Change the calibrated injector if the resistance is not approximately 105 ohms.

Ensure th e continuity of the following connections:

- Betw een track 12 of the comp uter connector and track 1 of the n eedle lift sensor connector.

- Betw een track 11 of the comp uter connector and track 2 of the n eedle lift sensor connector.


Ensure the insulation of the connection between track 12 of the comp uter connector and track 1 of theneed le lift sensor connector.

Ensure th e insulation betw een the 2 lines of the needle lift sensor.

Also check the cond ition of the w iring between the sensor connector and the sensor.

If the fault persists following these checks, change the calibrated injector.

DF005

Present

or memorised

Needle lift sensor circuit

DEF : Fault memorised

1.dEF : Open circuit or short circuit to 12 volts

2.dEF : Shor t cir cu it to ear th3.dEF : Stat ic consist ency

4.dEF : Dynam ic consistency5.d EF : Over-revving

DIESEL EQUIPMENT




If it is not possible to confirm the p resence of a fau lt on the vehicle, check the need le lift sensor circuits as

a p recaution (interference with the signal).

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MSACD7801.0

AFTER

REPAIR

DF005

CONT

NoneNOTES 3.dEF

Check the cond ition of the injector and its fuel supply (injector jamm ed, p ipe kinked , ...).

If the fault persists following these checks, change the calibrated injector (sensor faulty).


These faults are taken into accoun t in the event of interference with th e needle lift sensor signal.

Check the condition of the sensor wiring an d look for a circuit insulation fault (earthing of the shielding,

...).

If the fault persists following these checks, change the calibrated injector.

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

Ad vance solenoid valve circuit

DEF : Fault memorised

co.0 : Open cir cu it or shor t circu it to ea rth

cc.1 : Sh ort circu it to 12 volts1.dEF : Advance regulat ion d r ift

DF006

present

or

memorised

NOTES None

NoneNOTES dEF


If the fault is then registered p resent, apply th e fault finding procedu re associated w ith the typ e of faultdeclared.

If it is not possible to confirm the p resence of a fault with th e engine run ning, carry out a road test.

NoneNOTES co.0

Measure th e resistance of the advance solenoid valve at its connector.

Change the advance solenoid valve if the resistance is not ap pr oximately 15 ohms.


connector and track 1 of the advance solenoid valve connector.

Ensure that + after relay i s present on track 2 of the corrector connector, wiring end .

Check the connections on the 2 connectors.

If the fault p ersists following these checks, change the adv ance solenoid valve.

DIESEL EQUIPMENT




If it is not p ossible to confirm the presence of a fault on the veh icle, check the injection p um p setting and

check the advance solenoid valve circuits as a p recaution (setting value: 0.32 ± 0.02 mm).

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NOTES

MSACD7801.0

AFTER

REPAIR

DF006

CONT

Measure th e resistance of the advance solenoid valve at its connector.

Change the advance solenoid valve if the resistance is not ap pr oximately 15 ohms (short circuit).

Ensure the insu lation from + 12 volts of the connection between track 51 of the computer connector and

track 1 of the advan ce solenoid valve connector.

Ensure the insu lation between the ad vance solenoid valve control line and its + after relay supp ly.

NoneNOTES cc.1

This fault ind icates jamm ing of the ad vance solenoid valve, incorrect setting of the injection pum p or afuel sup ply problem.

It is taken into account w hen th e advance checked by th e needle lift sensor d iffers from th e adva nce

reference value requested by the compu ter by more than 3°.

- Check the condition of the needle lift sensor wire and its connections.

- Check the cond ition of the fuel sup ply (filter clogged, pipe kinked , incorrect diesel in winter, ...).

- Check the pu mp setting, check the securing of the pump pu lley, and carry out a more general check of

the timing.

- Visually check the conformity of the engine flywheel (4 notches without any other interfering

markings).

If the checks are correct, change the advance corrector.

Deal with DF005 first if it is declared also.Check the injection pu mp setting before carrying ou t any w ork (setting value: 0.32 ± 0.02 mm).

1.dEF

DIESEL EQUIPMENT




If the fault p ersists following these checks, change the adv ance solenoid valve.

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MSACD7801.0

AFTER

REPAIR

Fuel shut-off circuit


1.dEF : Consis tency of operat ion

2.d EF : Circu it fau lt

DF014

present

or

memorised

NOTES None

Place a mu ltimeter in voltmeter m ode on th e supply terminal of the fuel shut-off and start the "fuel shut-

off" actuator comm and .

- If during the command, the mu ltimeter indicates a permanent voltage of 12 volts , look for a short

circuit to 12 volts of the connection between track 53 of the comp uter connector and the fuel shut-off

(the command provides an alternating on/ off control).

Ensure that the engine imm obiliser is disarmed .NOTES dEF

Start the engine. Switch off the ignition while monitoring th e display on the d iagnostic equipmen t.

- If the display indicates 1.dEF du ring the compu ter supp ly maintaining p hase, change the fuel shut-off.

Measure the resistance of the fuel shut-off at its connector.

Change the fuel shu t-off if the resistance is not appr oximately 7.5 ohms.


connector and the fuel shu t-off.

Check the connections at the compu ter and ensure that the fuel shut-off sup ply terminal is secured

correctly.

NoneNOTES 2.dEF

If the fault persists following th ese checks, change th e fuel shu t-off.

DIESEL EQUIPMENT




If it is not possible to obtain th is display, there is no fault p resent on the vehicle.

Check the fuel shu t-off circuit as a p recaution.

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MSACD7801.0

AFTER

REPAIR

Main relay circuit


1.dEF : Relay cu ts ou t too la te

2.dEF : Relay cu ts ou t too soon

DF017

present

NoneNOTES

1.dEF

Check the connections at the m ain relay sup por t. Repair if necessary.Try another relay (note the faults mem orised, replace the relay, clear the faults m emory, sw itch off the

ignition and wait 10 seconds, read th e faults).

Check the connections at th e compu ter. Repair if necessary.

Ensure the insulation from earth of the connection between th e relay supp ort (coil earth) and track 42 of

the computer connector.

Ensure the insu lation from +Battery of the connection between th e relay sup port (pow er outp ut) and

tracks 23, 45 and 68 of the comp uter connector.

The relay cuts ou t too late or not at allNOTES

If the fau lt persists following these checks, chan ge the comp uter (refer to the "assistance" section for this

operation.

2.dEF

Check the connections at the m ain relay sup por t. Repair if necessary.

Try another relay (note the faults mem orised, replace the relay, clear the faults m emory, sw itch off the

ignition and wait 10 seconds, read th e faults).

