MR 342 Trafic 1
MR 342 Trafic 1
DIESEL EQUIPMENT
ANTI-POLLUTION
STARTING - CHARGING
XL0B - XL0C
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 2001
Engine and
peripherals
Contents
Page Page
16 STARTING - CHARGING
Alternator 16-1
Starter 16-6
Engine and
peripherals
Contents
Page
Engine mounting
Suspended engine mounting 19-6
ENGINE AND110
PERIPHERALS
Identification 10
Capacity Compression
Vehicle type Engine Gearbox Bore (mm) Stroke (mm)
(cm3 ) ratio
XLOB PK5
F9Q 760 1870 80 93 19:1
XLOC PK6
Workshop Repair Manual for reference: Mot. F9Q (high pressure common rail).
10-1
ENGINE AND PERIPHERALS
Oil consumption 10
OIL CONSUMPTION MEASUREMENT PROCEDURE
The operation must be carried out with the engine hot (the cooling fan having cut in) and after leaving to
stabilise for 15 minutes to allow all the oil to drain into the sump.
Seal the drain plug (with a paint mark on both the filler plug and the sump drain plug) in order to be able to
check later that it has not been removed.
b) Customer driving
Ask the customer to drive the vehicle for a period corresponding to about 1250 miles (2,000 km) or before the
minimum level is reached.
The operation must be carried out with the engine hot (the cooling fan having cut in) and after leaving to
stabilise for 15 minutes .
Note the quantity of oil and the mileage covered since the last top-up to maximum level.
10-2
ENGINE AND PERIPHERALS
Oil pressure 10
SPECIAL TOOLING REQUIRED
Mot. 836-05 Boxed kit for measuring oil
pressure
EQUIPMENT REQUIRED
22 mm long socket
CHECKING
USE
B+F
Oil pressure
1000 rpm 1.2 bar
3000 rpm 3.5 bars
10-3
ENGINE AND PERIPHERALS
Engine - Gearbox 10
SPECIAL TOOLING REQUIRED
Mot.1202-01
Pliers for large hose clips
Mot.1202-02
Mot. 1448 Remote operation clip pliers for
cooling system hose clips
T. Av. 476 Ball joint extractor
Wheel bolts 14
NOTE: because the battery is located under the left-
REMOVAL hand seat, the carpet must be unclipped and removed,
then the battery cover (A) can be removed by undoing
Put the vehicle on four axle stands (see Section 02 the screws.
Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift. Remove:
– battery cables,
During this operation (if using a lift) it is necessary – the front wheels,
to lash the vehicle to the lift with a strap to prevent – the engine undertray,
the vehicle from toppling over. – battery earth strap under the body and move all
cables away from the battery,
Refer to Section 02 Underbody lift for the strap
positioning.
10-4
ENGINE AND PERIPHERALS
Engine - Gearbox 10
– lower gearbox soundproofing material at (1). – both transmission flange mounting bolts on the relay
holder bracket,
– track rod end, using tool T. Av. 476,
– shock absorber base mounting bolts.
Remove:
– brake calliper and attach it to the suspension spring,
– ABS sensor,
– lower ball joint nut (use an Allen key cut down to
X = 22 mm to lock the ball joint if necessary),
Remove:
– brake calliper and attach it to the suspension spring,
– ABS sensor,
– lower ball joint nut (use an Allen key cut down to
X = 22 mm to lock the ball joint if necessary),
10-5
ENGINE AND PERIPHERALS
Engine - Gearbox 10
– headlight unit mounting screws (2). – bumper.
10-6
ENGINE AND PERIPHERALS
Engine - Gearbox 10
– separate the power steering reservoir from its – mountings of the air conditioning hoses (if fitted) on
bracket, the compressor and the condenser.
– air ducts on the heat exchanger and the
mounting (4), NOTE: plugs must be fitted to the hoses and pressure
relief valve to prevent moisture from entering the
system.
Remove:
– cooling assembly,
– air filter unit air intake tube,
– preheater unit mounting (1),
– turbo regulation solenoid valve at (2),
– turbocharging pressure sensor (3) from its mounting,
– impact sensor connector (6),
– the expansion bottle and remove it,
– computer protection plate (A).
10-7
ENGINE AND PERIPHERALS
Engine - Gearbox 10
Disconnect the connectors (5) and unclip the fuse
holder (6).
– mounting (9),
– clutch slave cylinder pipe by removing clip (B) and
move it out of the way,
Remove the earth strap mountings on the gearbox and
on the left-hand side member then move the whole
connection unit out of the way.
Disconnect:
– heater hoses at the bulkhead,
– brake servo vacuum pipe,
– fuel supply pipe (7) (fit anti-contamination plugs)
and connector (8),
10-8
ENGINE AND PERIPHERALS
Engine - Gearbox 10
– gearbox control cables, – mounting bolts (3) and undo bolt (4),
– heater casing (C) by disconnecting the connector (1),
10-9
ENGINE AND PERIPHERALS
Engine - Gearbox 10
Remove: – tie-rod (2) mounting bolts, then remove the
– power steering pipe mounting (7) and move it out of suspended mounting movement-limiter assembly.
the way,
– lower cross member (A) and front cross member (B),
REFITTING
Refit:
– left suspended mounting,
– right suspended mounting,
– the engine tie-bar.
10-10
ENGINE AND PERIPHERALS
Engine - Gearbox 10
Points to note regarding the clutch slave cylinder Refit the engine-gearbox assembly following the same
when separating the engine and gearbox method as for removal.
