Professional Documents
Culture Documents
SPECIFICATIONS
LIFTING
TOWING
LUBRICANTS CONSUMABLES
DRAINING FILLING
VALUES AND SETTINGS
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition anglaise
Renault 1997
http://vnx.su
SECTION VIEW
PRO00.1
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General
vehicle
Contents
Page
01 SPECIFICATIONS
Engine - Clutch - Gearbox
Vehicle identification
05 DRAINING FILLING
01-1
01-2
02 LIFTING
Trolley jack - Axle stands
Underbody lifts
Page
Engine
Gearbox
Power assisted steering
03 TOWING
All types
03-1
04 LUBRICANTS CONSUMABLES
Packaging
05-1
05-3
05-4
04-1
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Dimensions
Capacity - Grades
Belt tension
Accessories belt tension
Timing belt tension
Tightening the cylinder head
Tyres and wheels
Brakes
Brake limiter
Underbody heights
Values for checking the front axle
geometry
Values for checking the rear axle
geometry
07-1
07-2
07-5
07-7
07-11
07-12
07-14
07-15
07-16
07-17
07-20
07-21
The KANGOO Workshop Repair Manual has been prepared by specialists in repair methods
and diagnostics.
The document covers the methods and the diagnostic operations needed in order to obtain
high quality repairs for this vehicle.
However, if a removal - refitting operation involves no particular features, difficulties or
special tools, the method is not described in this manual, being considered very simple for
a vehicle repair specialist.
The labour times are the result of time and motion studies carried out in our workshops,
even though certain methods have not been described in the Workshop Repair Manual.
UNITS OF MEASUREMENT
TOLERANCES
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SPECIFICATIONS
Engine- Clutch - Gearbox
01
Engine
Vehicle type
Clutch type
Type
Capacity
(cm 3)
FC0A
KC0A
D7F
1149
180 CP 3300
JB1
FC0C
KC0C
E7J
1390
180 CP 3300
JB3
FC0D
KC0D
FC0E
KC0E
F8Q
1870
JB1
VEHICLE IDENTIFICATION
Example : FC0A
F : Body type
C : Project code
0A : Engine suffix
01-1
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SPECIFICATIONS
Vehicle identification
01
13187R
6
7
8
RENAULT S.A.
9
e0-00/00-0000-000-000-00
1
10
VF000000000000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
11
12
13
000000000000000
6
7
8
9
10
11
12
13
01-2
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LIFTING
Trolley jack - Axle stands
02
AXLE STANDS
12274-1R
85679-1G15
02-1
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12333-2G
LIFTING
Underbody lifts
02
SAFETY INSTRUCTIONS
1 - REMOVING COMPONENTS
Company FOG
Part Number FOG 449 8111 - 449 8411
or
FRONT
Company CHEMICO
Part Number 39 2550 0001
or
Company SCHENCH
Part Number 776 684
98703S
REAR
98704S
02-2
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TOWING
All types
03
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT
REAR
13189S
13366S
03-1
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LUBRICANTS CONSUMABLES
Packaging
DESCRIPTION
PACKAGING
04
PART NUMBER
LUBRICANTS
1 kg tin
77 01 421 145
100 g tube
77 01 028 179
ANTI-SEIZE
(high temperature grease) Turbo etc.
80 ml tube
77 01 422 307
180 g sachet
77 01 366 100
MULTIPURPOSE LUBRICANT
wheel sensor
Aerosol
77 01 422 308
MOLYKOTE "BR2"
for main bearing journal faces, thrust pad
guide tubes, clutch fork pads, lower suspension
arm bearings, torsion bar splines, steering box,
driveshaft splines
MOLYKOTE "33 Medium"
tubular rear axle rings,
anti-roll bar rings
MECHANICAL SEALANTS
100 g tube
77 01 417 404
1.5 kg tin
77 01 421 161
5661
100 g tube
77 01 421 042
77 01 404 452
kit
77 01 421 080
100 g tube
77 01 396 227
Perfect-seal "LOWAC"
coating fluid for seals
Mastic
for sealing exhaust pipe unions
RHODORSEAL
04-1
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LUBRICANTS CONSUMABLES
Packaging
DESCRIPTION
PACKAGING
04
PART NUMBER
MECHANICAL SEALANTS
AUTO joint grey
sealing paste
LOCTITE 518
for sealing the gearbox housing
Leak detector
100 g tube
77 01 422 750
24 ml syringe
77 01 421 162
Aerosol
77 11 143 071
ADHESIVES
"LOCTITE - FRENETANCH"
stops bolts slackening and allows them to be
released
24 cc bottle
77 01 394 070
"LOCTITE - FRENBLOC"
locks bolts
24 cc bottle
77 01 394 071