Check the connections at th e compu ter. Repair if necessary.

Ensure the continu ity of the connection between the relay sup port (pow er outpu t) and tracks 23, 45 and

68 of the compu ter connector (check the cond ition of the wiring).

Ensure the continu ity of the connection between the relay sup port (coil earth) and track 42 of the

compu ter connector (check the cond ition of the wiring).

The relay cuts ou t too soonNOTES

If the fau lt persists following these checks, chan ge the comp uter (refer to the "assistance" section for this

operation.

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

DF019

present

ormemorised

NOTES

Air flow sensor circuit


1.cc.1 : Short circuit to 12 volts of the sensor engine running

2.cc.1 : Short circuit to 12 volts of the sensor engine not running1.co.0 : Open circuit or short circuit of the sensor to earth engine running

2.co.0 : Open circuit or short circuit of the sensor to earth engine not running3.cc.1 : Short circuit to 12 volts of the sensor supply3.co.0 : Open circuit or short circuit of the sensor supply to earth1.d EF : Consistency

NOTES None

NoneNOTES dEF


- If the bargraph then registers present, app ly the fault finding procedure associated w ith the type of

fault declared.

- If it is not p ossible to confirm th e presence of a fault with the engine ru nning at idle speed, accelerate

the engine speed to more than 2000 rpm to confirm a possible information consistency fault.


sensors earth (track 21 of the compu ter connector)1.cc.1 / 2.cc.1

Ensure the insu lation from 12 volts of the connection between track 13 of the comp uter connector and

track 5 of the air flow sensor connector.

Ensure the continu ity of the connection between track 21 of the comp uter connector and track 2 of thesensor connector and ensure that -Battery is present on track 6 of the sensor conn ector (presence of a

voltage > 10.5 volts after ignition betw een tracks 4 and 6 of the connector).

If the fault p ersists following these checks, change the air flow sensor.

DIESEL EQUIPMENT




If it is not p ossible to confirm the presence of a fault on the veh icle, check the air flow sensor circuits as a

precaution.

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MSACD7801.0

AFTER

REPAIR

DF019

CONT


connector and track 5 of the sensor connector and ensure th at + after relay is present on track 4 of the

sensor connector (presence of a voltage > 10.5 volts between tracks 4 and 6 of the connector).


NoneNOTES 1.co.0 / 2.co.0


Ensure the continu ity and in sulation of the connection between track 19 of the comp uter connector and

track 3 of the sensor connector.

Ensure that th ere is a voltage > 10.5 volts between tracks 4 and 6 of the sensor connector.


NoneNOTES 3.cc.1 / 3.co.0


Check the conformity of the air intake circuit.


NoneNOTES 1.dEF


DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

Fuel temperatu re sensor circuit

co .1 : Open circuit or shor t circu it to 12 volt s

cc.0 : Short circu it to earth

DF021

present

NoneNOTES

NOTES

If fault DF042 5.dEF is present also, check the secur ing of the

pu mp 7-way roun d connector.


sensors earth (track 33 of the compu ter connector).

Also check the cond ition and tigh tening of the engine earth strapand the MH en gine earth near the oil filter.

co.1

Ensure the continuity and insulation from + 12 volts of the connection between track 63 of the compu ter

connector and track 6 of the pum p connector.


pu mp connector.


If the fault p ersists following these checks, change the fuel temperatu re sensor.

cc.0 NoneNOTES


track 6 of the pum p connector.

Check wh ether there is a short circuit on the sensor circuit (or the sensor) (resistance 2.2 Kohms at 20 °C).


If the fault p ersists following these checks, change the fuel temperatu re sensor.

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

Air temp erature sensor circuit

co .1 : Open circuit or shor t circu it to 12 volt s

cc.0 : Short circu it to earth

DF022

present

The air temp erature sensor is incorporated in th e air flow m eterNOTES

NOTES

If fault DF019 2.cc.1 is declared also, look for a op en circuit of the

sensors earth (track 21 of the compu ter connector)co.1

Ensure the continuity and insulation from +12 volts of the connection between track 64 of the compu ter

connector and track 1 of the air temperatur e sensor connector.


air temperatu re sensor connector.


If the fault p ersists following these checks, change the air temp erature sensor.

NoneNOTES cc.0


track 1 of the air temp erature sensor connector.

Check wh ether there is a short circuit on the sensor circuit (or the sensor) (resistance 3.3 Kohms at 20 °C).


DIESEL EQUIPMENT




If the fault p ersists following these checks, change the air temp erature sensor.

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MSACD7801.0

AFTER

REPAIR

NoneNOTES

Flywheel signal sensor circuit


1.dEF : Sta tic consistency2.dEF : Dynam ic consistency3.dEF : Over -r evving de tection

DF023

memorised

NoneNOTES dEF

Start the engine to try to confirm th e presence of a fault (or carry out a star ting test).

If the fault is then registered p resent, apply th e fault finding procedu re associated w ith the typ e of faultindicated.

If it is not possible to register the fault as present, clear the computer m emory, then r estart the engine.

App ly the fault finding p rocedur e below if the bargraph again ind icates that the fault is mem orised (dEF).

If the fault is not registered again, check the flywheel signal sensor circuits as a pr ecaution.

NOTES None1.dEF / 2.dEF

3.dEF

Measure th e resistance of the flywheel signal sensor at its connector. Change the sensor if the resistance is

not app roximately 1000 ohms.

Ensure the continu ity and in sulation of the following connections:

- Betw een track 8 of the comp uter connector and track B of the flywheel signal sensor connector.

- Betw een track 21 of the comp uter connector and track A of the flywheel signal sensor connector.

Also check the insulation betw een these 2 connections.


Visually check the gen eral cond ition of the wiring an d the w iring passage for risks of interference.

DIESEL EQUIPMENT




Check the position and cond ition of the sensor.

Check the cond ition of the target (deforma tion, mou nting, ...).

Check the conform ity of the target: 4 slots at 90°.

If the fault persists following th ese checks, change th e flywheel signal sensor.

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8/14/2019 Xc0u - Xb0u


NOTES

MSACD7801.0

AFTER

REPAIR

Power steering assembly relay control circuit

co.0: Open circuit or short circuit to earth (present)

cc.1: Short circuit to 12 volts (memorised)

DF029

present

or

memorised

NOTES

If the vehicle is not fitted w ith air conditioning, ensure th at the computer is

configur ed "withou t pow er steering" (for "withou t pow er steering electropum p

assembly").