10-11
111 TOP AND FRONT OF ENGINE
Timing belt tension wheel 11
SPECIAL TOOLING REQUIRED
Mot. 1054 TDC setting pin
Mot. 1453 Engine support tool
Mot. 1505 Tool for checking belt tension
Mot. 1543 Tool for pre-tensioning the belt
EQUIPMENT REQUIRED
Angular torque wrench
14 Torx socket
REFITTING
TIGHTENING TORQUE (In daNm and/or°)
Refit:
Tension wheel nut 5
– tension wheel plate by tightening the bolts to a torque
Tension wheel plate bolt 1 of 1 daNm,
– timing belt (see Section 11 Timing belt).
Crankshaft pulley bolt 2+115°±15°
Suspended engine mounting
upper linkage mounting bolt 10.5
Wheel bolt 14
REMOVAL
Remove:
– timing belt (see Section 11 Timing belt).
– both tension wheel plate bolts.
11-1
TOP AND FRONT OF ENGINE
Timing belt 11
SPECIAL TOOLING REQUIRED
Mot. 1054 TDC setting pin
Mot. 1505 Tool for checking belt tension
Mot. 1543 Tool for pre-tensioning the belt
Mot. 1367-02 Engine support tool
EQUIPMENT REQUIRED
Angular torque wrench
14 Torx socket
Wheel bolt 14
REMOVAL
11-2
TOP AND FRONT OF ENGINE
Timing belt 11
Fit the engine support tool Mot. 1367-02 between the Unclip the wiring from the engine mounting and move
lower cross member and the engine sub-frame. it out of the way.
Remove:
– accessories belt (see Section 07 Accessories belt
tension),
– tie-rod (1) mounting bolts, then remove the
suspended mounting movement-limiter assembly,
Bring the top part of the tool (A) into contact with the
sump.
11-3
TOP AND FRONT OF ENGINE
Timing belt 11
Timing adjustment
11-4
TOP AND FRONT OF ENGINE
Timing belt 11
Remove:
– accessories belt tensioner (3),
– crankshaft accessories pulley by blocking the flywheel,
– timing cover from underneath the car (lower the engine using the engine
support tool Mot. 1453).
NOTE: using a pencil to mark the inner timing cover opposite the mark on
the camshaft pulley.
11-5
TOP AND FRONT OF ENGINE
Timing belt 11
Loosen the tensioner by loosening the nut (5), then remove the timing belt.
11-6
TOP AND FRONT OF ENGINE
Timing belt 11
REFITTING The crankshaft groove (4) should be located at the
centre of the two ribs (2) on the crankshaft closure
TENSIONING PROCEDURE cover, mark (3) on the crankshaft timing sprocket
should be offset one tooth to the left of the vertical axis
Engine cold (ambient temperature). of the engine.
11-7
TOP AND FRONT OF ENGINE
Timing belt 11
Fit the new timing belt by aligning the belt markings with those of the
camshaft and crankshaft sprockets.
Place the tensioner against the belt by tightening bolt (2) on the tensioner
support.
11-8
TOP AND FRONT OF ENGINE
Timing belt 11
Remove pin Mot. 1054.
Fit the crankshaft accessories pulley together with washer R1 (4) which is
included in the kit with tool Mot. 1543.
NOTE: Do not forget to remove it again when fitting the crankshaft pulley.
11-9
TOP AND FRONT OF ENGINE
Timing belt 11
Fit Mot. 1543 and the cover
numbered 1 on the crankshaft
accessories pulley bolt.
11-10
TOP AND FRONT OF ENGINE
Timing belt 11
Connect the sensor of Mot. 1505.
Tension the belt by turning bolt (2) until the recommended fitting value
88 ± 3 Hz is obtained.
Tighten the tensioner to a torque of 1 daNm.
11-11
TOP AND FRONT OF ENGINE
Timing belt 11
Refit the pin Mot. 1054 and set the timing to its setting
point, (begin to press on the pin half a tooth before
alignment of the mark on the camshaft pulley and
that made by the operator on the inner timing
housing, to prevent it falling into a crankshaft
balance hole).
11-12
TOP AND FRONT OF ENGINE
Cylinder head gasket 11
SPECIAL TOOLING REQUIRED
Mot. 1054 TDC setting pin
Mot. 1202-01
Pliers for large hose clips
Mot. 1202-02
Mot. 1448 Remote operation clip pliers for
cooling system hose clips
Mot. 1505 Belt tension setting tool Hz
measurement
Mot. 1543 Tool for pre-tensioning the belt
EQUIPMENT REQUIRED
14 Torx socket
High pressure pipe wrench
(e.g. Facom DM19 wrench)
Angular torque wrench
Cylinder head testing tool
Wheel bolt 14
REMOVAL
11-13
TOP AND FRONT OF ENGINE
Cylinder head gasket 11
Remove: – turbocharger pipe (C),
– timing belt (see Section 11 Timing belt). – connector (3) as well as the injector and pre-heater
– heater casing (B) by disconnecting the connector (1), plug connectors,
– thermoplunger unit mounting (4),
– fuel return pipe at (5) (fit anti-contamination
plugs),
11-14
TOP AND FRONT OF ENGINE
Cylinder head gasket 11
– fuel pipe (1) (fit anti-contamination plugs) and – air pipe (A) as well as the turbocharger air outlet pipe,
connector (2), then move it out of the way,
– stays (5) and (6), then the catalytic converter (7),
11-15
TOP AND FRONT OF ENGINE
Cylinder head gasket 11
CLEANING REFITTING
Apply the product to the part to be cleaned, wait Centre the cylinder head on the dowels.
approximately 10 minutes, then remove it using a
wooden spatula. Lubricate the threads and under the heads of the
mounting bolts.
