N.T.

3303A XB0J - XC0J

Special features of the F8Q 632 engine fitted with the Lucas Epic injection pump
The cleanliness rules must be observed for all operations on this vehicle.

For information not contained in this Technical Note, refer to MR 325 and 337.

77 11 206 456

SEPTEMBER 1999
All copyrights reserved by Renault.

Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed."

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

C RENAULT 1999

Contents
Page Page

11 TOP AND FRONT OF ENGINE
Timing belt 11-1

14 ANTIPOLLUTION
Oil vapour rebreathing Exhaust gas recirculation(EGR) 14-1 14-2

12 FUEL MIXTURE
Inlet/exhaust manifolds 12-1

13 DIESEL EQUIPMENT
Specifications Special features Cleanliness Location of components Operation Injection warning light Immobiliser function Injection/air conditioning programming Idle speed correction Pre-postheating control Injectors Negative flow solenoid valve and electrical solenoid Positive flow solenoid valve and advance solenoid valve Pump connector Injection pump Pump - Timing Accelerator potentiometer Centralised coolant temperature management Computer Wiring diagram Key 13-1 13-3 13-5 13-7 13-9 13-10 13-11 13-12 13-14 13-15 13-17 13-18 13-20 13-22 13-24 13-27 13-29 13-30 13-31 13-32 13-34

TOP AND FRONT OF ENGINE Timing belt
The method for removing - refitting the timing belt remains unchanged (refer to NT 2701A features for HTD2 belts) except for the procedure for timing the injection pump, for which the method described in section 13 "Pump-Timing" MUST be followed. In contrast to existing pumps, the LUCAS EPIC pump requires a complete timing operation, after setting the tension of the new timing belt.

11

11-1

FUEL MIXTURE Inlet/exhaust manifolds
TIGHTENING TORQUES (in daN.m)

12
2.7

Manifold mounting nut

REMOVING THE INLET AND EXHAUST MANIFOLDS

Put the vehicle on a two post lift and disconnect the battery. Remove the cover from the air filter unit (1). From below, remove the mounting bolts (2) for the air filter unit.

15826R1

12-1

. 12 PRO12.from above for nuts (A). NOTE : the nuts (B) may be refitted with their was- hers before the exhaust manifold is refitted. 12-2 .from below for nuts (B). Remove the diesel fuel supply pipe mounting on the timing cover.3 REFITTING Observe the correct tightening torques for the nuts. Remember to replace and correctly position the seals (3) and (4) (see previous page).FUEL MIXTURE Inlet/exhaust manifolds Remove the clip mounting the exhaust gas recirculation pipe. remove the nuts (C) mounting the exhaust manifold. Remove the nuts mounting the inlet manifold : . From above. Release the exhaust downpipe and attach it to the engine sub-frame.

Resistance : 31 ± 2 Ω Resistance : 31 ± 2 Ω Resistance : 31 ± 2 Ω Resistance : 1.5/1 ◊ C101 or EURO 96 ENGINE SPEED (rpm) SMOKE OPACITY Idle speed 825 ± 50 Max.m Injector holder tightening on cylinder head: 7 daN.an advance solenoid valve.0 m-1 (33 %) Legal maximum 2. with load 4600 ± 100 Homologation value 1. .027 Electronic rotary pump with: .C.a flow valve position sensor (cannot be removed).5 m-1 (64 %) DESCRIPTION MAKE/TYPE SPECIAL NOTES Injection pump LUCAS DIESEL E. no load 5175 ± 50 Max.I. Timing using pin Mot. . Diesel Control Unit . .1 Ω Resistance : 52 ± 4 Ω Resistance : 41 ± 4 Ω Integral in pump Resistance : 2716 ± 60 Ω at 20°C D.39 ± 0.m Pump timing Positive flow solenoid valve Negative flow solenoid valve Advance solenoid valve Electrical solenoid Advance cam position sensor Flow valve position sensor Pump temperature thermistor Injection computer Injectors Injector holders LUCAS RDNOSDC 6751H LUCAS LCR 67354 13-1 .P.DIESEL EQUIPMENT Specifications 13 Ratio Catalytic converter Depollution standard Engine Vehicles Gearbox Type Suffix Bore (mm) Stroke (mm) Capacity (cm 3) XB0J XC0J ◊ C55 JB1 F8Q 632 80 93 1870 21.C. 1520 on the pump. .90 track Rating: 125 to 140 bars Injector holder tightening: 7 daN.U.a positive flow solenoid valve. . R8640 A111A H111.an electrical solenoid.an advance valve position sensor (cannot be removed).a negative flow solenoid valve.

m Dual track potentiometer Resistance ≈ 760 Ω at 20°C Integral in computer Electrical valve with integral flap and position sensor Valve resistance: 8 ± 0.5 mm Length: 300 mm With pre-postheating function (operation controlled by computer) Resistance : 0.6 Ω Tightness: 2 daN.10 10 454 to 8 623 13 588 to 11 332 25 2 175 to 1 928 2 364 to 2 140 50 857 to 763 850 to 773 80 325 to 292 290 to 275 13-2 .5 Ω at 20 °C Sensor resistance: 4 KΩ at 20 °C Fault finding tool Pre-postheating unit Heater plugs Accelerator potentiometer Engine speed sensor Absolute pressure sensor EGR valve Fault finding BERU CTS MGI PIERBURG - Temperature in °C (± 1°) Air temperature sensor (Resistance in Ohms) Coolant temperature sensor (Resistance in Ohms) .DIESEL EQUIPMENT Specifications 13 SPECIAL NOTES DESCRIPTION MAKE/TYPE Return pipes NAGARES BRE/6-12 External diameter : 6 mm Internal diameter : 2.