NoneNOTES co.0

Measure the resistance of the p ower steering electropum p assem bly relay coil (in the engine

compartment connection unit).

Change the relay if the resistance is not approximately 80 ohms.

Measure the resistance of the p ower steering electropum p assem bly relay coil (in the engine

compartment connection unit).

Change the relay if the resistance is not approximately 80 ohms.

App ly the fault find ing procedu re below if the fault app ears againafter clearing of the compu ter memory followed by activation of actu ator com mand "POWER STEERING ASSEMBLY RELAY".

cc.1

DIESEL EQUIPMENT


Check the connections on the relay sup port th en on the compu ter connector.


connector and terminal 2 of the electropu mp assembly relay supp ort.

Ensure that +after ignition is present on terminal 1 of the electropum p assembly relay sup port.

If the fault p ersists following these checks, change the pow er steering electropu mp assembly relay.

Ensure the insu lation from +12 volts of the connection between track 50 of the comp uter connector and

terminal 2 of the electropu mp assembly relay supp ort.

If the fault p ersists following these checks, change the pow er steering electropu mp assembly relay.



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MSACD7801.0

AFTER

REPAIR

DF038

present

or

memorised

Immersion heater relay circuit


1.co.0: Open circuit or short circuit to earth relay 1 circuit

1.cc.1 : Short circuit to 12 volts relay 1 circuit2.co.0: Open circuit or short circuit to earth relay 2 circuit

2.cc.1 : Short circuit to 12 volts relay 2 circuit

NOTES

If the vehicle is not fitted w ith imm ersion heaters, change the computer

configuration u sing the command "Compu ter configuration without immersion

heaters".

Use comman ds "Immersion heaters group 1 relay" then "Immersion heaters group 2 relay" to try to

confirm the p resence of a fault.

If at the end of the comm and the fault is registered present, app ly the fault finding p rocedure associated

with th e type of fault d eclared.

NoneNOTES dEF

If it is not possible to register the fault as p resent, check the imm ersion heater relay w iring as a

precaution.

Measure th e resistance of the coil of the relay concerned between terminals 1 and 2.

Change the relay if the resistance is not approximately 80 ohms (relay 1) and 65 ohms (relay 2).

Ensure the continu ity and in sulation from earth of the connection between track 27 (relay 1) or track 47

(relay 2) of the compu ter connector and track 2 of the supp ort of the imm ersion heater relay concerned.

Ensure that + after relay is present on track 1 of the sup por t of the imm ersion heater relay concerned.

Check the connections on the compu ter connector and on the supp ort.

NoneNOTES 1.co.0 / 2.co.0

Measure th e resistance of the coil of the relay concerned between terminals 1 and 2.

Change the relay if the resistance is not approximately 80 ohms (relay 1) and 65 ohms (relay 2).

Ensure the insu lation from + 12 volts of the connection between track 27 (relay 1) or track 47 (relay 2) of

the compu ter connector and track 2 of the supp ort of the imm ersion heater relay concerned.

NoneNOTES 1.cc.1 / 2.cc.1

If the fault p ersists following these checks, change the immersion heater relay concerned.

DIESEL EQUIPMENT


If the fault p ersists following these checks, change the immersion heater relay concerned.



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MSACD7801.0

AFTER

REPAIR

DF042

present

or

memorised

Fuel flow circuit


1.d EF : Drift w hen cold

2.d EF : Drift when warm3.dEF : "Stop" limit not reached

4.dEF : "Star t" limit not reached5.dEF : Open circuit or short circuit to 12 volts6.dEF : Shor t cir cu it to ea rth

NOTES If fault DF021 co.1 is present also, check that the p um p 7-way round connector is

secured correctly.

NoneNOTES dEF

Carry ou t a road test to try to confirm th e presence of a fault.

If the bargrap h then registers pr esent, app ly the fault finding p rocedur e associated w ith the type of fault

declared.

If it is not possible to register the fault as p resent, switch off the ignition w hile monitoring the d isplay on

the diagnostic equipm ent du ring the compu ter supp ly maintaining ph ase.


Measure th e resistance of the flow actuator betw een tracks 4 and 7 of the pum p connector.

Change the pu mp if the resistance is not between 0.5 and 1 ohm .

Ensure the continuity between tracks 4 / 5 / 49 of the comp uter connector and track 4 of the pum p

connector.

Ensure the insu lation from earth and from 12 volts of this connection.Check that +after ignition is present on track 7 of the pum p connector.


If all the checks are correct, reconnect the comp uter an d p um p connectors, then clear the comp uter

memory.

Exit fault find ing mod e and carry out a road test. Change the pu mp if the fault appears again.

DIESEL EQUIPMENT


If it is not possible to obtain a d isplay other th an "dEF", there is no fault pr esent on th e vehicle. Check the

pu mp wiring and the connections on th e 7-way round connector as a p recaution.



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MSACD7801.0

AFTER

REPAIR

DF042

CONT


Every time the ignition is switched off, the comp uter controls the flow actuator to test w hether th e flow

regulation slide valve is operating correctly. If the slide valve does n ot mov e in line with th e request, fault

3.dEF or 4.dEF is memorised.

Change the diesel injection pum p.


Ensure the continu ity and in sulation of the following connections:

- Betw een track 7 of the comp uter connector and track 3 of the pum p connector.



Ensure the insulation between these 3 connections.


DIESEL EQUIPMENT


If all the checks are correct, reconnect the comp uter an d p um p connectors, then clear the comp uter

memory.

Exit fault find ing mod e and carry out a road test. Change the pu mp if the fault appears again.



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MSACD7801.0

AFTER

REPAIR

DF045

present

or

memorised

Pre-heating relay circuit

d EF : Fault memorised

co.0 : Open circuit or short circuit to earth

cc.1 : Short cir cu it to 12 volts1.dEF: Consistency with diagnostic line return

NOTES First check the condition of the 70A fuse in th e engine comp artmen t connection

unit.

NoneNOTES dEF

Use the"Pre-heating relay"comman d to try to confirm th e presence of a fault.If at the end of the comm and the fault is registered present, app ly the fault finding p rocedure associated

with th e type of fault d eclared.

If it is not possible to register the fault as p resent, clear the computer m emory, sw itch th e ignition off and

then on again. App ly fault find ing procedure 1.dEF below if the fault is declared mem orised again (dEF).


track B1 of the relay un it connector.


NoneNOTES co.0 / cc.1

If the fault p ersists following these checks, change the relay un it.

DIESEL EQUIPMENT


If it is not possible to register the fault as present, check the heater p lug leads an d the connections on the

relay unit as a precaution.



