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MR 342 Trafic 1

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0% found this document useful (0 votes)
56 views110 pages

MR 342 Trafic 1

Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 110

Engine and peripherals

ENGINE ASSEMBLY AND LOWER ENGINE

TOP AND FRONT OF ENGINE

FUEL MIXTURE - TURBOCHARGING

DIESEL EQUIPMENT

ANTI-POLLUTION

STARTING - CHARGING

COOLING - ENGINE MOUNTING

XL0B - XL0C

77 11 303 322 MAY 2001 Edition Anglaise

"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

10 ENGINE AND PERIPHERALS 13 DIESEL EQUIPMENT


Identification 10-1 Technical specifications 13-1
Oil consumption 10-2 Special features 13-4
Oil pressure 10-3 Cleanliness 13-8
Engine - gearbox 10-4 Location of components 13-11
Injection warning light 13-15
Immobiliser function 13-16
Injection/air conditioning program 13-17
11 TOP AND FRONT OF ENGINE Idle speed correction 13-18
Pre/post-heating control 13-19
Timing belt tension wheel 11-1 Pre-heater plugs 13-20
Timing belt 11-2 Thermoplunger 13-21
Cylinder head gasket 11-13 Low pressure pump (booster pump) 13-23
Fuel filter 13-26
Checking diesel fuel pressure and flow 13-27
High pressure pump 13-28
12 FUEL MIXTURE - TURBOCHARGING Injector gallery 13-36
Injectors 13-40
Air intake 12-1 Pressure sensor 13-44
Air filter 12-2 Accelerator potentiometer 13-46
Manifolds 12-3 Central coolant temperature
Airflow sensor 12-7 management 13-47
Pressure regulating valve 12-9 Computer 13-48
Turbocharger pressure adjustment 12-10
Turbocharger 12-11
Air/air heat exchanger 12-14
14 ANTI-POLLUTION
Reaspiration of oil vapours 14-1
Exhaust gas recirculation 14-2

16 STARTING - CHARGING

Alternator 16-1
Starter 16-6
Engine and
peripherals

Contents

Page

19 ENGINE MOUNTING COOLING


Cooling
Technical specifications 19-1
Filling - bleeding 19-2
Checking 19-3
Diagram 19-4
Coolant pump 19-5

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

a) Topping-up to the maximum level

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.

Check visually using the dipstick.

Top up to the maximum level.

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.

c) Topping up to the maximum level

The operation must be carried out with the engine hot (the cooling fan having cut in) and after leaving to
stabilise for 15 minutes .

Check visually using the dipstick.

Top up to the maximum level.

Note the quantity of oil and the mileage covered since the last top-up to maximum level.

d) Measurement of the oil consumption

Quantity of oil added (in litres)


OIL CONSUMPTION =
km (in thousands)

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

The oil pressure should be checked when the engine


is warm (approximately 80°C).

Contents of kit Mot. 836-05.

USE

B+F

Connect the pressure gauge in place of the oil


pressure switch.

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

Disconnect the battery.


TIGHTENING TORQUES (in daNm)

Shock absorber base bolts 18

Steering ball joint nut 3.7

Suspended gearbox mounting fixing nut 6.2

Lower ball joint nut 11

Brake calliper mounting bolt 3.5

Engine tie-bar fixing bolt: 10.5

Suspended engine mounting upper


linkage mounting bolt 10.5

Driveshaft gaiter mounting bolts 3

Body mounting bolt for the suspended


engine mounting movement limiter 4.4

Mounting bolt on the engine for


suspended engine mounting cover 6.2

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.

FOLLOW CAREFULLY THE INSTRUCTIONS


GIVEN IN SECTION 13 "SPECIAL FEATURES"
AND "CLEANLINESS" BEFORE CARRYING OUT
ANY WORK

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 the driveshaft and then remove the hub unit


assembled with the driveshaft.

Left-hand side of the vehicle

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),

– track rod end, using tool T. Av. 476,


– driveshaft gaiter mountings,
– shock absorber base mounting bolts.

Remove the driveshaft and then remove the hub unit


assembled with the driveshaft.
Drain:
– refrigerant circuit using filling equipment. Remove:
– cooling system through the radiator bottom hose – number plate,
– gearbox and engine if necessary. – the direction indicators,
– the radiator grille,
Right-hand side of the vehicle

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.

Disconnect the connectors from the headlight units.

Remove the headlight units, not forgetting to remove


the retaining clip (3).

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).

– bonnet catch system mountings (5) and disconnect


the cable,
– front panel,

– lower radiator mountings as well as the top hose,


– connectors on the fan assembly and the condenser,

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),

– upper gearbox soundproofing material,

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),

– the exhaust downpipe mountings.


– thermoplunger unit mounting (2) and move it out of
the way, Disconnect the fuel tank sender connector at (5),
unclip it from under the body and attach it to the
engine.

Attach the workshop hoist.

Support the engine and gearbox assembly using a


hoist.
– power assisted steering hoses on the steering box
(drain the power steering reservoir first).

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),

– nut (1) and tap it with a copper hammer to disengage


the stud,
Using a workshop crane, remove the engine-gearbox
assembly.

REFITTING

Refit the engine-gearbox assembly following the same


method as for removal.

Refit:
– left suspended mounting,
– right suspended mounting,
– the engine tie-bar.

Refer to Section 19 Suspended mounting for


tightening torques.

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.