The positive flow solenoid valve and the advance solenoid valve cannot be separated.An advance valve position sensor (cannot be removed) (F). controls the solenoid valves. . This controls calculation of the advance and the flow. .P. The two sensors for the position of the advance valve and the flow valve cannot be separated as it is vital that their positions are memorised in the computer and in the injection pump.A flow valve position sensor (cannot be removed) (E).C. The following are located on the pump . then depending on the result of these calculations.DIESEL EQUIPMENT Special features 13 The E. .A diesel fuel temperature sensor (cannot be removed. located in the pump body). pump (Electronically Programmed Injection Control) is a completely electronic distributor type injection pump.I.An electrical solenoid (D).A positive flow solenoid valve (B). They are located on the lower section of the pump. They are located on the upper part of the pump. . The negative flow solenoid valve and the electrical solenoid cannot be separated.A negative flow solenoid valve (C). . This operation can only be carried out on an injection test bench. Before and during each operation on the EPIC system. The EPIC pump is associated with an injection computer known as the DCU (Diesel Control Unit). the cleanliness rules must be observed. . It also controls the EGR. 15821R 13-3 .An advance solenoid valve (A).

it may take 1 or 2 seconds for the engine to stop. start the engine and run it at idle speed to check there are no leaks of diesel fuel. return unions and high pressure outlets must be fitted with new plugs of a suitable size to prevent the introduction of impurities. IMPORTANT : The engine should not be operated with diesel fuel containing more than 10 % diester (modified vegetable oils). When repairing or removing the injection pump. the fuel supply unions. After switching off the ignition. 13-4 .DIESEL EQUIPMENT Special features CHECKING AFTER REPAIR 13 After each operation.

damage to or destruction of the EPIC system. • clothing.etc. and must be discarded after use. . After use they must be discarded (once used. It is prohibited to use cloths or conventional paper for cleaning.) Plugs which are not used must also be discarded.. causing problems with the electrical connection. IMPORTANT: Do not clean the engine using a high pressure cleaner as there is a risk of damaging the connec- tions. • Ensure that plastic bags are available which can be hermetically re-sealed several times. These materials leave lint which could contaminate the system’s fuel circuit.the ambient air. The plugs may only be used once. . • Ensure that lint-free wipes are available (the wipes have a SODICAM part number). . There is less risk of parts becoming contaminated if they are stored in this manner. for storing the parts which have been removed. All after sales operations must be carried out under good conditions of cleanliness. .foreign bodies such as hairs. Each wipe may only be used once. The bags may only be used once. • brushes.fibres from: • card. In addition. • paper. the plugs are dirtied. . The risks involved in the introduction of contamination are: . The cleanliness rules must be applied from the filter to the high pressure circuit components.. damp could stagnate in the connector. • cloths. WHAT CAUSES CONTAMINATION? The following cause contamination: . RULES TO BE OBSERVED BEFORE ANY OPERATION ON THE INJECTION SYSTEM • Ensure that plugs are available for the unions to be opened (the Parts Department sells a bag of plugs).seizure or leakage of a component. Cleaning is not sufficient to allow them to be re-used.paint. . 13-5 . Carrying out an operation under good conditions of cleanliness means that no impurity (particle of several microns in size) has penetrated the system during its removal or has penetrated the circuits via the fuel unions.DIESEL EQUIPMENT Cleanliness CLEANLINESS RULES WHICH MUST BE OBSERVED FOR OPERATIONS ON THE EPIC SYSTEM 13 Risks of contamination The EPIC system is very sensitive to contamination.metal or plastic swarf.

• Use the brush and the thinners to clean the parts to be removed. The plugs to be used are available from the Parts Department. only take the new component out of its packaging when its is ready to be fitted on to the vehicle. even if it is to be opened again shortly afterwards. blower. • Blow compressed air over the parts to be cleaned (tools. • For each operation use a clean brush which is in good condition (the brush must not lose hairs).DIESEL EQUIPMENT Cleanliness RULES TO BE OBSERVED BEFORE ANY OPERATION ON THE INJECTION SYSTEM 13 • For each operation use new thinners (used thinners contains impurities). The ambient air carries contamination. They must never be re-used. • All components of the injection system must be plugged and stored in an hermetically sealed plastic bag once removed. • After opening the circuit. • When using protective gloves. cover leather gloves with latex ones. • Hermetically seal the plastic bag. unions and injection system area). • If a component is being renewed. the tools to be used and the part of the workbench to be used. 13-6 . plug the openings to prevent contamination entering. workbench and the parts. RULES TO BE OBSERVED DURING THE OPERATION • As soon as the circuit is opened. or conventional cloth. scraper. These may cause contamination to enter the system. thinners. it is prohibited to use a brush. Pour it into an impurity-free container. • Wash your hands before and if necessary during the operation.