"LOCTITE SCELBLOC"
for bonding bearings
24 cc bottle
77 01 394 072
"LOCTITE AUTOFORM"
for bonding the flywheel to the crankshaft
50 cc bottle
77 01 400 309
150 g aerosol
77 01 408 464
Carburettor cleaner
300 ml aerosol
77 11 171 437
355 ml can
77 01 423 189
500 ml aerosol
77 01 408 466
Aerosol
77 01 405 952
400 ml aerosol
77 11 170 801
Injector cleaner
Super-concentrated unseizing agent
"DECAPJOINT " (FRAMET) for cleaning the
gasket faces of aluminium cylinder heads
Brake cleaner
04-2
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LUBRICANTS CONSUMABLES
Packaging
DESCRIPTION
PACKAGING
04
PART NUMBER
VARNISHES
"CIRCUIT PLUS"
varnish for repairing heated screens
Bottle
77 01 421 135
Kit
77 01 422 752
"CONTACT PLUS"
varnish for repairing rear screen supply terminals
BRAKES
Brake fluid
0.5 l bottle
04-3
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DOT4
77 01 421 940
DRAINING - FILLING
Engine
TOOLING REQUIRED
FILLING: plug(2)
D7F ENGINE
13369R
12560R
E7J ENGINE
13367R
13357R
05-1
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05
DRAINING - FILLING
Engine
DRAINING: plug (1)
05
F8Q ENGINE
13368R
13358R
05-2
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DRAINING - FILLING
Gearbox
05
D7F ENGINE
E7J ENGINE
13369R1
13367R1
F8Q ENGINE
13368R1
05-3
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DRAINING - FILLING
Power assisted steering
CHECKING THE LEVEL
POWER ASSISTED STEERING PUMP LEVEL
12422R1
05-4
http://vnx.su
05
07
Dimensions in metres
12333R
(1) Unladen
(2) Laden
07-1
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Components
Petrol engine
(oil)
When
draining
07
Grade
E.E.C. country
-15 C
-30 C -20 C
-10 C
+25 C
0 C +10 C +20 C +30 C
CCMC-G4
15W40-15W50
ACEA A2-96/A3-96 15W40-15W50
CCMC-G5
ACEA A2-96/A3-96
10W30-10W40-10W50
10W30-10W40-10W50
CCMC-G5
5W30
ACEA A2-96/A3-96 5W30
D7F
3,5
3.7 (1)
E7J
2.7
2.9 (1)
CCMC-G5
5W40-5W50
ACEA A2-96/A3-96 5W40-5W50
Other countries
-15 C
-30 C -20 C
-10 C
0 C
API SH 15W40
API SH 10W40
API SH 10W30
API SH 5W30
07-2
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Components
Diesel engine
(oil)
When
draining
07
Grade
E.E.C. country
-15 C
-30 C -20 C
+25 C
-10 C
CCMC-PD2
15W40
ACEA B2-96/B3-96 15W40
CCMC-PD2
10W40
ACEA B2-96/B3-96 10W40
CCMC-PD2
5W30
ACEA B2-96/B3-96 5W30
CCMC-PD2
5W40
ACEA B2-96/B3-96 5W40
4.7
F8Q
5.2 (1)
Other countries
-15 C
-30 C -20 C
+15 C
-10 C
0 C
API CF 15W40
API CF 10W40
API CF 10W30
07-3
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Components
Capacity
in litres
Manual gearbox
Notes
JB1
3.4
JB3
3.4
Brake circuit
Grade
07
Normal : 0.7
SAE J 1703
ABS : 1
and DOT 4
Fuel tank
approx.
50
Unleaded
petrol/diesel
Power assisted
steering
Separate
reservoir
1.1
Cooling
circuit
or
D7F
E7J
5.5
F8Q
7.4
(type D)
Only add coolant of the
same type
07-4
http://vnx.su
07
Mot.
1273
96601R
A
B
C
D
Sensor
Display
Connecting cable
Calibration checking plate
Principle
Resetting the zero:
The sensor, through the presser button (1), the
presser (2) and the outer pads (3), applies a
constant force to the belt.
07-5
http://vnx.su
07
96602R
GENERAL INSTRUCTIONS:
SEEM
Contact your After Sales Head Office for further
information.
- When checking, if the tension is below the minimum operating value, change the belt.
07-6
http://vnx.su
Tensioning process
Engine cold (ambient temperature).
Fit the new belt.
Position the sensor of Mot. 1273.
Turn the wheel of the sensor until it disengages (three "CLICKS").
Tension the belt until the recommended fitting value is displayed on Mot. 1273 .
Lock the tensioner, check it, adjust the value.
Turn the crankshaft over three times.
Check that the tension value is within the fitting tension tolerance, otherwise readjust it.
NOTE :
07-7
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07
D7F
ENGINE
07
Mot.
1273
ALTERNATOR BELT
10071R2
A
B
C
T
97267R4
Crankshaft
Alternator
Power assisted steering pump
Tensioner
Point for checking belt tension
Power assisted
steering belt,
multitooth
Tension
(US=SEEM unit)
Alternator
belt,
multitooth
Fitting
102 7
96 5
Minimum
operating
53
43
07-8
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E7J
ENGINE
07
Mot.