IMPORTANT NOTE: to avoid damaging the slave Refit:


cylinder, do not coat the gearbox output shaft with – left suspended mounting,
grease. – right suspended mounting,
– the engine tie-bar.
NOTE: to avoid leaks, replace the slave cylinder
after replacing the clutch mechanism. Refer to Section 19 Suspended mounting for
tightening torques.
Add brake fluid to the reservoir.
Refit using the same procedure as for removal in
Bleed the system using the bleed screw (D) located on reverse.
the union on the slave cylinder.
FOLLOW CAREFULLY THE INSTRUCTIONS
GIVEN IN SECTION 13 SPECIAL FEATURES FOR
THE PROCEDURE FOR STARTING THE ENGINE.

Perform the following operations:


– fill the gearbox with oil,
– fill the engine with oil, if necessary,
– fill and bleed the cooling system (see Section 19
Filling - bleeding),
– fill and bleed the power assisted steering circuit,
– fill the refrigerant circuit using the filling equipment.

Apply Loctite FRENBLOC to the brake calliper


mounting bolts before fitting and tighten them to the
correct torque.

Press the brake pedal several times to bring the


pistons into contact with the brake pads.
Make sure that the brake fluid reservoir is never
empty.

Top up the brake fluid.

IMPORTANT: tighten the bleed screw to a torque of


1 daNm.

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

Body mounting bolt for the


suspended engine mounting
movement limiter 4.4

Mounting bolt on the engine for


suspended engine mounting cover 6.2

Wheel bolt 14

REMOVAL

Put the car on a two-post lift.

Disconnect the battery.

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

Disconnect the battery.


TIGHTENING TORQUE (In daNm and/or°)
NOTE: because the battery is located under the left-
Tension wheel nut 5
hand seat, the carpet must be unclipped and removed,
Crankshaft pulley bolt 2+115°±15° then the battery cover (A) can be removed by undoing
the screws.
Suspended engine mounting
upper linkage mounting bolt 10.5

Body mounting bolt for the


suspended engine mounting
movement limiter 4.4

Mounting bolt on the engine for


suspended engine mounting cover 6.2

Wheel bolt 14

REMOVAL

Put the vehicle on four axle stands (see Section 02


Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift.

Remove the engine undertray and the left-hand side


protection.

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.

Unclip the power steering reservoir from its mounting


and move it to one side.

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.

Adjust the position of part (A) on the sump using the


adjusters (B).

Lift the engine slightly at point (C), then tighten screws


(D).

– Top Dead Centre pin plug.

11-3
TOP AND FRONT OF ENGINE
Timing belt 11
Timing adjustment

Turn the crankshaft in a clockwise direction (timing


end). When the mark (1) on the camshaft pulley
appears in the window (2) of the timing cover, push in
the Top Dead Centre pin Mot. 1054 to pin the
crankshaft (the mark on the camshaft pulley must be
located approximately in the centre of the window).

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.

Check that the tensioner is securely positioned on the


pin (1).

Check that pin Mot. 1054 is in place.

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.

Apply pre-tension between the


crankshaft timing sprocket and the
tensioner using tool Mot. 1543
and the cover 1, adjusting the
torque wrench to a torque of
1.1 daNm.

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.

Turn the crankshaft two revolutions.

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).

Remove the pin Mot. 1054.

Apply pre-tension between the crankshaft timing


sprocket and the tensioner using the tool Mot. 1543
and the cover 1, adjusting the torque wrench to a
torque of 1.1 daNm.

Position the sensor of Mot. 1505.

Check that the tension value is 85 ± 3 Hz. If not,


readjust it.

Tighten the tension wheel nut to a torque of 5 daNm.

NOTE: it is essential to torque-tighten the tension


wheel nut to avoid it becoming loose, which could
cause damage to the engine.

WARNING: remove the washer numbered R1 included


in the Mot. 1543 tool kit before fitting the crankshaft
pulley.

The crankshaft accessories pulley bolt MUST be


tightened to a torque of 2 daNm plus an angle of
115º ± 15º.

Refitting is the reverse of removal.

Refit the right-hand suspended engine mounting (see


Section 19 Suspended engine mounting for the
tightening torques).

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

Disconnect the battery.


TIGHTENING TORQUE (In daNm and/or°)

Tension wheel nut 5

Tension wheel plate bolt 1

Crankshaft pulley bolt 2+115°±15°

Suspended engine mounting


upper linkage mounting bolt 10.5

Body mounting bolt for the


suspended engine mounting
movement limiter 4.4

Mounting bolt on the engine for


suspended engine mounting cover 6.2

Wheel bolt 14

REMOVAL

Put the vehicle on four axle stands (see Section 02


Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift.
NOTE: because the battery is located under the left-
hand seat, the carpet must be unclipped and removed,
then the battery cover (A) can be removed by undoing
FOLLOW CAREFULLY THE INSTRUCTIONS the screws.
GIVEN IN SECTION 13 "SPECIAL FEATURES"
AND "CLEANLINESS" BEFORE CARRYING OUT Drain the cooling circuit through the lower radiator
ANY WORK hose.

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),

– the air filter unit,


– vacuum pipes (2),

– hoses on the cylinder head water outlet housing as


well as the coolant temperature sensor connector,

– brake servo vacuum pipe,

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),

– connectors (3) and Top Dead Centre sensor at (4),


– oil return pipe (1),
– mounting (2), having loosened the pipe at (3), then
remove the oil supply pipe at (4) and move it aside
towards the bulkhead,

– the exhaust downpipe mountings,

– cylinder head bolts,


– the cylinder head.

11-15
TOP AND FRONT OF ENGINE
Cylinder head gasket 11
CLEANING REFITTING

It is very important not to scratch the gasket faces Special notes


of any aluminium component.
Fit the cylinder head gasket. This is centred by two
Use the Décapjoint product to dissolve any remains of dowels.
the gasket still adhering.
Bring the pistons to mid-stroke position to prevent
Wear gloves whilst carrying out the following them from coming into contact with the valves as the
operation. cylinder head is tightened.