Please use great care during this operation, to Tighten the cylinder head using an angular torque
prevent any foreign bodies from being introduced wrench (see Section 07 Tightening the cylinder
into the oil galleries (ducts located in the cylinder head).
block and in the cylinder head).
Refitting is the reverse of removal.
CHECKING THE GASKET FACE Refit the timing belt (see procedure described in
Section 11 Timing belt).
Check for mating surface bow using a ruler and a set
of shims. Fill and bleed the cooling system, (see Section 19
Filling and Bleeding).
Maximum deformation: 0.05 mm.
11-16
112
FUEL MIXTURE
F9Q engine
Air intake 12
AIR INTAKE CIRCUIT DIAGRAM
20350
12-1
FUEL MIXTURE
F9Q engine
Air filter 12
FILTER ELEMENT REPLACEMENT
20301
12-2
FUEL MIXTURE
F9Q engine
Manifolds 12
Disconnect:
TIGHTENING TORQUE (in daNm) – airflow sensor connector (3),
– turbocharger air intake pipe (4).
Manifold mounting stud 0.8
Manifold mounting nut 2.8 Remove:
– air filter unit mounting nuts (5), then remove it,
EGR valve mounting bolt 0.8
REMOVAL
Remove the heater unit mounting bolt and three – turbocharger (see Section 12 Turbocharging:
nuts (2), then remove the unit. turbocharger).
20340
12-3
FUEL MIXTURE
F9Q engine
Manifolds 12
Disconnect:
– manifold pressure signal pipe (6),
– manifold air intake pipe (7),
– EGR solenoid valve (Exhaust Gas Recirculation) (8).
20549
12-4
FUEL MIXTURE
F9Q engine
Manifolds 12
Remove the EGR (Exhaust Gas Recirculation) pipe and the lifting bracket.
16157.S
12-5
FUEL MIXTURE
F9Q engine
Manifolds 12
Remove:
– nuts securing the manifolds,
– the manifolds.
DI1217
REFITTING
Change the manifold gasket and be careful to refit it correctly, and change the EGR valve gasket.
12-6
FUEL MIXTURE
F9Q engine
Air flowmeter 12
REMOVAL – both airflow sensor mounting screws (6) on the air
filter unit,
Disconnect: – the airflow sensor.
– the battery,
– heater unit connector (1).
20340
20554
Disconnect:
– airflow sensor connector (3), REFITTING
– turbocharger air intake pipe (4).
Proceed with refitting in the reverse order to removal
Remove:
– air filter unit mounting screws (5), then remove it,
20341
12-7
FUEL MIXTURE
F9Q engine
Air flowmeter 12
ALLOCATION OF TRACKS
Track Description
1 Air temperature
2 Earth
3 Reference 5V
4 +battery
5 Airflow signal
6 Earth
20555
12-8
TURBOCHARGING
F9Q engine
Pressure regulating valve 12
The LDA (A) of the pressure regulation valve is The solenoid valve, closed in the rest position, is
controlled by a solenoid valve (B) which is controlled energized after the engine is started following a delay
by the injection computer. This solenoid valve varies dependent on the coolant temperature.
the vacuum according to the engine operating range,
which enables the turbocharging pressure to be
regulated.
20570
12-9
TURBOCHARGING
F9Q engine
Turbocharger pressure adjustment 12
TURBOCHARGING PRESSURE CONTROL VALVE Calibration value
(WASTEGATE)
NOTE: the control valve operates in the opposite way Vacuum value
Rod movement (mm)
from the usual systems. (mbar)
Check that there are no leaks between the vacuum > 450 Rod at stop
pump and the control valve.
Operation on the vehicle. It may be necessary to adjust the wastegate rod length
(A) (if the pressure is not within tolerance) when
checking the calibration pressure.
20550
12-10
TURBOCHARGING
F9Q engine
Turbocharger 12
TIGHTENING TORQUE (in daNm)
REMOVAL
20341
Disconnect:
– airflow sensor connector (3),
– turbocharger air intake pipe (4).
Remove:
– air filter unit mounting screws (5), then remove it,
20312
12-11
TURBOCHARGING
F9Q engine
Turbocharger 12
Remove: Remove:
– catalytic converter mounting stays (1) and (2), – turbocharger oil supply pipe (5),
– nuts (3) securing the catalytic converter to the – turbocharger oil return pipe (6),
turbocharger, – three turbocharger mounting nuts (7),
– catalytic converter. – the turbocharger.
Disconnect:
– wastegate diaphragm control pipe (4),
– turbocharger air intake and outlet pipes.
20551
20552
12-12
TURBOCHARGING
F9Q engine
Turbocharger 12
REFITTING
Special precautions
For refitting operations, use the reverse procedure to
removal. ! Before refitting, make sure that the lubrication of
the turbocharger bearings is correct. To do this,
WARNING: it is imperative that the copper seal in the activate the starter motor having first
turbo oil supply union as well as the oil return pipe seal disconnected the high pressure regulator
be changed. connector (to inhibit the engine from starting)
(erase the computer memory). Sufficient oil
IMPORTANT: should arrive via the oil pressure pipes (place a
Before starting the engine, leave the pressure regulator container underneath). If this is not the case,
connector on the high pressure pump disconnected. change the lubrication pipe.
Then activate the starter motor until the oil pressure ! Ensure that no foreign bodies enter the turbine or
warning light extinguishes (persist for a few seconds). compressor during the refitting operation.
Reconnect the regulator, preheat and start the engine. ! If there has been a fault in the turbocharger, check
Run the engine at idle speed and check that there are that the air/air heat exchanger is not full of oil. If
no leaks at the oil connections. the air/air heat exchanger is full of oil, it must be
Erase the fault and check the turbocharging pressure removed, flushed with a cleaning agent and then
solenoid valve sensor. left to drain properly.
! Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
12-13
TURBOCHARGING
F9Q engine
Air/air heat exchanger 12
REMOVAL
Disconnect:
– heat exchanger air intake pipe (2),
– heat exchanger air outlet pipe (3),
20342
REFITTING
20342-1
Remove:
– heat exchanger mounting bolts (4),
– air/air heat exchanger.
12-14
113
DIESEL EQUIPMENT
F9Q engine Specifications 13
Engine
Vehicle
Gearbox Cubic Emission
type Bore Stroke Compression
Type Suffix capacity control
(mm) (mm) ratio
(cm 3 ) standard
Homologation
IDLE SPEED Max. - no load Max. - under load Max. - Max
value
800 ± 50 rpm 4160 ± 150 rpm 3700 ± 100 rpm 1.7 m -1 (50 %) 3 m-1 (70 %)
High pressure pump BOSCH CR / CP3 Pressure from 250 to 1350 bars
13-1
DIESEL EQUIPMENT
F9Q engine Specifications 13
Description Make/Type Special notes
Air flowmeter SIEMENS Flow sensor with integrated air temperature sensor
Track 1: air temperature
Track 2: earth
Track 3: 5V reference
Track 4: + battery
Track 5: airflow signal
Track 6: earth
13-2
DIESEL EQUIPMENT
F9Q engine Specifications 13
Description Make/Type Special notes
13-3
DIESEL EQUIPMENT
F9Q engine Special features 13
The Common Rail high pressure injection system is designed to deliver a certain quantity of diesel fuel to the
engine at a precisely determined moment.
DESCRIPTION
Dismantling the interior of the high pressure pump and the injectors is prohibited.
20560
13-4
DIESEL EQUIPMENT
F9Q engine
Special features 13
OPERATION
The Common Rail high pressure direct injection system is a sequential diesel injection system (based on the
multipoint injection system for petrol engines).
This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and
produces high engine torque at low engine speeds thanks to a pre-injection procedure.
The low pressure pump (also known as the booster pump) feeds the High Pressure pump via the fuel filter during
the starting phase only.
The high pressure pump generates the high pressure sent to the injector rail. The high pressure regulator located on
the pump modulates the value of the high pressure via the computer. The rail supplies each injector through a steel
pipe.
The computer:
– determines the value of injection pressure necessary for the engine to operate well and then controls the pressure
regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor
located on the rail,
– determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should
be started,
– controls each injector electrically and individually after determining these two values.
FOR ANY WORK CARRIED OUT ON THE HIGH PRESSURE INJECTION SYSTEM THE CLEANLINESS AND
SAFETY ADVICE SPECIFIED IN THIS DOCUMENT MUST BE FOLLOWED.
13-5
DIESEL EQUIPMENT
F9Q engine
Special features 13
POST-REPAIR CHECK
Re-prime the circuit. To do that, turn the low pressure pump over by switching on the ignition several times, or turn
the low pressure pump over with the diagnostic tool using the Actuator Commands menu.
After any operation, check that there are no diesel fuel leaks. Run the engine at idle speed until the fan
starts up, then accelerate several times with no load.
IMPORTANT: the engine must not be run with diesel fuel containing more than 10 % diester.
The system injects the diesel fuel into the engine at a pressure of up to 1350 bar. Before carrying out any work,
check that the injector rail is depressurised.
When the high pressure pump, injectors and high pressure supply, output and return unions are removed or
repaired, all orifices should be fitted with new blanking plugs of the correct size to prevent contamination
entering.
When replacing the High Pressure pipe, follow the method below:
– remove the High Pressure pipe,
– fit anti-contamination plugs,
– loosen the High Pressure rail.
– fit the High Pressure pipe.
– torque-tighten the union at the injector end,
– torque-tighten the union at the High Pressure rail end,
– torque-tighten the High Pressure rail mountings,
– torque-tighten the pump/rail pipe (pump end first).
13-6
DIESEL EQUIPMENT
F9Q engine Special features 13
It is vital to replace the fuel return pipe fitted to the injectors when it is removed.
The diesel temperature sensor cannot be removed. It is part of the fuel return rail.
It is forbidden to loosen a High Pressure pipe connection when the engine is running.
It is forbidden to remove the pressure regulator from the pump (type CP3).
13-7
DIESEL EQUIPMENT
F9Q engine Cleanliness 13
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE
DIRECT INJECTION SYSTEM
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
– damage to or destruction of the high pressure injection system,
– seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
IMPORTANT: it is not possible to clean the engine using a high pressure washer because of the risk of damaging
connections. Also the moisture may collect in the connectors and cause electrical connection problems.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
! Ensure that you have the plugs for the unions to be opened (bag of plugs sold by the Parts Stores). Plugs are to
be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not sufficient
to make them reusable). Unused plugs must be thrown away.
! Ensure that you have the resealable plastic bags for storing removed parts. There is less risk of parts stored in this
way being exposed to contamination. The bags must be used only once, and after use they must be thrown away.
! Make sure that lint-free towelette is to hand. Towelette part number: 77 11 211 707. The use of conventional cloth
or paper wipes is prohibited. These are not lint-free and may contaminate the fuel circuit of the system. Each lint-
free cloth should only be used once.
13-8
DIESEL EQUIPMENT
F9Q engine Cleanliness 13
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
! For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
! For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
! Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles remain adhered.
! When wearing leather protective gloves, cover these with latex gloves.
! As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Stores. They must not, under any circumstances, be reused.
! Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries
contamination.
! All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once
the plugs have been inserted.