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MSACD7801.0

AFTER

REPAIR

DF045

CONT

NoneNOTES 1.dEF

Ensure that the 2 connectors on th e relay unit are connected.

Ensure that the heater p lugs are connected.


tracks C1 and C2 of the relay un it 6-way connector.

Ensure that +after ignition is present on track A1 of the relay un it 6-way connector.Ensure that earth is present on track A2 of the relay un it 6-way connector.

Ensure that +before ignition is present on track 2 of the relay un it 3-way connector.

Check the connections on the relay unit and on the compu ter.

Disconnect the heater plugs and check/ ensure the insulation from earth of the wiring between the relay

un it and the heater p lugs. Check the condition of the heater plug leads.

Check and change the faulty heater p lugs (short circuit).

DIESEL EQUIPMENT


If the fault p ersists following these checks, change the relay un it.



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MSACD7801.0

AFTER

REPAIR

If necessary, carry out a complete check of the charging circuit u sing the Op tima

5800 d iagnostic equ ipm entNOTES

Carry ou t the operations necessary to obtain a correct comp uter su pp ly voltage:

6 volts < operating vo ltage < 16.5 volts.

- Battery charge check.

- Charging circuit check.- Check of the securing and condition of the battery terminals.

- Computer earth check.

DF047

present

or

memorised

Supply


1.dEF : Excess bat tery voltage

2.dEF : Bat ter y volta ge low

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

For app lication to Clio vehicles, refer to the following p age.NOTES

DF051

present

or

memorised

Brake p eda l switch circuit


1.dEF : Consistency between the 2 items of brake information

2.dEF : Consistency of the brake signal after starting

Monitor statuses ET013 Brake switch n° 1 information an d ET014 Brake switch n° 2 information with and

without action on the brake ped al.

Dur ing norm al operation, the 2 statuses are"not validated" if the pedal is not p ressed. They are validated

wh en the ped al is pressed.

Are the "pedal p ressed" and "ped al not pr essed" statuses of the brake ped al recognised correctly?

There is fault present at th e brake switch.

Carry ou t a simp le preventive check of the fitting of the switch and the

connection of its connector.

YES

Check the cond ition and setting of the brake switch.

Disconnect the brake switch, then check/ ensure that +after ignition i s present

on tracks A1 and A3 of the connector, wiring end .

Check the operation of the brake sw itch contacts (opening of the contact

between tracks A1 and B3 and closing of the contact between tracks B1 and A3

wh en the p edal is pressed).

Check and ensur e the continuity of the following connections:

- Betw een track B3 of the brake switch connector and track 20 of the compu ter

connector.


connector.

NO

DIESEL EQUIPMENT

Fault finding - Interpretation of faults 13KANGOO



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MSACD7801.0

AFTER

REPAIR

NOTES

DF051

present

or

memorised

YES

NO

DIESEL EQUIPMENT

Fault finding - Interpretation of faults 13CLIO

Brake p eda l switch circuit


1.dEF : Consistency between the 2 items of brake information

2.dEF : Consistency of the brake signal after starting

For app lication to Kangoo vehicles, refer to the p revious p age.

Monitor statuses ET013 Brake switch n° 1 information an d ET014 Brake switch n° 2 information with and

without action on the brake ped al.

Dur ing norm al operation, the 2 statuses are"not validated" if the pedal is not p ressed. They are validated

wh en the ped al is pressed.

Are the "pedal p ressed" and "ped al not pr essed" statuses of the brake ped al recognised correctly?

There is fault present at th e brake switch.

Carry ou t a simp le preventive check of the fitting of the switch and the

connection of its connector.

Check the cond ition and setting of the brake switch.

Disconnect the brake switch, then check/ ensure that +after ignition i s present

on tracks A1 and B1 of the connector, wiring end .

Check the operation of the brake sw itch contacts (opening of the contact

between tracks A1 and B3 and closing of the contact between tracks B1 and A3

wh en the p edal is pressed).

Check and ensur e the continuity of the following connections:


connector.

- Betw een track A3 of the brake switch connector and track 44 of the compu ter

connector.



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MSACD7801.0

REPLACEMENT OF THE COMPUTER

Clio / Kangoo :

Depend ing on the country, Clio and Kangoo veh icles may or m ay not be fitted with im mersion heaters as

stand ard . They are always fitted with a p ower steering electropu mp assembly if the vehicle is fitted w ith airconditioning.

The comp uter is pre-configured "with immersion heaters" and "without p ower steering" (for "w ithout p o-

wer steering electropum p assem bly"). When a computer is changed on a Clio or Kangoo vehicle, it is necessa-

ry to ensu re that the compu ter is configured correctly and to change this p re-configuration if necessary using

the comman ds "without imm ersion heaters" and "with p ower steering".

The configuration comm and with/ without Air Conditioning cannot be used on th ese vehicles (comp uter

configured "with AC" by default).

DIESEL EQUIPMENT

Fault finding - Assistance 13

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F9CD0A 1.0

DIESEL EQUIPMENT

Fault finding - Conformity check

Only carry ou t this conformity check following a check u sing the N XR or Clip.

Engine off; ignition onNOTES

Order Function Parameter / Status checked oraction

Display/ Notes

Diag.

1 ET 001 +after ignition computer

PR 004 Comp uter supply voltage

Status confirmed .

11.8 < PR004 < 13.2

2 Warning light on

instrument panel

ET 004 Fau lt war ning light

ET 008 Overheating w arning light

Status not confirmed .

Status not confirmed .Illuminated on the instru-

ment pan el for a few se-

cond s w hen the ignition is

switched on.

3 Pre-post heating

function

Pre-heating / fault warning light

ET 011 Pre-post heat ing activeET 027 Preheating relay comman d

Illuminated on the instrument

pan el for a few seconds when

the ignition is switched on .

Statu ses confirmed for a fewsecond s when th e ignition is

switched on.

4 Brake switch ET 013 brake n° 1 switch

information

ET 014 brake n° 2 switch

information

Statuses confirmed

if the br ake pedal is pr essed DF051

5 Load

potentiometer

ET 016 No-load switch

PR 017 load p otentiometer p osition

Status confirmed at No-load

at No-load = 0 %

at Full-load = 100 %

6 Immersion heaters

operation

ET 031 immersion heaters group 1

relay command

ET 032 immersion heaters group 2

relay command

Statuses confirmed in line

with operation

7 Fuel shut-off ET 033 fuel shut-off relay command Status not confirmed

engine off

13

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F9CD0A 1.0

DIESEL EQUIPMENT


NOTES

Order FunctionParameter / Status checked or

action

Display

/ Notes

Diag.