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.

No regrinding of the cylinder head is permitted.

Test the cylinder head to detect possible cracks using


the cylinder head test tools (a container and a kit for
the particular cylinder head, plug, sealing plate,
blanking plate). The approval number of the cylinder
head test container is 664000.

11-16
112
FUEL MIXTURE
F9Q engine
Air intake 12
AIR INTAKE CIRCUIT DIAGRAM

20350

1 Air/air heat exchanger


2 Air filter
3 Flow sensor
4 inlet manifold
5 Turbocharger
6 Air inlet

12-1
FUEL MIXTURE
F9Q engine
Air filter 12
FILTER ELEMENT REPLACEMENT

20301

Remove the three screws on the air filter cover to gain


access to the filter element.

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

NOTE: Removal of the manifolds requires removal of


the turbocharger (see Section 12 Turbocharging:
Turbocharger). The two manifolds cannot be removed
separately.

Put the vehicle on a two-post lift.

Disconnect the battery.

Remove the engine undertray.


20341
Disconnect the heater unit connector (1).

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).

Remove the EGR solenoid valve mounting screws (9)


and remove the valve.

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

Proceed in the reverse order to removal.

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).

Remove the heater unit mounting bolt and three nuts


(2), then remove the unit.

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

Connector for airflow sensor with built-in air


temperature sensor.

Track Description
1 Air temperature
2 Earth
3 Reference 5V
4 +battery
5 Airflow signal
6 Earth

20555

Air temperature sensor resistance: (between tracks 1


and 2) ≈ approximately 2170 ohms at 20 °C.

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

X Timed period (seconds)


20553
Y Temperature (°C)

The pressure regulation valve is open in rest position.


The engine operates as normally aspirated.

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)

120 between 1 and 4


The absence of control pressure limits the
turbocharging pressure. 400 between 10 and 12

Check that there are no leaks between the vacuum > 450 Rod at stop
pump and the control valve.

Calibration pressure check On the vehicle itself

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.

Loosen the lock nut (1).

20550

Use a magnetic base fitted with a gauge which should


be positioned at the end of the wastegate rod 20551
(inserted as close as possible to the centre line of the
wastegate).
Carry out the adjustment by tightening or loosening the
A vacuum is applied progressively to the wastegate adjusting wheel (2) half a turn at a time until the correct
using pressure gauge Mot. 1014. calibration pressure is obtained.

NOTE: check the calibration pressure after


retightening the lock-nut (1).

Check the repair by carrying out a road test, checking


the "RCO turbocharging control valve" and the
"turbocharging pressure" parameters on the
diagnostic tools.

12-10
TURBOCHARGING
F9Q engine
Turbocharger 12
TIGHTENING TORQUE (in daNm)

Turbocharger mounting nut 2.4 ± 1


Turbo oil supply connection 2.4 ± 4
Engine oil supply connection 2.6 ± 0.2
Oil return union bolt 1.2 ± 0.1
Nuts mounting the catalytic converter
on the turbocharger 2.6 ± 0.2

REMOVAL
20341

NOTE: it is recommended that the turbocharger


mounting nuts on the exhaust manifold are sprayed – both exhaust system mounting nuts (6) and allow it to
with a releasing agent while they are still hot; it will rest on the engine sub-frame.
then be easier to remove them.

Put the car on a two-post lift.

Disconnect the battery.

Remove the engine undertray.

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

Remove the retaining clip screw (1).

Disconnect:
– heat exchanger air intake pipe (2),
– heat exchanger air outlet pipe (3),

20342

REFITTING

Refitting is the reverse of removal.

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

XLOC PK5 and


F9Q 760 80 93 1870 19: 1 EU 00
XLOB PK6

ENGINE SPEED (rpm) SMOKE OPACITY

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 %)

Description Make/Type Special notes

High pressure pump BOSCH CR / CP3 Pressure from 250 to 1350 bars

Booster pump (low pressure) Maximum pressure: 2. bars


BOSCH EKP3
Flow: 80 to 100 litres/hour minimum

Diesel pressure sensor BOSCH Screwed to the injection rail


Resistance: tracks 1,2 and 1,3 = 4.3 Mohms
tracks 2,3 = 1050 ohms

Injectors BOSCH Solenoid injector


Resistance: < 2 ohms
Maximum pressure 1600 bar

Pressure regulator Incorporated in the high pressure pump (not


- removable)
Resistance: approx. 5 ohms at 20 °C

Injection computer BOSCH EDC15 128-track computer

Accelerator pedal sensor HELLA Double track potentiometer


Track 1 resistance: 1200 ± 480 ohms
Track 2 resistance: 1700 ± 680 ohms

Pre/postheating unit NAGARES BED/7 With pre/post-heating function controlled by the


injection computer

Engine speed sensor MGI Resistance: 800 ± 80 ohms at 20 °C

13-1
DIESEL EQUIPMENT
F9Q engine Specifications 13
Description Make/Type Special notes

Pre-heater plugs BERU or CHAMPION Resistance: 0.6 ohms, connector disconnected

Air intake temperature sensor SIEMENS Incorporated in the flow sensor


Resistance: approx. 2170 ohms at 20 °C

Diesel fuel temperature MAGNETTI Resistance: approx. 2050 ohms at 25 °C


sensor MARELLI and
ELTH

Atmospheric pressure sensor - Incorporated into the computer

Camshaft sensor ELECTRICIFIL Hall effect sensor

Turbocharging pressure DELCO Resistance: 4 Kohms between tracks A and C


sensor Resistance: 5 Kohms between tracks B and C
Resistance: 9 Kohms between tracks A and B