! The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
In fact, these elements are liable to cause the entry of impurities into the system.
! A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
13-9
DIESEL EQUIPMENT
F9Q engine Cleanliness 13
13-10
DIESEL EQUIPMENT
F9Q engine Location of components 13
20299
13-11
DIESEL EQUIPMENT
F9Q engine Location of components 13
18297R
13-12
DIESEL EQUIPMENT
F9Q engine Location of components 13
16181R 20549
20552 20303
13-13
DIESEL EQUIPMENT
F9Q engine Location of components 13
20302 20304-1
20305 20300
13-14
DIESEL EQUIPMENT
F9Q engine Injection warning light 13
Vehicles using the high pressure diesel fuel system are fitted with two injection warning lights. These warning lights
are used during the preheating phase and when there is an injection fault.
! The preheating warning light comes on when the ignition is switched on, remains lit during the preheating phase
and then goes out (see section 13 Pre/post-heating control).
! When there is an injection fault (level of severity 1), the fault warning light which is also the preheating warning light
comes on permanently, indicating the need to consult a Renault Dealer. These faults are:
– internal computer fault,
– engine immobiliser fault,
– engine speed fault (vehicle does not start),
– accelerator potentiometer fault,
– airflow sensor fault,
– vehicle speed sensor fault,
– exhaust gas recirculation valve fault,
– turbo regulation solenoid valve fault,
– turbocharging pressure sensor fault,
– Top Dead Centre sensor and camshaft sensor synchronisation fault.
! When there is a serious injection fault (level 2), the warning light with the symbol of an engine and the word STOP
flashes to indicate that the vehicle must be stopped immediately. These faults are:
– internal computer fault,
– injector fault,
– computer feed voltage fault,
– rail pressure sensor fault,
– rail pressure regulator fault,
– Top Dead Centre sensor and camshaft sensor synchronisation fault.
! If the engine overheats, the warning light with the engine symbol and the word STOP remains lit.
13-15
DIESEL EQUIPMENT
F9Q engine Immobiliser function 13
This vehicle is fitted with an engine immobiliser system which is controlled by a key recognition system.
Injection computers are supplied without a code, but they can all be programmed with one.
If a computer is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine
immobiliser function must be checked.
To do this, switch on the ignition for a few seconds without starting the engine, then switch it off. With the ignition off,
the engine immobiliser function comes into operation after approximately 10 seconds (the red engine immobiliser
warning light flashes).
WARNING:
These vehicles have a special injection computer which does not function unless it is coded.
Consequently, it is strongly recommended not to carry out tests using computers borrowed from the stores or from
another vehicle, to prevent coding and uncoding problems which could render the computers useless.
13-16
DIESEL EQUIPMENT
F9Q engine Injection/air conditioning programming 13
THIS VEHICLE IS FITTED WITH A VARIABLE OUTPUT COMPRESSOR
There is no air conditioning computer on this type of engine. The injection computer controls the compressor clutch
according to the request for the compressor to operate (AC function requested by the driver), which can be
interrupted at any moment by the refrigerant fluid pressure sensor.
When the air conditioning function is selected, the idle speed does not change; it is 800 rpm.
During certain stages of operation, the injection computer stops the compressor from functioning.
The compressor is prevented from operating for 2 seconds after the engine has started.
If the potentiometer position is greater than 45%, and the vehicle speed is below 25 kph, the compressor is cut off.
Anti-stall protection
If the foot is lifted from the accelerator pedal and the engine speed is below 675 rpm, the compressor clutch is
disengaged. It is re-engaged when the engine speed exceeds this figure.
The compressor does not come into operation when the coolant temperature is greater than + 102 °C.
13-17
DIESEL EQUIPMENT
F9Q engine Idle speed adjustment 13
IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
The purpose of this adjustment is to compensate for the drop in voltage due to switching on a power consumer when
the battery is not well charged. To achieve this, the idle speed is increased, which increases the speed of rotation of
the alternator, and this increases the battery voltage.
The lower the voltage, the more significant the correction. Correction of the engine speed is therefore variable. It
begins when the voltage drops to below approximately 12 volts. Idle speed may reach a maximum of 900 rpm.
Idle speed is held at 1250 rpm. if the accelerator pedal potentiometer is faulty.
If the information from the accelerator pedal position potentiometer and the brake switch information does not
correspond, the speed is changed to 1250 rpm.
The travelling idle speed is modified according to the gear engaged in the gearbox:
– in 1st and 2nd gear, the idle speed is 825 rpm.,
– for other gears the speed is 870 rpm.
If the vehicle is stationary with a gear engaged (clutch pedal depressed), then the maximum engine speed is limited
to 3000 rpm.
13-18
DIESEL EQUIPMENT
F9Q engine Pre/postheating control 13
The pre/postheating function is controlled by the 2) Starting the engine
preheating unit.
The plugs remain supplied while the starter is
PRE/POSTHEATING OPERATING PRINCIPLE being activated.
1) Ignition on - Preheating
3) Post-heating with the engine running
a) Variable preheating
During this phase the plugs are supplied
The time period for warning light illumination and continuously according to coolant temperature.
the feed to heater plugs depends on the coolant
temperature and the battery voltage.
For idle speed without pressing the accelerator pedal.
20569
20568
X Time in seconds
Y Coolant temperature in °C X Time in seconds
Y Coolant temperature in °C
In all cases the preheating warning light
illumination time cannot exceed 10 seconds.
b) Fixed preheating
13-19
DIESEL EQUIPMENT
F9Q engine Pre-heater plugs 13
The pre-heater plug resistance is 0.6 ohm (connector
disconnected).