8 Diesel

temperature

sensor

Coolant

temperature

sensor

Air temp erature

sensor

Atmospheric

pressure sensor

PR 001 Fuel tem peratu re

PR 002 Coolant temp eratur e

PR 003 Air tem peratu re

PR 016 Atmosph eric pressu re

- 40°C < PR001 < 140°C

- 32°C < PR002 < 140°C

- 32°C < PR003 < 140°C

420 mbar<PR016<

1070 mbar

9 Miscellaneous

parameters

PR 007 flow of air at in let

PR 011 idle regu lation reference

PR035 id le speed correction

PR 012 engine speed seen by theneed le lift

PR007 = 400±100 kg/ h

PR011 = 850 rpm

if PR035 = 0 rpm

PR012 = 0 rpm

10 EGR function PR 024 EGR solenoid valve OCR PR024 = 95 %

11 Advance solenoid

valve

Comm and : adv ance solenoid valve The actuator shou ld be heard

to click

12 AC compressor Command: AC compressor

proh ibition relay

AC selected on the

instrument p anel, the

compressor should click

13 Fuel shut-off Command: fuel shut-off The actuator should be heard

to click gen tly

14 Fan assembly Command: fan assembly low speed

Comm and : fan assembly high

speed

(if AC option fitted)

The fan assembly shou ld be

heard op erating at low speed

The fan assembly shou ld be

heard op erating at h igh

speed

13Only carry ou t this conformity check following a check u sing the N XR or Clip.

Engine off; ignition on

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F9CD0A 1.0

DIESEL EQUIPMENT


NOTES

Order Function

Parameter / Status checked or

action

Display

/ Notes Diag.

15 Miscellaneous

statuses

ET 033 Fuel sh ut -off comm and

ET 025 Power steering assembly

relay comm and (if AC option fitted)

ET 027 Pre-pos t heat ing relay

command

Statuses confirmed

16 Miscellaneous

parameters

PR004 Comp uter supp ly voltage

PR 006 Engine sp eed

(if PR 035 = 0)

PR 007 Air flow a t inlet

PR 011 Idle regu lation reference

PR 012 Engine sp eed seen by the

need le lift

PR 020 Fuel flow reference

12.5<PR004<15 V

Idle speed

PR 006 = 850 rpm

20<PR007<50 kg/ h

PR011 = 850 rpm

PR012 ≈ 850 rpm

PR020 ≈ 6 mg/ stroke at idle

17 EGR function PR 024 EGR solenoid valve RCO PR024 = 5 % depend ing on

the operation of the EGR

18 AC function ET 006 Air cond itioning request

ET 007 Air cond itioning

authorisation

PR 006 Engine sp eed

ET 037 Low sp eed fan assem bly

relay command

Statuses confirmed

in line w ith AC operation

PR006 = 875 rpm

Status confirmed

13Only carry ou t this conformity check following a check u sing the N XR or Clip.

Engine warm , at idle speed, no pow er consum ing equipment op erating

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F9CD0A 1.0

DIESEL EQUIPMENT


Only carry ou t this conformity check following a check u sing the N XR or Clip.

Road testNOTES

Order Function Parameter / Status checked oraction

Display/ Notes

Diag.

21 Vehicle speed

information

PR 018 Vehicle speed in km/ h

22 Flows

PR 007 flow of air at in let

PR 020 fuel flow reference

at approximately 80 km/ h

at full-load

360<PR 0007<400 kg/ h

PR 020 > 6 mg/ cp

CHART

6

13

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MSACD7801.0

Only refer to these custom er complaints following a complete check using the

diagnostic equipm entNOTES

NO DIALOGUE WITH THE ENGINE MANAGEMENT COMPUTER

STARTING PROBLEM (engine does not start or is di fficult to start)

PASSENGER COMPARTMENT HEATING PROBLEM WHEN COLD (difficulty in increasing the

temperature of the engine)

FLASHING OF THE INJECTION FAULT WARNING LIGHT

SPORADIC LACK OF POWER

PERMANENT LACK OF POWER

CHART 1

CHART 2

CHART 3

CHART 4

CHART 5

CHART 6

DIESEL EQUIPMENT

Fault finding - Customer complaints 13

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MSACD7801.0

AFTER

REPAIR

CHART 2STARTING PROBLEM

(engine does not start or is difficult to start)

Only refer to this custom er complaint following a complete check using the


If no fault is declared by th e diagnostic equ ipm ent, ensure that the problem is not due to an engine

imm obiliser system fault or a battery charge p roblem.

If the p roblem p ersists:

Check the fuel supp ly circuits (of the p um p an d the injectors) :

- Diesel filter: Abnormal presence of water or smell of petrol.

- Presence of air bubbles in the transparent pipes up stream of the injection pum p before starting (in the

case of a a significant quant ity of bubbles, look for the air leak).

- Cond ition of the d iesel return rail on the injector carriers (if there is a clearance on the clips, change the

rail).

- Look for a diesel leak (pum p inlet click-fit union, pu mp HP outlet, return rail or injector carrier discharge

pipes).

Check the injection p um p setting (recomm end ed value for all F9Q eng ines: 0.32 ± 0.02 mm).

If necessary, carry out a complete check of the engine (starter d rive speed , pump setting, cond ition of the in-

jectors, valve clearances, comp ressions, ...).

If the p roblem only occur s at extremely low t emp eratures, check the op eration of the pre-heating:

Use the "Pre-heating relay"comm and and check that there is a voltage on the h eater p lug leads.If none of the heater p lugs are supp lied, check the connection of the intermediate 2-way connector and the

3-way connector on the r elay un it. Also check the cond ition of the 70 Amp fuse on the engine comp artment

connection u nit.

If only one grou p of heater plugs is without a su pp ly, check the w iring.

If the fault p ersists, change the relay u nit.

Carry out a road test followed by a check using the d iagnostic equipment .

Deal with any faults declared.

DIESEL EQUIPMENT

Fault finding charts 13

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MSACD7801.0

AFTER

REPAIR

CHART 3PASSENGER COMPARTMENT HEATING PROBLEM WHEN COLD

(difficulty in increasing the temperature of the engine)

Only refer to this custom er complaint if the vehicle is fitted w ith imm ersion

heaters and following a complete check using the diagnostic equipm entNOTES

Check the operation of the engine cooling circuit immersion h eaters.