1273
ALTERNATOR BELT
13511R
A
B
C
T
13510R
Crankshaft
Alternator
Power assisted steering pump
Tension wheel
Point for checking belt tension
Tension
(US=SEEM unit)
Alternator
belt,
multitooth
Power assisted
steering belt,
multitooth
Fitting
101 6
106 6
Minimum
operating
52
59
13363R1
07-9
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F8Q
ENGINE
07
Mot.
1273
ALTERNATOR BELT
13512R
A
B
C
T
13509R
Crankshaft
Alternator
Power assisted steering pump
Tension wheel
Point for checking belt tension
Tension
(US=SEEM unit)
Alternator
belt,
multitooth
Power assisted
steering belt,
multitooth
Fitting
115 5
116 6
Minimum
operating
70
68
07-10
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07
E7J engine
NOTE :
Fitting: 30 U.S.
Minimum operating : 26 U.S.
F8Q engine
D7F engine
There are special features for tensioning the timing belt: refer to section 11.
13094R
07-11
http://vnx.su
07
In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the
cylinder head mounting holes.
All the cylinder head bolts must be systematically renewed after removal.
There is no cylinder head retightening operation.
Using engine oil, lubricate the threads and under the heads of the bolts.
D7F ENGINE
E7J ENGINE
Tighten all the bolts to 2 daN.m, then angle tighten to 90 in the order shown below.
Tighten all the bolts to 2 daN.m, then angle tighten to 97 2 in the order shown below.
10
10
90775S
90775S
- Repeat the slackening and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10.
- Repeat the slackening and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10
07-12
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10
90775S
07-13
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07
Vehicle
Wheel rim
Tyres
07
Cold inflation pressure
(in bars) (1)
Front
Rear
5 B 13
165/70 R 13 C 88/86
2.8
3.6
5 B 13
165/70 R 13 83 (2)
2.6
2.9
5.5 J 14
165/70 R 14
2.4
3.0
FC0X
KC0X
07-14
http://vnx.su
07
Vehicle
Front
Normal
Rear
Min.
FC0X
20
Normal
Max. (1)
normal
payload
203.2
normal
payload
204.45
increased
payload
228.3
increased
payload
229.5
17.7
KC0X
Front
Rear
0.07
Front
Brand new
Rear
Minimum
Brand new
Brake fluid
Minimum
With ABS
4.6 (1)
3.15 (2)
FC0X
17.8
5.5
KC0X
2
No ABS
SAE J1703
DOT 4
4.2 (1)
2.8 (2)
With ABS
4.8
FC0X (3)
17.8
KC0X (3)
5.5
2
No ABS
4.5
(1) Leading brake shoe.
(2) Trailing brake shoe.
(3) Increased payload.
07-15
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SAE J1703
DOT 4
07
BRAKING PRESSURE
Vehicle
Fuel tank
(driver on board)
Front
Rear
FC0X
KC0X
normal payload
100
35.4
FC0X
KC0X
increased payload
100
38
90966S
07-16
http://vnx.su
+8
0
+8
0
Vehicle
At the front
H1 - H2 = ... mm
07
At the rear
H4 - H5 = ... mm
- 60.5 (1)
402 (1)
- 54.1 (2)
430 (2)
FC0X
73.5
KC0X
Tolerance : 7.5 mm
The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed 5 mm, the drivers side always being the higher.
Any adjustment of the underbody height means that the brake limiter and the headlights must be adjusted.