DIESEL EQUIPMENT Location of components 13 Photo 16 623 1 2 3 4 5 6 7 8 9 10 11 12 Air filter Inlet air temperature sensor EGR valve Accelerator pedal position potentiometer D.U. computer Feed relay Preheating unit Fuel filter Engine speed sensor and coolant temperature sensor Negative flow solenoid valve and electrical solenoid Positive flow and advance solenoid valves EPIC injection pump 13-7 .C.

DIESEL EQUIPMENT Location of components 13 15821R1 2 4 5 6 7 Positive flow and advance solenoid valves Inlet air temperature sensor EGR valve Pre-postheating unit Accelerator pedal position potentiometer 10 11 12 14 TDC sensor Coolant temperature sensor Negative flow solenoid valve and electrical solenoid Injection pump pin opening 15759R 15763R2 13-8 .

This function. the injection computer determines the position of this cam ring while modifying the start of movement of the piston plungers. the computer controls the closure of the electrical solenoid then checks the change in engine speed. Starting While the engine is starting. it generates the control signals for the various solenoid valves.positive and negative flow solenoid valves operation. the computer operates the negative flow solenoid valve. For major accelerations and decelerations. The results obtained are continuously monitored. The position sensor for this cam ring permanently informs the computer of the position of the start of injection. The stroke of the piston plungers determines the amount of diesel injected to each cylinder. 13-9 . . The engine operates in the various states below: Pre-starting When the ignition is turned on until the engine starts. The EPIC injection pump is a rotary distributor type pump based on the DPC injection pump principle. .advance solenoid valve operation.advance piston minimum stop position. the flow is adjusted or cut depending on the mapping. Depending on this information and the mapping values memorised. which is identical to the DPC pump. Using the advance solenoid valve. Normal operation The flow is modified by the computer using the positive and negative flow solenoid valves. . uses piston plungers driven by rollers in contact with a cam ring.rotor maximum stop position. the system carries out a series of checks: . which is identical to that for the DPC injection pump. is carried out by a piston which has a circular movement. Two solenoid valves called the positive flow and negative flow solenoid valves allow this stroke to be modified and therefore the flow of diesel injected to be modified. The rotor position sensor (or flow valve) permanently informs the computer of the amount of diesel injected. allowing corrective action to be taken. The diesel fuel is then sent to the distribution section of the pump which determines the cylinder to be supplied. the rotor moves to the position indicated and the electrical solenoid is controlled. The diesel fuel is taken up by the supply pump and regulated in the pump body to a pressure called the transfer pressure. Stopping the engine When the driver switches off the ignition.DIESEL EQUIPMENT Operation 13 The DCU computer permanently monitors the parameters from the system sensors. If the engine speed does not drop. The pressure generation principle. The precisely machined cam ring determines the start and duration of the injection phase.

. If a fault is present from when the ignition is switched on.pump internal memory. the injection warning light illuminates during the preheating phase then extinguishes. . the warning light illuminates for a few seconds during the preheating phase then extinguishes for a short moment before illuminating again to indicate the fault. the warning light illuminates.if there is a fault in the injection system.positive flow solenoid valve.cam position sensor.feed to the computer or the injection pump.computer. .engine speed sensor. . .when the ignition is switched on. 13-10 . .DIESEL EQUIPMENT Injection warning light PRINCIPLE OF ILLUMINATION OF THE INJECTION WARNING LIGHT 13 A single warning light on the instrument panel is used for the two operations below: . .accelerator pedal position potentiometer. Components which may illuminate the injection warning light if they are faulty: . . .negative flow solenoid valve.electrical solenoid.

so that it will operate. then a check made to ensure that the immobiliser is operating correctly. 325 and 337. refer to section 82 of M.DIESEL EQUIPMENT Immobiliser function 13 This vehicle is fitted with a 2nd generation immobiliser. TESTING AN UNCODED INJECTION COMPUTER FROM STORES (this operation is NOT recommended) IMPORTANT: before testing an injection computer. it must have been programmed with the immobiliser code for the vehicle.R. IT IS IMPOSSIBLE TO BORROW A CODED COMPUTER FROM ANOTHER VEHICLE TO CARRY OUT A TEST. REPLACING AN INJECTION COMPUTER Injection computers are supplied uncoded. 13-11 . the computer MUST be decoded before being returned to stores. To do this. 325 or 337. the computer will not be able to be used again. To decode the computer. switch on the ignition for a few seconds then switch it off again. after 10 seconds the red immobiliser warning light should flash (to check that it is impossible to start the engine. the code for the vehicle must be programmed in. This operation must be carried out by personnel who have received adequate training. If an injection computer is to be replaced. The injection computer MUST have been programmed with the immobiliser code to operate. refer to section 82 of M. If this is not done.R. After the test. CHECKING OPERATION OF THE IMMOBILISER Remove the ignition key.