Use the "Immersion heaters group 1 relay" then "Immersion heaters group 2 relay"comm ands an d check

that th ere is a voltage on the 3 imm ersion heaters.

If there is a fault, check the imm ersion heaters sup ply w iring and the operation of the relays.

If the 3 imm ersion heaters are su pp lied correctly, check the cond ition of the imm ersion heaters (resistance

= 0.6 ± 0.1 ohm at 20°C).

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

CHART 4 FLASHING OF THE INJECTION FAULT WARNING LIGHT


diagn ostic equipmen t. The flashing of the warn ing light may be due to the u se of a

comp uter w ith an engine imm obiliser code program med on another vehicle (thecompu ters are not interchangeable).

NOTES

If no faults are declared by th e diagnostic equipm ent, the prob lem is certainly du e to a fault on the coded

line which perm its operation of the engine imm obiliser fun ction.

Ensure the continu ity and insu lation of the connection betw een track 59 of the compu ter connector and the

passenger compartment connection unit.

If the p roblem p ersists, refer to the fault find ing information in the engine immobiliser reference material

for the F9Q engine.

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

CHART 5 SPORADIC LACK OF POWER



Carry ou t the following checks on the wiring:- Possible deterioration of the engine wiring close to the EGR resulting in incorrect man agement of the

engine par ameter w ith no detection of a fault.

- Possible deterioration of the insulating material inside the spiral sleeve at the alternator resulting in

interference with the engine speed , load an d needle lift information.

Carry ou t the following checks at the injection pum p and th e fuel sup ply circuit:

- Remove the fuel shu t-off. If it is surround ed by splinters of any kind, change the injection p um p.

- Remove the diesel filter.

- Look for an abnormal presence of water or a smell of petrol.

Note: The presence of metal flakes at the bottom of the filter is normal and should not result in the

replacement of any parts.

If the custom er complaint is associated w ith a significant em ission of black smoke, check the conformity of

the air supply circuit:

- Securing and position of the pipes.

- Presence of a foreign body in the circuit.

DIESEL EQUIPMENT




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MSACD7801.0

AFTER

REPAIR

CHART 6 PERMANENT LACK OF POWER


diagnostic equipm ent

NOTES

Check the turbocharging pressure:

- Attach a pressure gauge and, during a road test, ensure that the turbocharging pressure is greater

than 0.9 bar.

Refer to the "Turbo" section of the Technical Note if the va lue is not corr ect.

Carry ou t the following checks at the injection p um p:

- Check the flush fitting of the pum p. This is obtained by a vertical line of yellow paint between the

up per and lower sections of the pu mp on the engine side. If there is an offset between the two

sections, change the injection pum p.

- Check the pu mp cover. If there is a trace of an impact, change the injection pum p.

Carry ou t the checks defined in CH ART 6 and check w hether th e air filter is clogged.

Check parameters PR017 "Load p otentiometer p osition" and PR007 "Air flow at in let".

- Check that the value of PR017 changes from 0% at No-load to 100% at Full-load.

- With the engine runn ing, check at idle (850 rpm) that the value of PR007 is between 20 and 50 kg/h.

- Check at full-load d uring a road test at more than 50 mph (80 km/ h) that the value of PR007 is between

360 and 400 Kg/h.

If the value of parameter PR007 "Air flow at inlet" is not correct, check the connections an d the w iring of

the air flow sensor and the conformity of the air circuit (+ presence of foreign bod ies). Change th e air

flow sensor if the value is still incorrect.

By m eans of PR020 "Fuel flow r eference value", check that the comp uter does in fact requ est the

maximum flow of 36 mg/stroke at full-load at an interm ediate engine speed.

DIESEL EQUIPMENT




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ANTIPOLLUTION

Exhaust gas recirculation (EGR) 14

PRESENTATION

12408R

DI1320

1 Inlet manifold

2 Exhau st manifold

3 Vacuum pump

4 EGR valve (t ightening torque of bolts:

2 daN.m)


6 Cylinder head

7 Diffuser

8 Flow meter

9 Turbo

10 Computer

11 Brake servo

12 EGR steel p ip e

13 Seal

14 Clip

14-1

8/14/2019 Xc0u - Xb0u


ANTIPOLLUTION


EGR solenoid valve bolt 1

Nut of steel pipes on inlet and exhaust

manifolds 2


REMOVAL OF THE EGR VALVE

On th e valve, d isconnect the vacuu m take-off pipe

(1).

Und erneath the solenoid valve, unclip and re-

move th e clip securing the steel pipe to th e EGR

solenoid valve.

Remove the two bolts securing the EGR valve (2),

then remove the valve.

16686R1

PURPOSE OF THE EGR SYSTEM

The exhaust gas recirculation EGR is used to re-

duce the nitrogen oxide (NOx) content of the ex-

haust gas.

PRINCIPLE OF OPERATION OF THE SOLENOID

VALVE

The EGR solenoid valve is controlled by an RCO si-

gnal emitted by the injection compu ter. The RCO

makes it possible to mod ulate the opening of the

solenoid valve and, consequently, the amoun t of

exhaust gas directed back toward s the inlet mani-

fold.

In line with th is signal, the solenoid valve applies

a quantified p art of the vacuu m pu mp vacuu m to

the diaph ragm (C). The diap hragm (C) moves and

pu lls the tie-rod (B) which au thorises passage of

the exhaust gas (by vacuum ) towards the inlet ma-

nifold.

MONITORING THE OPERATION OF THE SYSTEM

DURING A ROAD TEST

To ensure that th e EGR valve control system is

operating correctly, it is possible, by attaching a

pr essure gauge, to check the arrival of the p res-

sure information for the control of the opening of

th e EGR valve. Furth ermore, u sing after sales ser-

vice diagn ostic equip men t (except the XR25, it is

possible to read the param eter: PR 024 EGR so-

lenoid valve RCO.

3 In jection com puter

14-2

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ANTIPOLLUTION


94490R3

Procedure

Disconnect the pn eum atic pipe arriving at the EGR

valve (D) and connect a T-piece in its p lace.

Connect a p ressure gau ge to the pipe w hich re-mains free (0 ; - 1 000 mbars).

During the road test, it is then p ossible to monitor

the pr esence of a variable vacuum .

A To the inlet manifold

B Tie-rod

C Diaphragm

D Control vacuum for opening the EGR valve

E To the exhaust manifo ld

Disconnect th e EGR valve and the p ipe (D) connec-

ted to the EGR solenoid valve. Connect a vacuu m

in its place.

Create a vacuum of 300 mbars . The p ressureshould not fall by more than 2 mbars per second

(120 mbars per m inute).