07-17
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07
MEASUREMENT POINTS
12333R3
88636-4R
07-18
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88576R
88637R
07-19
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07
ANGLES
POSITION OF
FRONT AXLE
VALUES
07
ADJUSTMENT
CASTOR
355
325
255
225
30
H5 - H2
H5 - H2
H5 - H2
H5 - H2
= 97 mm
= 117 mm
= 137 mm NOT ADJUSTABLE
= 157 mm
H1 - H2
H1 - H2
H1 - H2
H1 - H2
=
7 mm
= 74 mm
NOT ADJUSTABLE
= 98 mm
= 164 mm
H1 - H2
H1 - H2
H1 - H2
H1 - H2
=
7 mm
= 74 mm NOT ADJUSTABLE
= 98 mm
= 164 mm
Maximum right/left
difference = 1
93012-1S
CAMBER
112
- 015
- 029
- 013
30
Maximum right/left
difference = 1
93013-1S
KINGPIN
805
1025
1101
1156
30
Maximum right/left
difference = 1
93014-1S
PARALLELISM
UNLADEN
Adjustable by
rotating track
rod sleeves
1 turn= 30
(3 mm)
UNLADEN
(For 2 wheels)
toe-out
+ 010 10
+ 1 mm 1 mm
93011-1S
RUBBER BUSHES
81603S1
07-20
http://vnx.su
ANGLES
VALUES
07
POSITION OF
REAR AXLE
ADJUSTMENT
UNLADEN
NOT ADJUSTABLE
UNLADEN
NOT ADJUSTABLE
UNLADEN
CAMBER
- 050 15
93013-2S
PARALLELISM
(For 2 wheels)
Toe-in
- 15 10
- 1,5 mm 1 mm
93011-2S
RUBBER BUSHES
81603S1
07-21
http://vnx.su
Fault finding
LUCAS DIESEL INJECTION
INJECTION
ELECTRONICALLY CONTROLLED HYDRAULIC
SYSTEMS
IMMOBILISER
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
Renault 1997
http://vnx.su
Fault finding
Contents
Page
BATTERIE
DIESEL
PROJECTEURS
INJECTION
13 LUCAS
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Aid
Checking conformity
Customer complaints
Fault charts
Page
BATTERIE PROJECTEURS
(cont)
17 INJECTION
13-1
13-2
13-5
13-31
13-32
13-37
13-38
17-147
17-152
17-155
17-175
17-181
17-201
17-202
17-207
17-208
BATTERIE PROJECTEURS
17 INJECTION
E7J 780 engine
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Status and parameter checks
Status and parameter
interpretation
Customer complaints
Fault charts
Aid
Checking conformity
17-1
17-6
17-9
17-30
ELECTRONICALLY CONTROLLED
38 HYDRAULIC SYSTEMS
17-36
17-56
17-57
17-62
17-63
17-75
17-80
17-83
17-103
17-109
17-128
17-129
17-134
17-135
http://vnx.su
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Checking conformity
Aid
Customer complaints
Fault charts
38-1
38-2
38-4
38-18
38-19
38-20
38-21
Fault finding
Contents
Page
BATTERIE PROJECTEURS
82 IMMOBILISER
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Customer complaints (petrol
version)
Fault charts (petrol version)
Customer complaints (diesel
version)
Fault charts (diesel version)
Checking conformity
Aid
88
82-1
82-2
82-4
82-14
82-15
82-25
82-26
82-34
82-39
AIRBAG - PRETENSIONERS
Introduction
Wiring
XR25 fiche
Interpretation of XR25 bargraphs
Checking conformity
Checking the pretensioners
Aid
http://vnx.su
88-1
88-2
88-5
88-7
88-22
88-23
88-24
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
..............................................................
05
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
Checking conformity
.........................................................................
32
Customer complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
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F8Q
630 / 662
13
CONDITIONS FOR APPLYING THE TESTS DESCRIBED IN THIS FAULT FINDING DOCUMENT
The tests described in this fault finding section should only be applied to the vehicle if the title of the fault
treated corresponds exactly to the display noted on the XR25 when the ignition is switched on.
If a bargraph is interpreted when flashing, the conditions for confirming the presence of an actual fault (and
the necessity of applying the fault finding) are shown in the "Notes" section or at the start of the bargraph
interpretation.
If a bargraph is only interpreted if it is permanently illuminated, the application of these tests recommended
in the fault finding document when the bargraph is flashing will not allow the cause of the memorised fault
to be determined. In this case, only checking of the wiring and connections of the faulty component should
be carried out (the fault is simply memorised as it was not present at the moment of testing).
NOTE :
SPECIAL TOOLING REQUIRED FOR OPERATIONS ON THE DPC DIGITAL INJECTION SYSTEM
DPCF01 1.0
13-1
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13
FI21760-1
DPCF01 1.0
13-2
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13
FI21760-2
DPCF01 1.0
13-3
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13
BARGRAPH SYMBOLS
If illuminated, there is a fault with the product tested. The associated text
defines the fault.
The bargraph may be :
- Permanently illuminated
: fault present.
- Flashing
: fault memorised
- Extinguished
: no fault or not diagnosed
Indefinite
- illuminated when the function or condition on the fiche is met.
Extinguished
ADDITIONAL NOTES
Certain bargraphs have a *. The *.. command, when the bargraph is illuminated,
allows additional information on the type of fault or status to be displayed.
DPCF01 1.0
13-4
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13
Fiche n 60 1/2
Bargraph 1 RH extinguished
Code present
NOTES
Use bornier El. 1332 for any operations on the computer connector.
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on another vehicle. If the XR25 is not the cause of the fault and dialogue is not established with another computer on the same vehicle, a faulty computer may be causing interference on the K and L fault finding lines.
Disconnect connections successively to determine which computer is at fault.
Check the ISO selector is on position S8, that you are using the latest XR25 cassette and the correct access
code (D34).
Check the battery voltage and carry out any necessary operations to ensure the correct voltage (U battery
> 10.5 volts).
Check the 15 Amp fuses on the engine connection unit have not blown (positions 3 and 4).
Check the connection and condition of the connections on the computer connector and the connection
R67 engine / dashboard.