Turbocharger operating BITRON Resistance: 16.5 ± 1 ohm at 25°C


solenoid

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

EGR solenoid valve Track resistance: 8 ± 0.5 ohms at 20 °C


(tracks 1 and 5)
PIERBURG/SIEBE
Sensor resistance: 4 ± 1.6 Kohms at 20 °C
(tracks 2 and 4)

13-2
DIESEL EQUIPMENT
F9Q engine Specifications 13
Description Make/Type Special notes

Turbocharger ALLIED SIGNAL Wastegate setting:


(fixed geometry turbo)
120 mbars for rod travel between 1 and 4 mm
400 mbars for rod travel between 10 and 12 mm
> 450 mbars with rod at end of travel

Thermoplungers - Resistance: 0.45 ± 0.05 ohms at 20 °C

Coolant temperature sensor ELTH Resistance: 2252 ± 112 ohms at 25 °C

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

The system consists of:


– low pressure pump (1) (located in the fuel tank),
– fuel filter (2),
– priming valve (3),
– high pressure regulator (4) mounted on the pump (it is forbidden to separate the regulator from the pump. If there
is a fault in one component, both must be changed),
– high pressure pump (5),
– injection rail (6) fitted with a diesel fuel pressure sensor and a pressure limiter (7),
– four solenoid injectors,
– various sensors,
– injection computer.

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.

The injected flow to the engine is determined by:


– the duration of injector control,
– the injector opening and closing speed,
– needle travel (determined by the type of injector),
– the normal hydraulic flow of the injector (determined by the type of injector),
– the high pressure rail pressure controlled by the computer.

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.

It is absolutely vital that you observe the tightening torque:


– of the high pressure pipes,
– of the cylinder head injector,
– of the pressure sensor.

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 prohibited to dismantle the insides of the pump.

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

Risks relating to contamination

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.

WHAT ARE THE SOURCES OF CONTAMINATION?

Contamination is caused by:


– metal or plastic chips,
– paint,
– fibres,
! boxes,
! brushes,
! paper,
! clothing,
! cloths.
– foreign bodies such as hairs,
– ambient air,
– etc.

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).

! Use a brush and thinners to clean the connections to be opened.

! 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.

! Wash your hands before and during the operation if necessary.

! When wearing leather protective gloves, cover these with latex gloves.

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

! 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

1 Diesel fuel filter with heater


2 Camshaft sensor
3 Airflow sensor with air temperature sensor
4 Exhaust gas recirculation valve (EGR)
5 Thermoplunger unit
6 Turbo regulation solenoid
7 Turbocharging pressure sensor
8 Injection computer
9 Impact sensor
10 Preheating unit
11 Coolant temperature sensor
12 Engine speed sensor
13 Solenoid injector
14 High pressure pump

13-11
DIESEL EQUIPMENT
F9Q engine Location of components 13

18297R

1 High pressure pump


2 Common injection rail
3 Injector
4 Pressure regulator
5 Pressure sensor
6 Fuel temperature sensor
7 Pressure regulator

13-12
DIESEL EQUIPMENT
F9Q engine Location of components 13

16181R 20549

8 Camshaft sensor 12 EGR valve


13 Thermoplunger unit

20552 20303

9 Light-off catalytic converter 14 Turbo regulation solenoid valve


10 Turbocharger 15 Turbocharger pressure sensor
11 Airflow sensor with integrated temperature sensor 16 Preheating unit

13-13
DIESEL EQUIPMENT
F9Q engine Location of components 13

20302 20304-1

17 Fuel filter 19 Injection computer

20305 20300

18 Impact sensor 20 Accelerator potentiometer

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.

PRINCIPLE FOR LIGHTING UP OF THE WARNING LIGHTS

! 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.

REPLACING AN INJECTION COMPUTER

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).

SPECIAL POINTS FOR TESTING THE INJECTION COMPUTER

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.

The tracks used for the air conditioning function are:


– one wire on track A F4 of the computer which controls the air conditioning compressor clutch,
– one wire on track A G4 of the injection computer. This wire carries the request for the compressor to start operating.

When the air conditioning function is selected, the idle speed does not change; it is 800 rpm.

COMPRESSOR OPERATION PROGRAMMING

During certain stages of operation, the injection computer stops the compressor from functioning.

Engine starting program

The compressor is prevented from operating for 2 seconds after the engine has started.

Recovery of output when the vehicle starts moving

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.

Thermal protection program

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

X: Engine speed in rpm.


Y: Coolant temperature in °C

CORRECTION ACCORDING TO ELECTRICAL LOAD

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.

CORRECTION OF IDLE SPEED WHEN THE POTENTIOMETER IS FAULTY

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.

IDLE SPEED CORRECTION WHEN DRIVING

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.

IDLE SPEED LIMITATION WHEN STATIONARY

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

After the warning light goes out the plugs remain


supplied for a fixed period of 10 seconds.

13-19
DIESEL EQUIPMENT
F9Q engine Pre-heater plugs 13
The pre-heater plug resistance is 0.6 ohm (connector
disconnected).

TIGHTENING TORQUE (in daNm)

Pre-heater plugs 1.5

Plugs may be removed without having to open the


high pressure circuit.

REMOVAL

Unclip the plug connector.

Clean the outside of the plug to avoid any dirt entering


the cylinder.

Loosen and remove the plugs.

15762S

REFITTING

Proceed in the reverse order to removal.