REMOVAL
15762S
REFITTING
13-20
DIESEL EQUIPMENT
F9Q engine Thermoplunger 13
The four thermoplungers are located on a water unit Control strategy
mounted on the engine lifting bracket.
When the thermoplungers are operating the idle speed
The objective of the system is to reheat the coolant. is brought to 825 rpm.
The thermoplungers are supplied with 12 volts by Thermoplungers cannot operate in the case of:
three relays. One relay controls two thermoplungers, – preheating,
the two other relays control one thermoplunger each. – post-heating,
This enables control of one, two, three or four – if the engine speed is below 700 rpm,
thermoplungers as required. – heated windscreen on.
The resistance of the thermoplungers is: If the conditions mentioned above apply, the
0.45 ± 0.05 ohms at 20 °C. thermoplungers are controlled according to a mapping
related to the air and coolant temperature.
20567
X Coolant temperature in °C
Y Air temperature in °C
13-21
DIESEL EQUIPMENT
F9Q engine Thermoplunger 13
If the battery voltage is > 13.5 volts
If not then
If not then
If not then
If not then
13-22
DIESEL EQUIPMENT
F9Q engine Low pressure pump (booster pump) 13
SPECIAL TOOLING REQUIRED
IMPORTANT: Disconnect:
During all operations on the fuel tank or fuel supply – anti-blowback pipe (1),
circuit, it is vital to: – fuel tank filler neck (2).
– refrain from smoking or bringing incandescent
objects close to the work area,
– protect yourself against diesel fuel splashes when
the pipes are removed (due to residual pressure).
REMOVAL
20310-1
20310
13-23
DIESEL EQUIPMENT
F9Q engine Low pressure pump (booster pump) 13
Remove the fuel tank mounting bolts (3).
20315
20308
13-24
DIESEL EQUIPMENT
F9Q engine Low pressure pump (booster pump) 13
REFITTING
20315
13-25
DIESEL EQUIPMENT
F9Q engine Fuel filter 13
The fuel filter is located in the engine compartment. It Unscrew the filter cover (4) and remove the filter
is contained in a removable cartridge. This cartridge cartridge.
contains a diesel fuel heater.
REMOVAL
20302
13-26
DIESEL EQUIPMENT
F9Q engine Checking diesel pressure and flow 13
It is possible to check the pressure and flow in the low pressure fuel circuit.
The low pressure is provided by the booster pump (electric pump fitted in the fuel tank which feeds the high pressure
pump during starting phases).
Mot. 1311-01
or Fuel pressure test kit
Mot. 1328
Mot. 1311-03 I adapter for fuel pressure test
kit
EQUIPMENT REQUIRED
Fit an I adapter, Mot. 1311-03, to be able to connect Make the pump flow into a 2000 ml graduated
the fuel pressure test kit Mot. 1311-01 to the outlet (2) cylinder. Turn on the ignition to run the pump. The
of the fuel filter. pump is supplied for 10 seconds if the engine is not
started.
Turn over the fuel pump with the diagnostic tool or by
direct feed to the pump or by switching on the ignition. The flow read should be at least 80 to 100 litres/hour.
Read the pressure, which should be 2.5 bars WARNING: it is forbidden to measure the pressure
maximum. and flow of the high pressure pump.
20302
13-27
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
DISMANTLING THE PUMP INTERNALS IS
PROHIBITED
EQUIPMENT REQUIRED
13-28
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
– radiator grille mounting screws (6),
FOLLOW THE CLEANNESS INSTRUCTIONS
– radiator grille.
CLOSELY
REMOVAL
Disconnect:
– the battery,
– heater unit connector (1).
Remove:
– heater unit bolt and three nuts (2),
– heater unit.
20289
Remove:
– both headlight unit mounting screws (7),
– headlight units.
20340
Disconnect:
– airflow sensor connector (3),
– turbocharger air intake pipe (4).
Remove:
– air filter unit mounting bolts (5),
– air filter unit,
20253
20341
13-29
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
Remove: – bolt through the bumper (11),
– bonnet catch (8), – front upper cross member central mounting
– upper bumper mounting bolts (9), bolts (12), then the reinforcing strut,
– air/air heat exchanger air inlet and outlet pipes, – cooling radiator mounting bolts (13),
– computer shield mounting bolt (14),
– front upper cross member mounting bolts (15),
– upper cross member by pivoting it round the bumper.
20293
20342-1
13-30
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
Disconnect: – High Pressure pipes using tool Mot. 1383, then fit
– pressure regulator (1), plugs,
– pressure sensor (2),
– fuel temperature sensor (3).
20349
20348
20346
13-31
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
Set the engine to Top Dead Centre using pin Place the pulley retaining tool Mot. 1200-02 in position
Mot. 1054. on the pulley.
20338-2
Remove:
– timing cover screws (1),
– the valve timing cover.
20345
20338
13-32
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
Position the F9Q extractor claws for Mot. 1525-01,
then the pulley extractor Mot. 1525.
20338-1
13-33
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
REFITTING Refitting the rail and the High Pressure pipes
Leave removal of the protection plugs from any Refit the rail and screw up the mounting bolts by hand
component until last. without tightening them (the rail must be loose).
For refitting operations, proceed in the reverse order to Refit the High Pressure pipes by hand-tightening the
removal. nuts at the pump and injectors end, then the rail end.
NOTE: be careful not to put the High Pressure pipes or Tighten the rail mounting bolts (3) to a torque setting of
the rear pump support under any strain. 2.2 daNm).
20349
20348
13-34
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
The diesel fuel return pipe (4) must be replaced every
time it is removed.