Check the computer is correctly fed:
- Earth on track 2 of the computer connector (check the condition and tightness of the engine earth
strap and the engine earth MH near to the gearbox housing).
- + after ignition feed on track 1 of the computer connector.
AFTER REPAIR
When communication is established, deal with any fault bargraphs which may be
illuminated.
DPCF01 1.0
13-5
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13
Fiche n 60 1/2
Bargraph 1 LH illuminated
Computer
NOTES
None
Replace the computer (consult the "Aid" section for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-6
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13
Bargraph 2 LH illuminated
NOTES
co.1
Fiche n 60 1/2
*02 :
Use bornier El. 1332 for any operations on the computer connector.
NOTES
If bargraphs 2RH and 3LH are also illuminated, look for a CO of the sensor earth (track 3 of the computer connector)
Also check the condition and tightness of the engine earth strap and
the gearbox engine earth.
Ensure the continuity and insulation in relation to + 12 volts of the following connection :
- Between track 25 on the computer connector and track 2 on the coolant temperature sensor
connector.
Ensure the continuity of the following connection :
- Between track 3 on the computer connector and track 1 on the coolant temperature sensor connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the coolant temperature sensor then erase the computer memory.
If the "coolant temperature sensor circuit" fault reappears, replace the computer (consult the "Aid"
section for this operation).
cc.0
NOTES
None
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-7
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13
Bargraph 2 RH illuminated
NOTES
co.1
Fiche n 60 1/2
*22 :
Use bornier El. 1332 for any operations on the computer connector.
NOTES
If bargraphs 2LH and 3LH are also illuminated, look for a CO of the
common sensor earth (track 3 of the computer connector)
Ensure the continuity and insulation in relation to + 12 volts of the following connection :
- Between track 24 on the computer connector and track 2 of the air temperature sensor connector.
Ensure the continuity of the following connection :
- Between track 3 on the computer connector and track 1 of the air temperature sensor connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the air temperature sensor then erase the computer memory.
If the "air temperature sensor circuit" fault reappears, replace the computer (consult the "Aid" section
for this operation).
cc.0
NOTES
None
If the fault persists after these tests, replace the air temperature sensor then erase the computer memory.
If the "air temperature sensor circuit" fault reappears, replace the computer (consult the "Aid" section
for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-8
http://vnx.su
13
Bargraph 3 LH illuminated
NOTES
co.0
Fiche n 60 1/2
*03 :
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Ensure the continuity and insulation in relation to earth of the connection between track 23 on the
computer connector and track 3 on the pump connector (10 tracks).
Also ensure the insulation of this connection in relation to the connection between track 3 on the computer connector and track 5 on the pump connector (potentiometer earth).
Also ensure the continuity of the connection between track 4 on the computer connector and track 4 on
the pump connector.
Look for a possible potentiometer short circuit (between tracks 4 and 5 on the 10 track connector) or a
short circuit in its feed.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the load potentiometer ( consult the "Aid" section for this
operation).
If the "load potentiometer circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
If BG2LH and 2RH are also illuminated, look for a CO on the sensor
earth (track 3 of the computer connector).
Ensure insulation from 5 volts and from 12 volts of the connection between track 23 on the computer
connector and track 3 on the pump connector (10 tracks).
Also ensure the insulation of this connection in relation to the connection between track 4 on the
computer connector and track 4 on the pump connector(+ 5 volts potentiometer).
Ensure the continuity of the connection between track 3 on the computer connector and track 5 on the
pump connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the load potentiometer ( consult the "Aid" section for this
operation).
If the "load potentiometer circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-9
http://vnx.su
13
CONT
dEF
NOTES
None
Ensure the insulation (+12 Volts and earth) of the following connection :
- Between track 4 on the computer connector and track 4 of the pump connector (10 tracks).
If the fault persists after these tests, replace the load potentiometer ( consult the "Aid" section for this
operation).
If the "load potentiometer circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-10
http://vnx.su
13
NOTES
Bargraph 3 RH flashing
Fiche n 60 1/2
The engine speed sensor circuit fault is present if the bargraph illuminates when
the engine is running.
Use bornier El. 1332 for any operations on the computer connector.
Measure the resistance of the flywheel signal sensor at its connector. Replace the sensor if the resistance
is not approximately 250 ohms.
Ensure the continuity and insulation of the following lines:
- Between track 8 on the computer connector and track B on the flywheel signal sensor connector.
- Between track 3 on the computer connector and track A on the flywheel signal sensor connector.
Also check the insulation between these two connections.
Test the connections on the 2 connectors.
Carry out a visual inspection of the general condition of the wiring and its routing for possible
interference.
Check the positioning and condition of the sensor.
Check the condition of the target (deformation, mounting, noise....).
Check the conformity of the target: 2 gaps at 180.
If the fault persists after these tests, replace the flywheel signal sensor.