Ensure that no contamination enters the cylinder


during this operation.

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

20549 Non shaded area: thermoplunger not supplied


Shaded area: thermoplunger supplied

13-21
DIESEL EQUIPMENT
F9Q engine Thermoplunger 13
If the battery voltage is > 13.5 volts

If not then

Thermoplungers not supplied One thermoplunger is supplied

If after 20 seconds the battery


voltage is > 13.5 Volts

If not then

Thermoplungers not supplied Two thermoplungers supplied

If after 20 seconds the battery


voltage is > 13.5 Volts

If not then

Thermoplungers not supplied Three thermoplungers supplied

If after 20 seconds the battery


voltage is > 13.5 Volts

If not then

Thermoplungers not supplied Four thermoplungers are supplied if


the battery voltage is > 13.5 volts
and if the conditions mentioned
above are met

13-22
DIESEL EQUIPMENT
F9Q engine Low pressure pump (booster pump) 13
SPECIAL TOOLING REQUIRED

Mot. 1397 Fuel pump securing nut

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

WARNING: before removing any components, take


precautions to trap fuel running out of the pipes (do not
clamp pipes, this could damage them).

Put the car on a two-post lift.

Disconnect the battery.

Remove the fuel tank filler pipe access flap.

20310-1

Place a component jack under the tank to hold it.

20310

13-23
DIESEL EQUIPMENT
F9Q engine Low pressure pump (booster pump) 13
Remove the fuel tank mounting bolts (3).

20315

20309 Remove the pump mounting nut (7) using tool


Mot. 1397.
Lower the tank slightly to be able to gain access to the
fuel pipes and the electrical wiring. Allow any fuel in the sender unit to flow out, then
remove the pump/sender assembly, taking care not to
Disconnect: damage the float.
– pump electrical connector (4),
– fuel return pipe (5),
– fuel outlet pipe (6). NOTE: if several hours will elapse between removing
and refitting the pump and sender assembly, screw the
nut back on the fuel tank to prevent any distortion.

20308

Remove the fuel tank and drain it if necessary.

13-24
DIESEL EQUIPMENT
F9Q engine Low pressure pump (booster pump) 13
REFITTING

Replace the sealing gasket.

Refit the pump/sender assembly, positioning the mark


on the sender (8) opposite the three raised lines (9) on
the tank.

Refit the nut and tighten to a torque of 6 daNm.

After tightening, check that the mark (8) on the pump/


sender assembly does in fact line up with the marks
(9) on the tank.

20315

For the other refitting operations, proceed in the


reverse order to removal.

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.

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.

To replace the filter it is therefore necessary to remove


the whole unit.

REMOVAL

FOLLOW THE CLEANNESS INSTRUCTIONS


CLOSELY

WARNING: watch out for the residual pressure and


the quantity of diesel fuel remaining in the pipes.

Disconnect the battery.

Disconnect from the filter:


– the diesel fuel heater connector (1),
– the fuel supply pipe to the engine (2), 19910
– the pipes (3) coming from the tank,

Remove the filter by unclipping it from its support. REFITTING

Take care to line up the mark on the cover and the


mark on the bowl correctly.

It is vital to respect the position of the connections to


the filter.

Be careful not to squeeze or damage the pipes.

IMPORTANT: re-prime the system by switching on the


ignition several times, or turn the low pressure pump
over with the diagnostic tool using the Actuator
Commands menu.

From time to time it is necessary to bleed the water


trapped in the diesel fuel filter via the bleed plug (5).

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).

SPECIAL TOOLING REQUIRED

Mot. 1311-01
or Fuel pressure test kit
Mot. 1328
Mot. 1311-03 I adapter for fuel pressure test
kit

EQUIPMENT REQUIRED

2000 ml graduated cylinder

LOW PRESSURE CHECK (BOOSTER PUMP) FLOW TEST (BOOSTER PUMP)

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

SPECIAL TOOLING REQUIRED

Mot. 1054 TDC setting pin


Mot. 1383 Tool for removing and refitting
the high pressure pipes
Mot. 1200-02 Pump pulley retaining tool
Mot. 1525 Pulley extractor
Mot. 1525-01 Extractor claws for F9Q
Mot. 1367 Engine support bar
Mot. 1367-02 Engine support tool

EQUIPMENT REQUIRED

Low torque wrench

TIGHTENING TORQUE (in daNm and/or °)

High Pressure pipe 2.5 ± 0.2

High pressure pump mounting 3 ± 0.3

Rear pump support mounting 3 ± 0.3

High Pressure pump pulley nut 1.5 then 60 ± 10°

Injection rail mounting bolt 2.2 ± 0.2

WARNING: before carrying out any work, connect


the diagnostic tool to the injection computer and check
that the injection rail is not under pressure.

Make a note of the fuel temperature.

13-28
DIESEL EQUIPMENT
F9Q engine High pressure pump 13
– radiator grille mounting screws (6),
FOLLOW THE CLEANNESS INSTRUCTIONS
– radiator grille.
CLOSELY

REMOVAL

Put the car on a two-post lift.

Disconnect:
– the battery,
– heater unit connector (1).

Remove:
– heater unit bolt and three nuts (2),
– heater unit.

20289

Disconnect the headlight units.

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

– air/air heat exchanger air inlet and outlet pipes (10),


20597

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).

Move the electrical wiring loom aside.

20349

– rail mounting bolts (4),


– rail,
20347 – rear pump support mounting bolts (5),
– rear pump support.
Remove:
– diesel fuel supply and return pipes, then fit plugs,

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.