20549
13-35
DIESEL EQUIPMENT
F9Q engine Injector rail 13
SPECIAL TOOLING REQUIRED
EQUIPMENT REQUIRED
13-36
DIESEL EQUIPMENT
F9Q engine Injector rail 13
FOLLOW THE CLEANNESS INSTRUCTIONS
CLOSELY
REMOVAL
Disconnect:
– heat exchanger air intake pipe (2),
20341
Disconnect:
– pressure regulator (6),
– pressure sensor (7),
– fuel temperature sensor (8).
20342-1
Remove:
– air filter unit mounting bolts (5),
– air filter unit,
20347
13-37
DIESEL EQUIPMENT
F9Q engine Injector rail 13
Remove: REFITTING
– diesel fuel supply and return pipes, then fit plugs,
Leave removal of the protection plugs from any
component until last.
20346
20349
20349
13-38
DIESEL EQUIPMENT
F9Q engine Injector rail 13
The diesel fuel return pipe (4) must be replaced every
time it is removed.
20549
13-39
DIESEL EQUIPMENT
F9Q engine Injectors 13
IT IS FORBIDDEN TO DISMANTLE THE INSIDE OF
AN INJECTOR OR TO SEPARATE THE INJECTOR
HOLDER FROM THE NOZZLE.
EQUIPMENT REQUIRED
13-40
DIESEL EQUIPMENT
F9Q engine Injectors 13
FOLLOW THE CLEANNESS INSTRUCTIONS
CLOSELY
REMOVAL
Disconnect:
20341
– heat exchanger air intake pipe (2),
– diesel fuel return pipe, then fit plugs,
20342-1
20346
– airflow sensor connector (3),
– turbocharger air intake pipe (4).
Remove:
– air filter unit mounting bolts (5),
– the air filter unit,
13-41
DIESEL EQUIPMENT
F9Q engine Injectors 13
Remove the high pressure pipe using tool Mot. 1383. REFITTING
Fit plugs to maintain cleanness. Leave removal of the protection plugs from any
component until last.
Disconnect the injector connector.
Change the washer beneath the injector.
Remove:
– injector mounting clamp,
– injector,
– flame shield washer.
DI1326
CLEANING
NOTE: be careful not to place the High Pressure pipes
under any strain.
It is absolutely forbidden to use the following when
cleaning the injector:
To do this:
– wire brush,
– undo the injection rail (the rail should be loose),
– emery cloth,
– refit the High Pressure pipes by hand-tightening the
– ultrasonic cleaner.
nuts at the injectors end first.
– tighten the rail mounting bolts to a torque setting of
To clean the nose of the injector, let it soak in 2.2 daNm).
degreaser, then wipe it with a lint-free cloth.
– torque-tighten the High Pressure pipes to 2.5 daNm,
tightening the nuts at the injectors end first.
13-42
DIESEL EQUIPMENT
F9Q engine Injectors 13
The diesel fuel return pipe (4) must be replaced every
time it is removed.
20549
13-43
DIESEL EQUIPMENT
F9Q engine Pressure sensor 13
– airflow sensor connector (3),
TIGHTENING TORQUE (in daNm) – turbocharger air intake pipe (4).
REMOVAL
Disconnect:
– heat exchanger air intake pipe (2), 20341
20342-1
13-44
DIESEL EQUIPMENT
F9Q engine Pressure sensor 13
Disconnect the pressure sensor (6). REFITTING
20347
20349
13-45
DIESEL EQUIPMENT
F9Q engine Accelerator potentiometer 13
GENERAL INFORMATION Track assignments:
17785R
20300
NOTE: a fault on the accelerator position
potentiometer causes changes in the idle speed or
REFITTING engine operation (see Section 13 "Idle speed
correction").
Refitting is the reverse of removal.
13-46
DIESEL EQUIPMENT
F9Q engine Central coolant temperature management 13
OPERATION
20557
It illuminates when the coolant temperature exceeds
115 °C and extinguishes when the temperature falls
below 110 °C.
The coolant temperature sensor (1) (injection and
coolant temperature indicator on the instrument panel)
is a sensor with three tracks.
13-47
DIESEL EQUIPMENT
F9Q engine Computer 13
GENERAL INFORMATION
REMOVAL
Disconnect:
– turbo regulation solenoid valve (2),
– turbocharging pressure sensor (3) and unclip it,
– preheating unit,
20304
20303
Remove:
– metal shield mounting bolts (4) and remove it from
above,
20304-1
REFITTING
13-48
DIESEL EQUIPMENT
F9Q engine Computer 13
ALLOCATION OF TRACKS
CONNECTOR A
CONNECTOR B
13-49
DIESEL EQUIPMENT
F9Q engine Computer 13
CONNECTOR C
13-50
114
ANTI-POLLUTION
F9Q engine
Oil vapour rebreathing 14
CIRCUIT DIAGRAM
DI1322
14-1
ANTI-POLLUTION
F9Q engine
Exhaust gas recirculation 14
CIRCUIT DIAGRAM
15881R
1 Engine
2 Injection computer
3 Inlet manifold
4 Exhaust manifold
5 EGR (Exhaust Gas Recirculation) solenoid valve
6 Coolant temperature sensor
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content
of the exhaust gases.
14-2
ANTI-POLLUTION
F9Q engine
Exhaust gas recirculation 14
OPERATING PRINCIPLE
OPERATING CONDITIONS
X Time
Y Coolant temperature (°C)
15761R
1 Solenoid feed
2 Sensor feed
4 Sensor earth
5 Solenoid earth
6 Sensor output
14-3
116 STARTING - CHARGING
Alternator 16
OPERATION - FAULT FINDING The customer complains of a charging fault but the
warning light is operating correctly.