If the "engine speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-11
http://vnx.su
13
Bargraph 4 LH flashing
NOTES
cc.0
Fiche n 60 1/2
*04 :
The vehicle speed sensor circuit fault is present if the bargraph illuminates during a road test. Use bornier El. 1332 for any operations on the computer
connector.
NOTES
None
Ensure the insulation from earth of the connection between track 12 on the computer connector and
track B1 on the vehicle speed sensor connector.
Also ensure the insulation of this connection in relation to the connection between track 3 on the computer
connector and track B2 on the vehicle speed sensor connector.
Test the connections on the 2 connectors.
Check the vehicle speed sensor feed:
- +after ignition feed on track A of the sensor connector
- Earth on track B2 of the sensor connector.
If the fault persists after these tests, replace the vehicle speed sensor, then erase the computer memory.
If the "vehicle speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
co.1
NOTES
None
Ensure the continuity and insulation in relation to 12 volts of the connection between track 12 on the
computer connector and track B1 on the vehicle speed sensor connector.
Also ensure the insulation of this connection in relation to the vehicle speed sensor+ after ignition feed line
(track A of the sensor connector).
Test the connections on the 2 connectors.
Check the vehicle speed sensor feed:
- +after ignition feed on track A of the sensor connector
- Earth on track B2 of the sensor connector.
If the fault persists after these tests, replace the vehicle speed sensor, then erase the computer memory.
If the "vehicle speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-12
http://vnx.su
NOTES
Bargraph 4 RH illuminated
13
Fiche n 60 1/2
None
Replace the computer (consult the "Aid" section for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-13
http://vnx.su
13
Bargraph 5 LH flashing
Fiche n 60 1/2
NOTES
The needle lift sensor circuit fault is present if the bargraph illuminates when the
engine is running. Use bornier El. 1332 for any operations on the computer
connector.
The "needle lift sensor circuit" fault may be connected to absence of injection at the cylinder with the
sensor.
Check the condition of the injector and its fuel supply.
If the fault persists after these tests, replace the injector with the sensor.
If the "needle lift sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-14
http://vnx.su
13
NOTES
co.0
*25 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Measure the resistance of the altimetric corrector relay coil (position H on engine connection unit).
Ensure the continuity and the insulation from earth of the connection between track 15 of the computer
connector and terminal 2 of the corrector relay mounting.
Ensure the presence of + after ignition feed on track 1 of the corrector relay mounting.
Test the connections on the computer connector and the relay mounting.
If the fault persists after these tests, replace the altimetric corrector relay.
If the "altimetric corrector circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
Measure the resistance of the altimetric corrector relay coil (position H on engine connection unit).
Replace the relay if the resistance is not approximately 85 ohms.
Ensure the insulation from +12 volts of the connection between track 15 on the computer connector
and terminal 2 on the corrector relay mounting.
If the fault persists after these tests, replace the altimetric corrector relay.
If the "altimetric corrector circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-15
http://vnx.su
13
NOTES
co.0
*06 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Measure the resistance of the advance corrector at the 10 track pump connector (between tracks 2 and
7). Replace the advance corrector if the resistance is not approximately 12 ohms.
Ensure the continuity of the connection between track 6 on the computer connector and track 7 on the
pump connector.
Ensure the presence of + after ignition feed on track 2 of the corrector connector, wiring side.
Ensure the insulation from earth of the connection between track 6 on the computer connector and track 7
on the pump connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the advance corrector .
If the "advance solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
None
Measure the resistance of the advance corrector at the 10 track pump connector (between tracks 2 and
7). Replace the advance corrector if the resistance is not approximately 12 ohms.
Ensure the insulation from +12 volts of the connection between track 6 on the computer connector and
track 7 on the pump connector.
If the fault persists after these tests, replace the advance corrector .
If the "advance solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-16
http://vnx.su
13
CONT
1.dEF
NOTES
This fault indicates that the advance corrector is seized, the injection pump has been incorrectly set or
there is a fuel supply fault.
It is taken into account when the advance noted by the needle lift sensor differs by more than 5 from the
advance value requested by the computer.
NOTE : If there is a fault where the advance corrector is seized, there will be a characteristic noise when
the ignition is switched on (irregular clicking of the corrector).
- Check the condition of the fuel supply to the pump and the injectors (filter blocked, pipe kinked, air
leak, ...).
Check the type of diesel fuel used in extreme cold weather (a "summer " type diesel fuel may cause
this fault at -15 C).
- Check the pump timing and check the tightness of the pump pulley.
- If the fuel supply and the pump timing are correct, replace the advance corrector.
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-17
http://vnx.su
13
NOTES
co.0
*26 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Measure the resistance of the fast idle solenoid valve at its connector. Replace the fast idle solenoid valve
if the resistance is not approximately 45 ohms.
Ensure continuity of the connection between track 16 on the computer connector and track 1 on the fast
idle solenoid valve connector.