Eliminate the vacuum to return the solenoid valve

to atmospheric pressure.

Following th is operation, clear the compu ter me-

mory.

CONDITION OF OPERATION

The computer continuously controls the EGR sole-

noid valve by means of an RCO type signal, except

in the cases described below:

- if the air temperature is greater than 55°C,

- in line with an engine speed / flow / a ir

temperature / coolant temperature / altitude

pattern.

- after having exited the starting phase for 10 se-

conds ,

- if the engine speed is roughly greater than

3250 rpm,

- of the battery voltage is below 10 volts ,

- during the deceleration phase,

- if the engine speed is below 650 rpm,

- in the event of failure:

• of the calibrated injector,

• of the air flow sensor,

• of the advance solenoid valve,

• of the EGR solenoid valve,

• of the EGR regulation.

Special notes

After each entr y into the id le phase, the EGR is

supp lied for 60 seconds and is then interrup ted.

CHECK OF THE SEALING AND OPERATION OF THE

EGR SOLENOID VALVE (VEHICLE STATIONARY)

After the fan assembly has cut in at least once,

stop the engine and sw itch off the ignition.

Disconnect the electrical connector.

Sup ply the solenoid valve d irectly with 12 volts .

14-3

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ANTIPOLLUTION

Oil vapours rebreathing 14

DI1321 DI1322

A Engine peripherals oil vapours rebreathing

pipe

B Top of engine oil vapours rebreathing pipe

C Oil separator (connected to the engine at its

base)

D Oil vapour rebreathing pipe connected to the

intake pipe

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STARTING - CHARGING

Alternator 16


Mot. 1273 Tool for checking belt tension

REMOVAL


Disconnect the battery and the alternator electri-

cal connections.

Remove:

- the sound d eadening cover and the air supply

pipe,

- the right front wheel and the mud shield,

- the timing cover lower bolt,

- the bumper lower bolts.

Special features of the Clio II

Remove:

- the radiator gr ille ,

- the radiator upper fasteners,

- the upper crossmember.

All types

Remove:

- the accessories belt,

- the alternator mounting bolts.

Special features of the Kangoo

Remove the mou nting bolts (1) and slacken the

mou nting bolts (2) of the alternator sup port.

Remove the alternator.

REFITTING


Refer to section 07 "Accessories be lt tensioning"

for the belt tension value.

16659R

PRF1601

Special features of the Clio II

Slacken th e two alternator m oun ting bolts (3) on

the front su rface by several turns.

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STARTING - CHARGING

Starter 16

REMOVAL



Remove:

- the battery tray disconnecting the connectors

(1) and (2) and the p ipes (4) and u nclipp ing the

d iesel filter and the prim ing un it,

- the turbo outle t a ir tube,- the mounting bolts securing the harness on the

gearbox,

- the starter mounting bolts and remove the star-

ter from un derneath.

REFITTING


Check that the starter locating pin is present.16603R2

16602R


Mot. 1368 Tool for tightening Torx bolts

- the immersion heater support on the gearbox

(Kangoo only),

- the turbo support strut (5) using tool

Mot. 1368,

- the turbo oil return pipe (6),

- the power steering pipe mounting bolt (7)

(Kangoo only),

- the starter connections,

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CLUTCH

Clutch plate - Disc 20

VEHICLE

TYPE

ENGINE

TYPECLUTCH PLATE DISC

XB0U

XC0UF9Q

215 CP OV 4000

26 splines VM : Moss green

D = 200 mm VR : Purple - RedE = 6.8 mm BP : Pigeon blue

85873S

90693-2R1894990R1

Monod isc clutch op erating d ry, cable controlled.

Clutch stop in constant contact.

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CLUTCH


REMOVAL

Fit im mobilising tool Mot. 582-01.

Remove the clutch plate mou nting bolts and re-

move th e clutch d isc.

Check and change any faulty parts.


Mot. 582 -01 Immobilising tool

TIGHTENING TORQUE (In daN.m)

Clutch plate mounting bolt 2

REPLACEMENT (following removal of the gearbox)

95414S

Gradually screw in th e bolts in a star forma tion,

then tighten th e clutch plate mou nting bolts to

the specified torqu e.

Remove imm obilising tool Mot. 582-01.

Coat with MOLYKOTE BR2 grease:

- the tu be gu id e,

- the fork pad s.

99055R1

REFITTING

Clean the clutch sha ft splines and refit the assem-bly without any lubricant.

Fit the disc (hub offset gearbox side).

Align.

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CLUTCH


After refitting the gearbox, place the cable on th e

clutch fork and check the op eration of the play

compensation system.

Check the clutch release travel.

The fork travel shou ld be:

X = 27.4 to 30.7 mm

97758-1R

NOTE: in the event of an op eration w hich d oes

not require rem oval of the gearbox, or after fit-

ting the gearbox, DO NOT LIFT the fork as it may

come free of the notch (A) of the stop.

99054R

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MANUAL GEARBOX

Identification

Clio vehicles fitted w ith the F9Q engine are equ ip-

ped w ith JB3 type gearbox.

Kangoo vehicles fitted with the F9Q engine ar e

equipped with JC5 type gearbox.

Workshop Repair Manual "B.V. JB. JC" deals with

the complete repair of this un it.

21

0 0 0J CX

X 0 0 0 0 0 0

B

C

A

D

14834-1R

IDENTIFICATION PLATE

A mark (1), located on the gearbox casing, indi-

cates:

At A Type of gearbox

At B Gearbox ind ex

At C Man ufactu rin g n um ber

At D Factory of manufacture

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MANUAL GEARBOX

Gears 21

IndexStep down

ratioVehicle 1st 2nd 3rd 4th 5th

JB3

Reverse

905XB0U

16

--

55

11

--

37

22

--

41

28

--

37

30

--

29

41

--

31

11

--

39

Index Step downratio

Vehicle 1st 2nd 3rd 4th 5th

JC5

Reverse

087XC0U

16

--

55

11

--

41

22

--

43

28

--

37

35

--

34

41

--

31

11

--

39

Speedometer

drive gear

21

--

19

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MANUAL GEARBOX

Gearbox (Removal - Refitting) 21


B. Vi. 31-01 Set of pu nches

Mot. 1040-01 Sub-frame dolly

T. Av. 476 Tool for extracting ball joints

Brake caliper bolt 4

Lower ball joint nut 5.5Shock absorber base bolt 18

Engine tie-bar bolt 6.5

Gearbox surround and starter bolt 4.5

Bolt securing the suspended engine

mounting to the gearbox 4

Wheel bolt 9

Steering ball joint nut 4


REMOVAL


Remove the battery.