. It is possible to display the power absorbed using the fault finding tool. the idle speed is modified to a maximum of 875 rpm. The injection computer and the AC computer are connected by two wires: . IMPORTANT: the power absorbed is never 0. With the AC operating.DIESEL EQUIPMENT Injection/air conditioning programming INJECTION COMPUTER/AC COMPUTER CONNECTION 13 The compressor is of the variable capacity type. When the AC function is selected. 13-12 .Power absorbed information (track 47). The minimum value read is approximately 250 Watts. when the power absorbed by the compressor is 500 Watts.The connection from the injection computer to the air conditioning computer (track 55). operating or not. This wire transmits information on the authorisation or prevention of compressor operation. This informs the injection computer of the power absorbed by the compressor. the value should be between 250 and 5000 Watts. regardless of the status of the compressor.

compressor operation is cut. It is started again after a few seconds if conditions allow. Return of performance If there is a major change in the position of the accelerator pedal (difference in potentiometer information greater than 32 %) and if the engine speed is less than 2000 rpm.DIESEL EQUIPMENT Injection/air conditioning programming COMPRESSOR OPERATION PROGRAMMING 13 In certain phases of operation. Protective programming at maximum engine speed Compressor operation is prevented if the engine speed is greater than 4700 rpm. compressor operation is prevented for a few seconds. compressor operation is cut. Return of power when the vehicle moves If the potentiometer position is less than 30 % and if the engine speed is less than 1000 rpm. Engine starting phase Compressor operation is prevented after the engine has been started for 5 seconds . It is started again after 4 seconds if the engine speed increases. 13-13 . Thermal protection programming Compressor operation is prevented if the coolant temperature is greater than 105 °C. Anti-stalling protection If the no load position is not recognised and if the engine speed is less than 500 rpm. the injection computer prevents the operation of the compressor.

the idle speed is set to 850 rpm. Correction of the speed is therefore variable. In both cases. 13-14 . the greater the correction made. IDLE SPEED CORRECTION DEPENDING ON GEAR SELECTION The idle speed is modified according to the gear engaged in the gearbox : . pressing the brake pedal allows the idle speed to return to normal (information from the stop switch).in 2nd gear. the idle speed is held at 1000 rpm.in 1st gear.DIESEL EQUIPMENT Idle speed correction IDLE SPEED CORRECTION DEPENDING ON COOLANT TEMPERATURE 13 The idle speed is increased and may reach 900 rpm for a coolant temperature of . IDLE SPEED CORRECTION DEPENDING ON HEATED WINDSCREEN INFORMATION If the heated windscreen is selected at the instrument panel. the idle speed is held at 1300 rpm. It begins when the voltage drops below approximately 12 Volts. . the idle speed is set to 875 rpm. The lower the battery voltage. the idle speed is set to 900 rpm. To do this. allowing the alternator to rotate more. If both of the accelerator pedal potentiometer tracks are faulty. CORRECTION DEPENDING ON ELECTRICAL BALANCE This correction aims to compensate for the drop in voltage due to the operation of consumers when the battery charge is low.for the other gears. the idle speed is set to 925 rpm.23 °C. The idle speed may reach a maximum of 900 rpm. the computer receives + 12 Volts information on track 18. . The idle speed is increased to 1000 rpm. IDLE SPEED CORRECTION IN THE EVENT OF A POTENTIOMETER FAULT If one of the accelerator pedal potentiometer tracks is faulty. and consequently increasing the battery voltage. If the information from the accelerator pedal position potentiometer is incoherent with the information from the stop switch. the idle speed is increased.

time (s) For a given idle speed with no action at the accelerator pedal 180 15876-1S .DIESEL EQUIPMENT Pre-postheating control The pre-postheating function is controlled by the preheating unit. b) Fixed preheating After the warning light has extinguished. 1) Ignition .Postheating In this phase the plugs are fed continuously depending on the coolant temperature and the position of the flow valve. 13 PRINCIPLE OF PRE-POSTHEATING OPERATION 2) Starting The plugs are fed while the starter motor is operating. 13-15 .20 0 20 40 60 Coolant temperature °C In all cases the injection warning light will not be illuminated for longer than 15 seconds. the plugs remain fed for a fixed period of 15 seconds .Preheating a) Variable preheating The time that the warning light is illuminated and the heater plugs are fed depends on the coolant temperature and the atmospheric pressure. 3) Engine running .

the plugs are fed for a a period calculated depending on the air temperature.DIESEL EQUIPMENT Pre-postheating control If the coolant temperature sensor is faulty. 13 15762S In all cases the plugs may not be fed for longer than 180 seconds. 13-16 .

.the pipes to the correct torque.5 Replace the flame arresting washer and the seals under the injectors. REMOVING THE INJECTORS THE CLEANLINESS RULES MUST BE STRICTLY OBSERVED Tighten : . .the injectors to the correct torque.the high pressure pipes. Hand tighten the two nuts for each pipe.the injectors. Take care to prevent diesel spraying on electrical equipment which could cause an operating fault. Disconnect the battery.DIESEL EQUIPMENT Injectors REFITTING 13 TIGHTENING TORQUES (in daN. The supply opening and the injector head must be plugged. Remove: . DI1323 13-17 .m) Injector holder on cylinder head High pressure pipe nuts 7 2.the injectors. . Fit: .the pipes. Run the engine at idle speed to check there are no leaks.