Put the engine support tools Mot. 1367 and Remove:


Mot. 1367-02 in position. – High Pressure pump sprocket nut (2).

Remove the suspended engine mounting.

20338-2

20339 – High Pressure pump mounting nuts (3).

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.

Extract the pump by tightening the thrust bolt (4) of the


pulley extractor.

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).

To do this: Torque-tighten the High Pressure pipes to 2.5 daNm,


tightening the nuts at the pump and injectors end first,
then the rail end.
Refitting the rear pump support

Refit the rear pump support and hand-tighten the


mounting bolts so as to bring the support into contact
with the cylinder head and the pump.

Torque-tighten the rear pump support mounting bolts


to 3 daNm, tightening bolt (1) on the pump first, then
bolts (2) on the cylinder head.

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

Refit the suspended engine mounting (refer to the


method in "Section 19").

For other operations, refitting is the reverse of


removal.

IMPORTANT: re-prime the system by switching on the


ignition several times, or turn the low pressure pump
over with the diagnostic tool using the Actuator
Commands menu.

13-35
DIESEL EQUIPMENT
F9Q engine Injector rail 13
SPECIAL TOOLING REQUIRED

Mot. 1383 Tool for removing and refitting


the high pressure pipes

EQUIPMENT REQUIRED

Low torque wrench

TIGHTENING TORQUE (in daNm)

High Pressure pipe 2.5 ± 0.2

Injection rail mounting bolt 2.2 ± 0.2

Pressure sensor 3.5 ± 0.2

IMPORTANT: before carrying out any work, connect


the After-Sales diagnostic tool, set up communication
with the injection computer and check that the injection
rail is not under pressure.

Make a note of the fuel temperature.

13-36
DIESEL EQUIPMENT
F9Q engine Injector rail 13
FOLLOW THE CLEANNESS INSTRUCTIONS
CLOSELY

REMOVAL

Disconnect the battery.

Remove the retaining clip screw (1).

Disconnect:
– heat exchanger air intake pipe (2),

20341

Disconnect:
– pressure regulator (6),
– pressure sensor (7),
– fuel temperature sensor (8).

Move the electrical wiring loom aside.

20342-1

– airflow sensor connector (3),


– turbocharger air intake pipe (4).

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.

Refit the rail and screw up the mounting bolts by hand


without tightening them (the rail must be loose).

Refit the High Pressure pipes by hand-tightening the


nuts at the pump and injectors end, then the rail end.

Tighten the rail mounting bolts (3) to a torque setting of


2.2 daNm).

Torque-tighten the High Pressure pipes to 2.5 daNm,


tightening the nuts at the pump and injectors end first,
then the rail end.

20346

– High Pressure pipes using tool Mot. 1383, then fit


plugs,

20349

20349

– rail mounting bolts (9),


– the rail.

13-38
DIESEL EQUIPMENT
F9Q engine Injector rail 13
The diesel fuel return pipe (4) must be replaced every
time it is removed.

20549

For other operations, refitting is the reverse of


removal.

IMPORTANT: re-prime the system by switching on the


ignition several times, or turn the low pressure pump
over with the diagnostic tool using the Actuator
Commands menu.

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.

SPECIAL TOOLING REQUIRED

Mot. 1383 Tool for removing and refitting


the high pressure pipes

EQUIPMENT REQUIRED

Low torque wrench

TIGHTENING TORQUES (in daNm)

High Pressure pipe 2.5 ± 0.2

Injection rail mounting bolt 2.2 ± 0.2

Injector clamp mounting bolt 2.5 ± 0.5

IMPORTANT: before carrying out any work, connect


the After-Sales diagnostic tool, set up communication
with the injection computer and check that the injection
rail is not under pressure.

Make a note of the fuel temperature.

13-40
DIESEL EQUIPMENT
F9Q engine Injectors 13
FOLLOW THE CLEANNESS INSTRUCTIONS
CLOSELY

NOTE: injectors may be replaced individually.

REMOVAL

Disconnect the battery.

Remove the retaining clip screw (1).

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

Refit the injector.

20349 Torque-tighten the injector flange to 2.5 daNm.

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

For other operations, refitting is the reverse of


removal.

IMPORTANT: re-prime the system by switching on the


ignition several times, or turn the low pressure pump
over with the diagnostic tool using the Actuator
Commands menu.

13-43
DIESEL EQUIPMENT
F9Q engine Pressure sensor 13
– airflow sensor connector (3),
TIGHTENING TORQUE (in daNm) – turbocharger air intake pipe (4).

Pressure sensor 3.5 ± 0.2 Remove:


– air filter unit mounting bolts (5),
– the air filter unit,
IMPORTANT: before carrying out any work, connect
the After-Sales diagnostic tool, set up communication
with the injection computer and check that the injection
rail is not under pressure.

Make a note of the fuel temperature.

REMOVAL

Disconnect the battery.

Remove the retaining clip screw (1).

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

Replace the seal.

Screw in the sensor and torque-tighten it to 3.5 daNm.

Connect the sensor.

For other operations, refitting is the reverse of


removal.

IMPORTANT: re-prime the system by switching on the


ignition several times, or turn the low pressure pump
over with the diagnostic tool using the Actuator
Commands menu.

20347

Remove the pressure sensor (7).

20349

13-45
DIESEL EQUIPMENT
F9Q engine Accelerator potentiometer 13
GENERAL INFORMATION Track assignments:

The accelerator pedal potentiometer is incorporated in


the accelerator pedal. Its replacement therefore
Track Description
requires replacement of the accelerator pedal.
1 Track 2 earth

REMOVAL 2 Track 1 earth


3 Track 1 signal
Disconnect:
– the battery, 4 Track 1 feed
– accelerator pedal connector (1).
5 Track 2 feed
Remove: 6 Track 2 signal
– three pedal mounting screws (2),
– pedal.