These vehicles are equipped with alternators with
internal ventilation and integral regulator. There is also If the regulated voltage is less than 13.5 V, check the
a warning light on the instrument panel which has the alternator. The fault could be caused by:
following functions: – damaged diode,
– the warning light comes on when the ignition is – broken wire,
switched on, – charred or worn tracks.
– the light goes out when the engine starts,
– if the warning light comes on while the engine is
running it shows there is a "charging" fault. Checking the voltage
The warning light does not come on when the Start the engine and increase the engine speed until
ignition is switched on. the voltmeter needle registers a stable regulated
voltage.
Check:
– that all electrical connections are good; This voltage should be between 13.5 V and 14.8 V.
– whether the bulb is blown (to find out, connect the
circuit to earth; the bulb should light up). Switch on as many power consumers as possible; the
regulated voltage should be between 13.5 V and
14.8 V.
The warning light comes on when the engine is
running. WARNING: the battery and regulator must be
disconnected before arc welding work is carried
This indicates a charging fault which could be caused out on the vehicle.
by:
– broken alternator drive belt or charging circuit,
– damage inside the alternator (rotor, stator, diodes or
brushes),
– regulator fault,
– overvoltage.
16-1
STARTING - CHARGING
Alternator 16
IDENTIFICATION
CHECKING
800 64
2000 81
4000 118
6000 123
16-2
STARTING - CHARGING
Alternator 16
FAULT FINDING
Diagnostic tools make it possible to check the alternator by measuring the voltage and the output current, with or
without electrical power consumers.
NOTE: the workstation's ampermetric clamp is of the inductive type (measurement range: 0 to 1,000 A). It is placed
in position without disconnecting the battery, which allows computer memories and adjustment programs to be
saved.
Fit the ampermetric clamp directly to the alternator output, with the arrow on the clamp pointing towards the
alternator (the station will detect an incorrect position).
On completion of the test, the values found will lead to the following diagnostic messages, where appropriate:
– battery voltage, no load < 12.3 V = battery discharged.
Without consumers:
– regulated voltage > 14.8 V ⇒ regulator faulty,
– (regulated voltage, no load < 13.2 V) or (charging current < 2 A) ⇒ charging fault.
With consumers:
– regulated voltage > 14.8 V ⇒ regulator faulty,
– regulated voltage < 12.7 V ⇒ it is necessary to check the alternator output against its specification:
Engine
F9Q
Current (amps)
Minimum current the alternator must supply
with all power consumers switched on 80
(3000 rpm)
If the measured output is correct but the regulated voltage is too low, the alternator is not faulty.
16-3
STARTING - CHARGING
Alternator 16
REMOVAL Remove:
– alternator mounting bolts, then remove the alternator
Put the vehicle on four axle stands (see Section 02 with the help of a screwdriver.
Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift.
Remove:
– engine undertray and the left-hand side protection.
– radiator air deflector,
– accessories belt (see Section 07 Accessories belt
tension),
– pulley.
16-4
STARTING - CHARGING
Alternator 16
REFITTING
16-5
STARTING - CHARGING
Starter 16
IDENTIFICATION
XL0B
F9Q 760 Valéo D7 R44
XL0C
16-6
STARTING - CHARGING
Starter 16
REMOVAL – turbocharger air outlet pipe,
– expansion box,
Put the vehicle on four axle stands (see Section 02 – stays (1) and (2), then the catalytic converter (3),
Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift.
REFITTING
16-7
119
COOLING SYSTEM
Specifications 19
VOLUME AND GRADE OF COOLANT
THERMOSTAT
Engine type Starts to open at (°C) Fully open at (°C) Travel (mm)
19-1
COOLING SYSTEM
Filling and bleeding 19
FILLING
BLEEDING
19-2
COOLING SYSTEM
Check 19
SPECIAL TOOLING REQUIRED
Replace the expansion bottle valve with adapter If liquid passes through the expansion bottle valve, the
M.S. 554-01. valve must be replaced.
Connect this to tool M.S. 554-07. On pump M.S. 554-07 fit tool M.S. 554-06 and fit the
assembly on the valve to be checked.
Warm up the engine then switch it off.
Increase the pressure, which should stabilise at the
Pump to put the circuit under pressure. valve rating pressure with a test tolerance of ± 0.1 bar.
19-3
COOLING SYSTEM
Diagram 19
1 Engine
2 Radiator
3 Hot bottle with degassing after thermostat
4 Heater matrix
5 Thermostat mounting
6 Thermoplunger mounting (if fitted)
7 ∅ 16 mm restriction
8 Coolant/oil heat exchanger
9 Coolant pump
10 Thermostat
11 Bleed screw
19-4
COOLING SYSTEM
F9Q engine
Coolant pump 19
SPECIAL TOOLING REQUIRED
Mot.1202-01
Pliers for large hose clips
Mot.1202-02
Mot. 1448 Remote operation clip pliers for
cooling system hose clips
REFITTING
TIGHTENING TORQUE (in daNm)
NOTE: put a drop of Loctite FRENETANCH on
Water pump bolts 0.9
bolts (3) and (4).
REMOVAL
Remove:
– the timing belt (see section 11 "Timing belt").
– the coolant pump.
16153R
Refit:
– the coolant pump fitted with a new seal by tightening
the bolts to a torque of 0.9 daN.m,
– the timing belt (see method described in section 11
"Timing belt").
19-5
ENGINE MOUNTING
Suspended engine mountings 19
TIGHTENING TORQUES (in daNm)
A 4.4 G 10.5
B 6.2 H 6.2
C 10.5 I 8.5
D 4.4 J 6.2
E 4.4 K 4.4
F 18 L 4.4
19-6