They are: . Remove the three seals. 15824S 15822S 13-18 . Wipe the solenoid valve sealing faces with lintfree wipes. Remove the bolts mounting the electrical connector to the connector mounting. Do not use a blower.5 ± 0. . Do not clean the sealing faces on the pump or on the solenoid valves with detergents.DIESEL EQUIPMENT Negative flow solenoid valve and electrical solenoid 13 TIGHTENING TORQUES It is vital to note the position of these wires in the connector. Solenoid valve mounting bolt High pressure pipe nut 6± 0.the electrical connector for the pump.the battery. THE CLEANLINESS RULES MUST BE STRICTLY OBSERVED Disconnect: .6 2. Remove the solenoid valve unit and the plastic mounting ( IMPORTANT: the electrical solenoid core is not attached to the solenoid valve.2 REMOVAL OF THE NEGATIVE FLOW SOLENOID VALVE AND THE ELECTRICAL SOLENOID The solenoid valves on the lower part of the EPIC injection pump cannot be replaced separately. . remove the wires for the negative flow solenoid valve and the electrical solenoid (red/white and blue/white) (see section 13 "Pump connector"). In the connector.m Slacken the four bolts holding the solenoid valve unit and the solenoid valve mounting.the electrical solenoid. beginning with the outer bolts. ENSURE CLEANLINESS IS MAINTAINED.the negative flow solenoid valve. it is also fitted behind a spring). Nm daN.

Torque tighten the four bolts. holding them in place by hand (do not let the seals. dampen them with a little diesel fuel. Fit the new seals on the pump body. take care to order a part with identical markings/references. Do not fit them on the solenoid valves. 13-19 . Hand tighten the two other mounting bolts for the solenoid valves. NOTE : the core of the electrical solenoid is matched to the body. Refitting is then the reverse of removal. in order to bring the solenoid valves up against the pump body. To hold them in position. then refit the remainder of the connector) (see section 13 "Pump connector"). the core or the spring fall from the electrical solenoid). Run the engine at idle speed to check there are no leaks. Position the solenoid valves and the mounting opposite their position. If it is replaced. Simultaneously screw in but do not tighten the two inner mounting bolts.DIESEL EQUIPMENT Negative flow solenoid valve and electrical solenoid 13 REFITTING Renew the old seals. Take care when refitting not to damage the terminals and the connector (first fit the terminals into the clip holder in order to ensure they are correctly clipped in.

Remove the bolts mounting the electrical connector to the connector mounting. Remove the solenoid valve unit and remove the four seals.the electrical connector for the pump. . .the battery. remove the four terminals for the two solenoid valves (see section 13 "Pump connector"). They are: .DIESEL EQUIPMENT Positive flow solenoid valve and advance solenoid valve 13 15823S TIGHTENING TORQUES (in Nm) Solenoid valve mounting bolt 6± 0. In the connector.6 Disconnect: . ENSURE CLEANLINESS IS MAINTAINED. Note their position in the connector.the positive flow solenoid valve.the advance solenoid valve. REMOVAL OF THE POSITIVE FLOW SOLENOID VALVE AND THE ADVANCE SOLENOID VALVE The solenoid valves on the upper part of the EPIC injection pump cannot be replaced separately. Slacken the four bolts holding the solenoid valve unit beginning with the outer bolts. THE CLEANLINESS RULES MUST BE STRICTLY OBSERVED 13-20 .

Do not clean the sealing faces on the pump or on the solenoid valves with detergents. Position the solenoid valve unit and tighten the inner bolts. 13-21 . Do not fit them on the solenoid valves. Hand tighten the four mounting bolts for the solenoid valves then torque tighten them. Take care when refitting not to damage the terminals and the connector (first fit the terminals into the clip holder in order to ensure they are correctly clipped in. Run the engine at idle speed to check there are no leaks. Fit the new seals on the pump body. Do not use a blower. then refit the remainder of the connector) (see section 13 "Pump connector"). then the outer ones. Refitting is then the reverse of removal. REFITTING Renew all the old seals.DIESEL EQUIPMENT Positive flow solenoid valve and advance solenoid valve 13 Wipe the solenoid valve sealing faces with lintfree wipes.

15825R 13-22 . .the comb(B).DIESEL EQUIPMENT Pump connector 13 SPECIAL TOOLING REQUIRED Elé. .the comb (B). .the clip holder (D). . 1044-01 and simultaneously pulling on the wire to be removed. . Refit: .the terminals (E) unlocking the tabs using tool Elé.the white wiring retaining clip (C).the black connector holder (A).the white wiring retaining clip (C). To remove the connector.the clip holder (D). . remove the following components in order: . Gently pull it to lock the tabs. 1044 -01 Tool for removing the connector clips REMOVAL OF THE INJECTION PUMP CONNECTOR THE CLEANLINESS RULES MUST BE STRICTLY OBSERVED REFITTING Push on the wire to be clipped in. Reposition the assembly in the black connector holder (A).