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

The injection computer uses the coolant temperature


to control:
– the injection system,
– the fan relay:
! the cooling fan is activated at low speed then at
high speed if the coolant temperature goes above
90 °C and stops when the temperature falls below
95 °C,
! the fan unit can be controlled by the air
conditioning.

COOLANT TEMPERATURE WARNING LIGHT

The warning light is controlled by the computer via the


multiplex network.

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.

Two tracks for the coolant temperature signal to the


computer (tracks B E1 and B K3).

This system allows the engine cooling fan to be


controlled by the injection computer. It consists of a
single temperature sensor used for the injection, the
engine cooling fan, the temperature indicator and the
temperature warning light on the instrument panel.

13-47
DIESEL EQUIPMENT
F9Q engine Computer 13
GENERAL INFORMATION

The injection computer is located behind a sheet metal


shield under the expansion bottle.

REMOVAL

Disconnect the battery.

Remove the expansion bottle mounting screw (1) and


move it out of the way.

Disconnect:
– turbo regulation solenoid valve (2),
– turbocharging pressure sensor (3) and unclip it,
– preheating unit,

20304

– computer mounting bolts (5) and remove it, having


disconnected it beforehand.

20303

Remove:
– metal shield mounting bolts (4) and remove it from
above,

20304-1

REFITTING

Proceed with refitting in the reverse order to removal.

If the computer has been changed, carry out


programming of the immobiliser code by following the
procedure described in the Section "Immobiliser".

13-48
DIESEL EQUIPMENT
F9Q engine Computer 13
ALLOCATION OF TRACKS
CONNECTOR A

A3 --- Load potentiometer earth (track 2)


A4 →← CAN L MULTIPLEX LINK (Passenger compartment)
B1 ← Heated windscreen input
B3 --- Load potentiometer earth (track 1)
B4 →← CAN H MULTIPLEX LINK (Passenger
compartment)
C1 ← Load potentiometer input signal (track 1)
C3 →← FAULT FINDING
E1 --- Load potentiometer feed (track 1)
E2 ← Clutch switch input
E4 ← Vehicle speed input
F1 ← Load potentiometer input signal (track 2)
F3 ← Stop switch input
F4 → Air conditioning compressor control output
G4 ← Air conditioning request input
H2 --- Load potentiometer feed (track 2)

CONNECTOR B

B2 --- EGR position potentiometer earth


B3 ← Plugs diagnostics input
C1 ← Turbocharger pressure sensor signal input
C2 ← EGR position potentiometer signal input
C3 → Preheating control relay
D1 ← Diesel fuel pressure sensor input
D3 ← Air temperature sensor input
D4 → Feed control relay output
E1 --- Coolant temperature sensor earth
E3 --- + after ignition
F2 --- EGR position potentiometer feed
F3 → Thermoplunger control relay 2 output
(2 thermoplungers)
G1 --- Fuel temperature sensor earth
G2 --- Airflow sensor feed
G3 ← Engine speed sensor signal
H2 --- Diesel fuel pressure sensor feed
H3 ← Engine speed sensor signal
H4 ← Airflow sensor signal input
J2 --- Turbocharging pressure sensor feed
J3 ← Fuel temperature input
K3 ← Coolant temperature sensor input
L1 → High Pressure regulation valve output
L2 → Turbo regulation solenoid valve output
L3 --- Power earth
L4 --- Power earth
M1 → EGR solenoid valve output
M2 --- + After relay
M3 --- + After relay
M4 --- Power earth

13-49
DIESEL EQUIPMENT
F9Q engine Computer 13
CONNECTOR C

A1 → Booster pump control output


A2 → Fan low speed control relay output
A3 --- Airflow sensor earth
A4 --- Turbocharger pressure sensor earth
B3 --- Diesel fuel pressure sensor earth
B4 → Fan high speed control relay output
C1 --- Camshaft sensor earth
E4 → Thermoplunger control relay 3 output
(1 thermoplunger)
J4 → Thermoplunger control relay 1 output
(1 thermoplunger)
K4 ← Camshaft position sensor signal
L1 → Injector command 4
L2 --- Injector 3 feed
L3 --- Injector 2 feed
L4 → Injector command 2
M1 → Injector command 1
M2 → Injector command 3
M3 --- Injector 1 feed
M4 --- Injector 4 feed

13-50
114
ANTI-POLLUTION
F9Q engine
Oil vapour rebreathing 14
CIRCUIT DIAGRAM

DI1322

13042R A Oil vapour rebreathing pipe for the bottom of engine

1 Engine B Oil vapour rebreathing pipe for the top of engine.


2 Oil separator
3 Air filter unit C Oil separator.
4 Inlet manifold
D Oil vapour rebreathing pipe linked to the intake
pipes.
CHECKING

To ensure the correct operation of the anti-pollution


system, the oil vapour rebreathing circuit must be kept
clean and in good condition.

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

REMOVING THE VALVE

The EGR valve is press-fitted into the intake manifold.

To facilitate its replacement it is preferable to remove the manifolds.

PURPOSE OF THE EGR SYSTEM

Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content
of the exhaust gases.

The injection computer authorises gas to pass by controlling a solenoid valve.

14-2
ANTI-POLLUTION
F9Q engine
Exhaust gas recirculation 14
OPERATING PRINCIPLE

The valve is controlled by an Opening Cyclic Ratio


(RCO) signal sent by the injection computer. The RCO
signal modulates the opening of the valve and
consequently the quantity of exhaust gas directed
back to the inlet manifold.