Ensure the presence of + after ignition feed on track 2 on the fast idle solenoid valve connector, wiring side.
Ensure the insulation from earth of the connection between track 16 on the computer connector and track 1
on the fast idle solenoid valve connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the fast idle solenoid valve.
If the "fast idle solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
Measure the resistance of the fast idle solenoid valve at its connector. Replace the fast idle solenoid valve
if the resistance is not approximately 45 ohms.
Ensure insulation from +12 volts of the connection between track 16 on the computer connector and
track 1 on the fast idle solenoid valve connector.
If the fault persists after these tests, replace the fast idle solenoid valve.
If the "fast idle solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-18
http://vnx.su
13
NOTES
co.0
*27 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Measure the resistance of the EGR solenoid valve at its connector. Replace the EGR solenoid valve if the
resistance is not approximately 45 ohms.
Ensure continuity of the connection between track 5 on the computer connector and track 1 of the EGR
solenoid valve connector.
Ensure the presence of + after ignition feed on track 2 of the EGR solenoid valve connector, wiring side.
Ensure the insulation from earth of the connection between track 5 on the computer connector and track 1
of the EGR solenoid valve connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the EGR solenoid valve.
If the "EGR solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
cc.1
NOTES
Measure the resistance of the EGR solenoid valve at its connector. Replace the EGR solenoid valve if the
resistance is not approximately 45 ohms.
Ensure insulation in relation to +12 volts of the connection between track 5 on the computer connector and
track 2 of the EGR solenoid valve connector.
If the fault persists after these tests, replace the EGR solenoid valve.
If the "EGR solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-19
http://vnx.su
13
NOTES
co.0
*08 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
None
NOTES
Ensure the continuity and insulation in relation to earth of the connection between track 14 on the
computer connector and track B1 on the relay unit connector.
Ensure the presence of + after ignition feed on track A1 on the relay unit connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the relay unit.
If the "preheating relay No. 1 control circuit" fault reappears, replace the computer (consult the "Aid"
section for this operation).
cc.1
NOTES
Ensure insulation in relation to 12 volts of the connection between track 14 on the computer connector
and track B1 on the relay unit connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the relay unit.
If the "preheating relay No. 1 control circuit" fault reappears, replace the computer (consult the "Aid"
section for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-20
http://vnx.su
13
NOTES
co.0
*29 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Measure the resistance of the PAS pump assembly relay coil (position C on the engine connection unit).
Replace the relay if its resistance is not approximately 65 ohms.
Ensure the continuity and insulation from earth of the connection between track 20 on the computer
connector and terminal 2 on the pump assembly relay mounting.
Ensure the presence of + after ignition feed at terminal 1 of the pump assembly relay mounting.
Check the connections on the computer connector and the relay mounting.
If the fault persists after these tests, replace the PAS pump assembly relay.
If the "PAS pump assembly relay control circuit" fault reappears, replace the injection computer (consult
the "Aid" section for this operation).
cc.1
NOTES
Measure the resistance of the PAS pump assembly relay coil (position C on the engine connection unit).
Replace the relay if its resistance is not approximately 65 ohms.
Ensure the insulation from + 12 Volts of the connection between track 20 of the computer connector
and terminal 2 on the pump assembly relay mounting.
If the fault persists after these tests, replace the PAS pump assembly relay.
If the "PAS pump assembly relay control circuit" fault reappears, replace the injection computer (consult
the "Aid" section for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-21
http://vnx.su
13
10
Bargraph 10 LH flashing
NOTES
Fiche n 60 1/2
*10 :
Even if present at the moment of testing, this fault is still declared by a flashing
BG 10LH side. To confirm its presence and the necessity of following the fault finding below, erase the computer memory then start command mode G21*1*.
The fault is present if the bargraph flashes again.
Use bornier El. 1332 for any operations on the computer connector.
cc.1
NOTES
None
Ensure insulation in relation to 12 volts of the connection between track 18 of the computer connector
and the instrument panel warning light (track 6 on connector MA).
Test at the warning light bulb (bulb in short circuit).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-22
http://vnx.su
13
10
NOTES
co.0
*30 :
Fiche n 60 1/2
Use bornier El. 1332 for any operations on the computer connector.
NOTES
None
Check the condition of the preheating warning light bulb then the presence of +after ignition feed at
the warning light.
Ensure the continuity and insulation in relation to earth of the connection between track 9 of the
computer connector and the instrument panel preheating warning light (track 5 on CY connector).
Test the connections on the computer connector.
cc.1
NOTES
Ensure insulation in relation to 12 volts of the connection between track 9 of the computer connector
and the instrument panel preheating warning light (track 5 on connector CY).
Test at the preheating warning light bulb (bulb in short circuit).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-23
http://vnx.su
13
12
Bargraph 12 LH illuminated
Battery voltage
XR25 aid:
NOTES
Fiche n 60 1/2
*12 :
Carry out a complete check of the charging circuit using the Optima 5800 diagnostic station.