DIESEL EQUIPMENT Pump connector TERMINAL IDENTIFICATION 13 15820R Marking on pump side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 - Marking wiring side 13 4 11 10 9 8 7 6 5 Computer marking 13 + AVC 30 14 12 51 67 36 60 Allocation Advance valve position sensor signal Flow valve position sensor trigger Advance valve position sensor trigger Electrical solenoid control Flow valve position sensor signal Flow valve position sensor compensation Pump memory connection Pump memory and diesel temperature common wire Diesel temperature in the pump Positive flow solenoid valve control Positive flow solenoid valve feed Electrical solenoid feed Colour Green Red Red White-Red Yellow White Orange Blue Brown White-Black White-Black White-Red White-Green White-Blue White-Green White-Blue - 4 + AVC Advance solenoid valve feed Negative flow solenoid valve feed 3 2 1 89 90 9 Advance solenoid valve control Negative flow solenoid valve control Screening 13-23 .

. the methods for removing/refitting the fitting described above.DIESEL EQUIPMENT Injection pump REPLACEMENT OF THE REAR FITTING 13 TIGHTENING TORQUES (in daN. Torque tighten : . Wipe off the diesel residue using lint-free wipes. Position the rear fitting and hand tighten the bolts. located behind the drive pulley. Replace the seal. Remove the closure plate mounting bolts (P).3 IMPORTANT: if this method is not observed. there is a major risk of stressing the hydraulic head.the pump bolts.55 ± 0.2 ± 0.05 2.m) Closure plate Rear fitting 0. 15822R 13-24 . REFITTING Fit the pump mounting bolts. 12569S REMOVAL Remove the rear fitting before slackening the mounting bolts for the pump. Reposition the closure plate and torque tighten the bolts. REPLACEMENT OF THE CLOSURE PLATE SEAL NOTE: when replacing a cylinder head.the rear fitting bolts. observe THE CLEANLINESS RULES MUST BE STRICTLY OBSERVED. Disconnect the battery.

Disconnect the pump electrical connector. 1200-01 to retain the pump pulley. 1200-01 1054 1520 1522 1525 Pulley retaining tool TDC pin Injection pump setting pin Pump setting wheel Pulley extractor TIGHTENING TORQUES (in daN.m) Injector pipe nut Rear fitting bolt Pump mounting bolt Pulley nut 2. Mot. REMOVAL OF THE INJECTION PUMP Fit tool Mot. Mot. Disconnect the battery.6 0. 1054.5 Remove: .5 ± 0.5 ± 5. Mot. Pin the engine at TDC using tool Mot.the high pressure pipes.2 ± 2.3 0. . . 15872R 12419R 13-25 . .the pump pulley housing. Slacken the pulley mounting nut.the diesel supply and return pipes. THE CLEANLINESS RULES MUST BE STRICTLY OBSERVED.the pump rear fitting.5 ± 2.3 0. Fit plugs to all the pipes and outlets which have been disconnected.DIESEL EQUIPMENT Injection pump 13 SPECIAL TOOLING REQUIRED Mot. Mot.

REFITTING 13 Renew the O ring on the pump drive shaft.DIESEL EQUIPMENT Injection pump Fit tool Mot. Position the pump setting pin by turning the shaft using the wheel Mot. Slacken the three pump mounting bolts (fit the tool between the pulley spokes). Hand tighten the two nuts then torque tighten them. Fit the high pressure diesel pipes. 13-26 . Position then hand tighten the rear fitting bolts. IMPORTANT: the tightening of the pump support is important. NOTE : there is a flat to prevent tool Mot. Hand tighten all the bolts then torque tighten them. Fit then hand tighten the three pump mounting bolts on the accessories mounting. IMPORTANT : it is vital to keep tool Mot. IMPORTANT: remember the TDC pin and the pump setting tool. 1525 from turning. 1522 (see section 13 "Pump timing" ). Place the pump in a sealed bag if it is to remain removed. Torque tighten the pump mounting bolts then those of the rear fitting. 1525 for extracting the pulley then release the pulley from the pump shaft. Remove the injection pump by slackening the mounting bolts. Run the engine at idle speed to check there are no leaks. Refit the injection pump. Follow the procedure for setting the EPIC pump (see section 13 "Pump timing"). 1520 clean and in good condition.

1054. 1525. Bring the engine to the timing mark using the pin Mot. IMPORTANT: never turn the engine in the oppo- site direction to normal operation.5 PROCEDURE FOR SETTING THE INJECTION PUMP Checking the timing requires a complete timing operation. 1200-01 1054 1520 1522 1525 Pulley retaining tool TDC pin Injection pump setting pin Pump setting wheel Pulley extractor TIGHTENING TORQUES Slacken the pump drive shaft nut.Timing 13 SPECIAL TOOLING REQUIRED Mot. daN. Mot. 1200-01. Pump nut Plug for pump pin 5.5 ± 0. Mot. Mot. 15872R NOTE : a flat is provided to prevent tool Mot.m 5 Nm Release the pump from the pulley using the pulley extractor tool Mot. Move the diesel filter to one side and remove the injection pump pulley housing.DIESEL EQUIPMENT Pump . 1525 from turning. 12419R 13-27 . Position the injection pump pulley retaining tool Mot. Mot.