Disconnect the connectors on:

- the in ject ion computer ,

- the p re-heating un it ,

- th e im p act sen sor.

Remove:

- the pipe between the manifold and the turbo,- the d iesel filter,

- th e com p uter su p port,

- the fastener securing the harness to the gear-

box.

16686S

ESSENTIAL EQUIPMENT

Engine support tool

Component jack

Remove the battery p rotection sh ield bolts (A).

13088R

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MANUAL GEARBOX


Remove the tw o mou nting bolts (B).

13119R

13097-2R

- th e fron t w heels,

- the oil recla imer under the gearbox.

Remove on th e left and right han d sides:

- the brake calipers and place them aside,

- the m ud shield s,

- the steer ing ba ll jo in ts (T. Av. 476),

- the shock absorber base bolts,- the sub-frame - side member tie-rods (A),

- the driveshaft - stub axle carrier assembly

detaching it from the lower ball joint.

99070R1

Disconnect the clutch cable.

Remove:

- the gearbox surround and star ter upper bolts

(unscrew bolt (D) as mu ch as p ossible),- the bolts securing the earth strap to the gear-

box,

- the two TDC sensor bolts

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MANUAL GEARBOX


Check that the left-hand dr iveshaft rollers cannot

be removed by han d . If they can, check that th e

pins h ave not fallen into the gearbox.

Remove the turbo/ block strut.

Disconnect and remove the starter.

Disconnect:

- the reversing light connector ,

- the speedometer connector and remove the

sensor from the final drive.

Remove:

- th e exh au st d ow np ip e,

- the complete gear control rod removing bolt

(E) and the th ree heat shield bolts to gainaccess to the base of the gear lever ,

- the engine t ie-bar bolt ,

- the rea r mounting on the gearbox.

12993-1R2

Remove the engine - gearbox tie-rod .

To make rem oval of the steering u nit easier, if ne-

cessary position a shim to tilt the engine forward s.

Remove the steering u nit and place it aside.

Position the engine sup por t and relieve the en-

gine and transmission assembly.

13120S

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MANUAL GEARBOX


Engine support position

14278S

Remove the sub-frame by slackening th e four

mou nting bolts.

Position the compon ent jack und er the gearbox

without lifting it.

Uncoup le the gearbox from the engine having

first removed the nu t (E) and the engine - gearbox

mounting stud .

98755R1

85812-1R

12924R

Lower the engine as mu ch as possible.

Remove:

- the last gearbox surround upper bolt ,

- the bumper.

Position the sub-frame sup port d olly (Mot. 1040-

01) and low er the vehicle.

Remove the three moun ting bolts secur ing the

moun ting to the gearbox.

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MANUAL GEARBOX


REFITTING

Coat the walls of the tube guide and the fork pads

with MOLYKOTE BR2 grease.

Place the fork on th e notches of the clutch stop .

Coup le the gearbox to the engine without alte-

ring the height level of the engine.

Ensure that th e engine - gearbox centring bu shes

are present and positioned correctly.

The presence of stud (C) makes coup ling easier.

86308R2

Refit:

- the su b-fram e,

- the steering,- th e exh au st d ow np ip e,

- th e en gin e tie-bar.

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AIR CONDITIONING

Connecting pipes 62

LOW PRESSURE PIPE

REMOVAL

Remove the moun ting bolt on the pressure relief

valve.

Fit plugs on the p ressure relief valve and the pip e.

Remove the mou nting bolt on the comp ressor.

Fit plugs on the comp ressor and the pipe.

Unscrew the pipe retaining plate.

Remove the low pressure pipe.

REFITTING


Check the condition of the seals and lubricate

them with P.A.G. SP 10 oil.

When a p ipe is replaced, add 10 ml of SP 10 oil or

if a pipe bursts (rapid leak), add 100 ml .

NOTE:

- Bolts retaining the pipes

on th e compressor: 2.1 daN.m

- Nuts retaining the pipes

on th e pressu re relief valve: 0.8 daN.m

- Bolts retaining the pipes

on the cond enser: 0.8 daN.m


Drain the R134a refrigerant circuit using filling

equipmen t (refer to the procedure described in

th e "Air conditioning" manual).

PRO62.4

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AIR CONDITIONING

Connecting pipes 62

COMPRESSOR - CONDENSER HIGH PRESSURE PIPE

REMOVAL

Remove the mou nting bolt on the comp ressor.

Fit plugs on the comp ressor and the pipe.

Remove the m ounting bolt on the condenser.

Remove the p ipe

Fit plugs on the cond enser and th e pipe.

16679S

REFITTING


NOTE: wh en refitting this connecting pipe on the

compressor it is essential to position all the bolts

and then bring th em into contact before tighte-

ning them to the specified torqu e. The purp ose of

this is to ensure that the p ipe is positioned correct-

ly to preven t da mage to it at the "da mp er" (1).


them with P.A.G. SP 10 oil.



A Condenser outlet

B Compressor outlet





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AIR CONDITIONING

Connecting pipes 62

REFITTING



them with P.A.G.



NOTE:

- Bolt retaining the pipe

on th e d ehydration canister: 0.8 daN.m

- Nuts retaining the pipes

on th e pressu re relief valve: 0.8 daN.m

DEHYDRATION CANISTER - PRESSURE RELIEF

VALVE HIGH PRESSURE PIPE

REMOVAL

Detach the p ipes from its fasteners.

Disconnect the pressur e sensor connector.

Remove the moun ting bolt on the pressure relief

valve.

Fit plugs on the p ressure relief valve and the pip e.

Remove the m ounting bolt on the d ehydration ca-

nister.

Fit plugs on the dehyd ration canister and the

pipe.

Remove the pipe.





PRO62.6

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AIR CONDITIONING

Wiring diagram 62

104 Ignition sw itch

120 In jection com p uter

171 Air cond ition ing clu tch

206 Air cont ro l pressure switch

209 Lights stalk

225 Diagn ostic socket

247 Instru ment p anel

319 Air condit ioning cont ro l panel

320 Base fan assembly/ Air condit ioning

419 Air con dition in g u nit

597 Engine com par tm en t fu se box

645 Engine compartment connect ion unit

777 Pow er su p ply fu se board

R67 Fron t of en gin e/ En gin e

R107 Dashboard/ Front of engine

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AIR CONDITIONING

Wiring diagram 62

16685G

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AIR CONDITIONING

Wiring diagram 62

xc0u - xb0u

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