OPERATING CONDITIONS

The parameters which control the activation of the


EGR (Exhaust Gas Recirculation) solenoid valve are:
– coolant temperature,
– air temperature,
– atmospheric pressure,
– accelerator pedal position,
– engine speed, DI1421
– air flow,
– injection flow rate,
– turbocharging pressure. If there is a fault in:
– the coolant temperature sensor,
The EGR function is cut off if: – the air temperature sensor,
– the battery voltage is less than 9 volts, – the atmospheric pressure sensor.
– engine speed is below 600 rpm. The EGR solenoid valve is fed for 40 seconds on each
– engine speed is greater than 3000 rpm. return to idle speed if the air temperature is greater than
– mapping (engine speed/load) exceeds a given 15ºC.
threshold,
– vehicle speed is less than 12 kph, and engine speed
is less than 1000 rpm
– after running for 18 minutes if the air temperature
stays between 10 °C and 30 °C.

The EGR valve is not controlled after engine start-up


depending on coolant temperature mapping.

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

Connect a voltmeter across the battery terminals and


FAULT FINDING read the battery 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

Vehicle type Engine Alternator Current

XL0B Valéo SG 10B 050


F9Q 760 125 A
XL0C Valéo SG 12B 017

CHECKING

After 15 minutes warming up at a voltage of 13.5 volts.

Rpm 125 Amps

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).

Measurement is carried out in three stages:


– measurement of the battery voltage, ignition off,
– measurement of the regulated voltage and the output current, without consumers,
– measurement of the regulated voltage and output current, with a maximum number of consumers.

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 too low, check:


– alternator wear (brushes, etc.),
– battery connections,
– engine earth strap,
– correctness of the alternator,
– belt tension.

If the measured output is correct but the regulated voltage is too low, the alternator is not faulty.

The cause of the problem is to be attributed to one of the following sources:


– the vehicle has too many electrical power consumers,
– the battery is discharged.

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.

Disconnect the battery.

NOTE: because the battery is located under the left-


hand seat, the carpet must be unclipped and removed,
then the battery cover (A) can be removed by undoing
the screws.

– alternator from above the vehicle.

Remove:
– engine undertray and the left-hand side protection.
– radiator air deflector,
– accessories belt (see Section 07 Accessories belt
tension),
– pulley.

Disconnect the alternator's electrical connections and


those of the air conditioning compressor (if fitted).

16-4
STARTING - CHARGING
Alternator 16
REFITTING

To facilitate the installation of the alternator, compress


the rings (A).

Refer to Section 07 Accessories belt tension for the


tensioning procedure.

16-5
STARTING - CHARGING
Starter 16
IDENTIFICATION

Vehicle type Engine Starter

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.

Disconnect the battery.

NOTE: because the battery is located under the left-


hand seat, the carpet must be unclipped and removed,
then the battery cover (A) can be removed by undoing
the screws.

– starter electrical connections,


– starter mountings,
– starter motor.

REFITTING

Proceed in the reverse order to removal.

Remove: Check for the presence of the centring dowel when


– the engine undertray, refitting.

16-7
119
COOLING SYSTEM
Specifications 19
VOLUME AND GRADE OF COOLANT

Engine Volume (in litres) Grade Special notes

Protection down to - 20 ± 2°C for


GLACEOL RX (type D) temperate and cold countries.
F9Q 760 6.4
only use coolant liquid Protection down to - 37 ± 2°C for very
cold countries.

THERMOSTAT

Engine type Starts to open at (°C) Fully open at (°C) Travel (mm)

F9Q 760 89 101 7.5

19-1
COOLING SYSTEM
Filling and bleeding 19
FILLING

It is essential to open the bleed screws on the


cylinder head coolant pipe housing outlet.

Fill the circuit through the expansion bottle opening.

Close the bleed screws as soon as the liquid starts to


flow in a continuous stream.

Start the engine (2 500 rpm).

Adjust the level by overflow for a period of about


4 minutes.

Close the bottle.

BLEEDING

Allow the engine to run for about 20 minutes at


2500 rpm, until the engine cooling fan starts up (time
necessary for automatic degassing).

Verify that the liquid level is at or near the Maximum


marker.

NEVER OPEN THE BLEED SCREW WHEN THE


ENGINE IS RUNNING.

RE-TIGHTEN THE EXPANSION BOTTLE CAP


WHILE THE ENGINE IS WARM.

19-2
COOLING SYSTEM
Check 19
SPECIAL TOOLING REQUIRED

M.S. 554-01 Adapter for M.S. 554-07


M.S. 554-06 Adapter for M.S. 554-07
M.S. 554-07 Kit for testing cooling circuit
sealing

1 - Testing the sealing of the circuit 2 - Checking the valve rating.

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.

Stop pumping at 0.1 bar less than the valve is rated.


Valve rating value:
The pressure should not drop; if it does, look for the
leak.
Valve rating
Engines Colour of valve
Slowly unscrew the union of tool M.S. 554-07 to (in bar)
decompress the cooling circuit, then remove tool
M.S. 554-01 and refit the expansion bottle valve with a All types Brown 1.2
new seal.

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

The expansion bottle valve rating is 1.2 bar (colour brown).

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

Put the car on a two-post lift.

Disconnect the battery.

Remove the engine undertray.

Drain the cooling circuit through the lower radiator


hose.

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").

Fill and bleed the cooling circuit (see section 19


"Filling and bleeding").

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

* Order of tightening: tighten bolt (1) then (2) and (3).

19-6

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