1200-01.DIESEL EQUIPMENT Pump . Protect any sensitive parts. 15871R1 Position a container under the pump to collect the diesel fuel. Remove tool Mot. the pump must be returned to an injection test bench. Remove the tool Mot. Turn the pump in its direction of rotation using the wheel to bring the pump to the setting point (look into the timing opening for the position of the groove). IMPORTANT : it is vital to keep tool Mot. Refit the sprocket housing and reposition the diesel fuel filter. In this position. tighten the drive shaft nut on the pump to immobiliser the sprocket. IMPORTANT: take care since there will be a large amount of fuel in the unions and the injection pump. If either of these bolts is slackened. In this position. 13 Gently tighten tool Mot. IMPORTANT: do not alter the position of bolts (A). the pin will immobilise the pump. 1520 to find the point where the setting pin goes into the pump by the greatest amount. 1520 clean and in good condition.Timing Fit the adjusting wheel Mot. 1054 from the engine and tool Mot. IMPORTANT: remember to remove the TDC pin and the injection pump setting pin. Remove the setting plug on the pump. Let the engine run at idle speed to check there are no leaks and that engine operation is correct. 1520 from the injection pump. 13-28 . 1522 at the end of the pump drive shaft. Refit the plugs for the timing opening.

7 ± 0. 13-29 .5 KΩ 15760S NOTE : a fault in one of the two accelerator pedal position potentiometer tracks will cause a modification to the idle speed or engine operation (see section 13 "Idle speed correction" ). 15759R1 Track resistance : 1.DIESEL EQUIPMENT Accelerator potentiometer Track allocation: 1 Signal from track 2 2 Signal from track 1 3 5 V feed for track 2 4 Earth for track 1 5 Earth for track 2 6 5 V feed for track 1 REMOVAL OF THE POTENTIOMETER 13 Remove the unit from under the master cylinder. The repair must be validated using the fault finding tool. REFITTING Refitting is the reverse of removal. Unhook the accelerator cable from the unit. The potentiometer is supplied by the Parts Department with the unit.

2 for coolant temperature information and 1 for instrument panel indication. This warning light is controlled by the DCU computer. For vehicles not fitted with AC. • the fan assembly may be operated for the AC. . the fan. COOLANT TEMPERATURE WARNING LIGHT This system allows control of the engine cooling fan by the injection computer.the injection system. the coolant temperature indication and the temperature warning light on the instrument panel. only the slow fan speed is operational. • the cooling fan is operated at high speed if the coolant temperature exceeds 102 °C and is stopped when the temperature drops below 99 °C.the injection computer to be informed of the engine coolant temperature. 13-30 .G.the fan relays: • the cooling fan is operated at slow speed if the coolant temperature exceeds 99 °C and is stopped when the temperature drops below 96 °C. the injection computer manages: .R. It comprises a single coolant temperature sensor used for the injection. .indication of the coolant temperature on the instrument panel. 3 track sensor. 15763R1 244 Coolant temperature sensor (injection and coolant temperature indication on instrument panel).the E. It is operated when the temperature exceeds 105 °C. . Depending on the coolant temperature.DIESEL EQUIPMENT Centralised Coolant Temperature Management Centralised Coolant Temperature Management (GCTE) OPERATION 13 Sensor 244 allows: .

>< --<---<-------<---<---<---<---<---<---<---<---<-->--->--->--->--->-.>< -->--->--->--->--->--->-----------------------<------------------------------->--->--->--->-- FAULT FINDING LINE L AIR TEMPERATURE SENSOR INPUT LOAD POTENTIOMETER SENSOR INPUT (1) INJECTION PUMP SCREENING ENGINE SPEED SENSOR SIGNAL (TRACK B) ROTOR COMPENSATION INPUT (PUMP) CAM POSITION SENSOR INPUT (PUMP) ROTOR POSITION SENSOR INPUT (PUMP) PUMP SENSOR INPUT VEHICLE SPEED INPUT HEATED WINDSCREEN INPUT PLUG FAULT FINDING INPUT (2) IMMOBILISER INPUT PAS ELECTRO-PUMP ASSEMBLY (if AC option) FAST SPEED FAN RELAY CONTROL (if AC option) PREHEATING WARNING LIGHT OUTPUT ENGINE SPEED INFORMATION OUTPUT ELECTRICAL SOLENOID OUTPUT FAULT FINDING LINE K COOLANT TEMPERATURE SENSOR INPUT EGR VALVE FLAP POSITION INPUT DIESEL TEMPERATURE SENSOR INPUT LOAD POTENTIOMETER SENSOR INPUT (TRACK 2) EGR VALVE FLAP POSITION FEED LOAD POTENTIOMETER SENSOR FEED (TRACK 1) LOAD POTENTIOMETER SENSOR FEED (TRACK 2) BRAKE SWITCH INPUT AC INFORMATION (if AC option) PLUG FAULT FINDING INPUT (1) PUMP MEMORY INPUT/OUTPUT PREHEATING RELAY CONTROL SLOW SPEED FAN RELAY CONTROL COOLANT TEMPERATURE WARNING LIGHT OUTPUT AC PREVENTION OUTPUT (if AC option) EGR SOLENOID VALVE OUTPUT NEGATIVE FLOW SOLENOID VALVE CONTROL OUTPUT LOAD POTENTIOMETER SENSOR EARTH (TRACK 1) LOAD POTENTIOMETER SENSOR EARTH (TRACK 2] EGR VALVE FLAP POSITION EARTH AIR TEMPERATURE SENSOR EARTH COOLANT TEMPERATURE SENSOR EARTH PUMP DIESEL TEMPERATURE SENSOR ENGINE SPEED SENSOR EARTH (TRACK A) + BEFORE IGNITION FEED + BEFORE IGNITION FEED EARTH EARTH + AFTER IGNITION FEED ACTUATOR RELAY CONTROL FAULT WARNING LIGHT OUTPUT FUEL CONSUMPTION OUTPUT ADVANCE SOLENOID VALVE CONTROL OUTPUT POSITIVE FLOW SOLENOID VALVE CONTROL OUTPUT --<--->-PRO15097 INPUT OUTPUT 13-31 .DIESEL EQUIPMENT Computer ALLOCATION OF INJECTION COMPUTER TRACKS 13 3 4 8 9 11 12 13 14 15 17 18 19 20 22 23 24 26 30 33 34 35 36 37 39 41 42 46 47 49 51 52 53 54 55 59 60 61 62 63 65 66 67 74 76 77 78 79 81 82 84 85 89 90 .>< --<---<---<---<---------------<---<---<-.

DIESEL EQUIPMENT Wiring diagram 13 16600G 13-32 .

DIESEL EQUIPMENT Wiring diagram 13 16600D 13-33 .

DIESEL EQUIPMENT Wiring diagram KEY 104 Immobiliser 107 Battery 120 Injection computer (D.C.) 160 Stop switch 225 Diagnostic socket 234 Fan assembly relay 238 Injection locking relay 244 Coolant temperature sensor 247 Instrument panel 250 Vehicle speed sensor (passenger compartment) 257 Preheating unit 272 Injection air temperature sensor 273 Engine speed sensor 398 EGR valve 419 AC control unit 597 Engine fuse box 645 Passenger compartment connection ECU 680 to 682 Heater plugs 711 Diesel pump 777 Power feed fuse board 921 Accelerator potentiometer 927 Impact sensor (inertia sensor) 13 13-34 .U.

ANTIPOLLUTION Oil vapour rebreathing PRESENTATION OF THE CIRCUIT 14 13042R 1 2 3 4 Engine Oil decanter Air filter unit Inlet manifold CHECKING In order to guarantee the correct operation of the antipollution system. 14-1 . the oil vapour rebreathing circuit must be kept clean and in good condition.

To make it easier to replace.ANTIPOLLUTION Exhaust gas recirculation (EGR) PRESENTATION OF THE CIRCUIT 14 15881R 1 2 3 4 5 6 Engine Injection computer Inlet manifold Exhaust manifold EGR valve Coolant temperature sensor REMOVING THE VALVE The EGR valve is press fitted in the inlet manifold. 14-2 . remove the manifolds. The injection computer authorises the passage of the gas using an electrical valve. AIM OF THE EGR SYSTEM Exhaust gas recirculation is used to reduce the amount of nitrous oxides (NOx) in exhaust gas.

mapping (load potentiometer/engine speed pair) is greater than a certain threshold. • the vehicle speed information. . The EGR valve is fed for 30 seconds after the engine is started if the preliminary conditions allow. EGR operation is stopped if : . The computer permanently checks to determine the position of the EGR valve flap. . The vehicle must then exceed 6 mph (10 km/h) before the exhaust gas recirculation cycle at idle speed can be implemented. • one of the flow solenoid valves.coolant temperature.atmospheric pressure.atmospheric pressure is less than 890 mbars. OPERATING CONDITIONS The following parameters determine the operation of the EGR solenoid valve: .ANTIPOLLUTION Exhaust gas recirculation (EGR) OPERATING PRINCIPLE 14 The valve is controlled by an RCO signal from the injection computer. . The computer does not operate the EGR if there is a fault in: • the coolant temperature sensor. . 15761R 1 2 4 5 6 Solenoid feed Sensor feed Sensor earth Solenoid earth Sensor output 14-3 . .the coolant temperature is less than 15 °C or greater than 120 °C. . • the atmospheric pressure sensor. The RCO signal allows the valve opening to be modified. consequently changing the amount of exhaust gas diverted to the exhaust manifold. • the air temperature sensor. .engine speed. .battery voltage. . .accelerator pedal position.air temperature.the battery voltage is less than 10 Volts.the air temperature is less than 15 °C or greater than 60 °C.vehicle speed. • the EGR valve. The EGR valve is then closed for 30 seconds whenever the engine returns to idle speed.