Carry out the operations required to ensure correct voltage feed to the computer:
8 volts < correct voltage< 16 volts.
- Check the battery charge.
- Check the charging circuit.
- Check the tightness and condition of the battery terminals.
- Check the computer earth.
Ensure the presence of + after ignition feed on track 1 of the computer connector.
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-24
http://vnx.su
13
12
NOTES
Bargraph 12 RH illuminated
Fiche n 60 1/2
None
Programme the full load position of the accelerator pedal using command G31* (do not adjust the load
lever directly).
Enter code G31* on the XR25 (engine speed zero).
- Press the accelerator pedal when the display flashes "PF".
The display then shows "bon", "Fin" then "6/7.dIE" when the procedure has been completed correctly. Bargraph 12 RH side must be extinguished.
- Switch off the ignition.
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-25
http://vnx.su
13
13
NOTES
Fiche n 60 1/2
*13 :
None
cc.1
NOTES
Ensure insulation in relation to 12 volts of the connection between track 19 on the computer connector
and track 18 on the air conditioning computer connector.
Test the connections on the 2 connectors (+ intermediate connection engine / dashboard).
If the fault persists after these tests, replace the air conditioning control module.
If the "air conditioning cut out information "fault reappears, replace the diesel injection computer (consult
the "Aid" section for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-26
http://vnx.su
13
Fiche n 60 2/2
NOTES
None
Bargraph 4 LH side
NOTES
AFTER REPAIR
None
Bargraph 4 RH side
Fiche n 60 2/2
Preheating prevented
XR25 aid :
NOTES
Fiche n 60 2/2
None
13-27
http://vnx.su
13
Fiche n 60 2/2
Relay control
NOTES
None
Air conditioning
XR25 aid :
NOTES
10
AFTER REPAIR
If BG 9LH is extinguished when AC is requested, ensure the continuity and insulation of the connection between track 11 of the diesel computer connector and
track 20 of the AC computer connector.
Bargraph 10 LH side
Fiche n 60 2/2
NOTES
Fiche n 60 2/2
None
13-28
http://vnx.su
10
Bargraph 10 RH side
11
11
Bargraph 11 LH side
AFTER REPAIR
Fiche n 60 2/2
None
Bargraph 11 RH side
Fiche n 60 2/2
NOTES
None
XR25 aid :
NOTES
Fiche n 60 2/2
NOTES
13
Fiche n 60 2/2
None
13-29
http://vnx.su
18
13
19
NOTES
Vehicles fitted with power assisted steering but without air conditioning must
be configured to "without PAS".
These bargraphs show the computer configuration for the air conditioning and pump assembly power
assisted steering options.
Computers sold by the Parts Department are systematically configured for vehicles with air conditioning
and with the PAS pump assembly.
If the vehicle does not have air conditioning, use the command mode G50*4* to reverse the computer
configuration (the opposite command exists for configuring to "with AC": G50*3*).
If the vehicle is not fitted with a PAS pump assembly (vehicle without air conditioning), use command
mode G50*9* to reverse the computer configuration (the opposite command exists for configuring to
"with PAS": G50*8*).
NOTE : Vehicles fitted with power assisted steering but without air conditioning must be configured to
"without PAS".
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-30
http://vnx.su
13
A) On these computers it is necessary to programme the load lever full load position (this value is required to
replace and adjust the load lever position potentiometer).
Programming procedure:
Enter code G31* on the XR25 (engine speed zero)
Press the accelerator pedal until the display flashes "PF".
The display then shows "bon", "Fin" then "6/7.dlE" when the procedure has been carried out correctly.
Bargraph 12 RH side must be extinguished.
Switch off the ignition.
B) Lucas digital DPC injection computers are sold pre-configured to "with air conditioning".
If the vehicle does not have air conditioning, use command G50*4* on the XR25 to programme "without
air conditioning".
Lucas digital DPC injection computers are sold pre-configured to "with power assisted steering" (with power assisted steering pump assembly).
If the vehicle does not have a power assisted steering pump assembly (vehicle without air conditioning),
use command G50*9* on the XR25 to programme "without power assisted steering".
Vehicles fitted with power assisted steering but without air conditioning must be configured to "without
power assisted steering".
The load lever position potentiometer may only be replaced in After Sales if the full load position has been
programmed into the computer before the fault with the potentiometer.
Procedure for replacing and adjusting the load lever position potentiometer:
Fit the new potentiometer into position without locking the mounting bolts.
Connect the potentiometer and set up the XR25 (S8 code D34).
Start command G32* on the XR25, keep the accelerator pedal fully depressed (do not touch the load lever
directly) and turn the potentiometer until the display on the XR25 shows a value other than H.L (outside limits). Adjust the setting by turning the potentiometer to obtain 0 on the display.
Tighten the mounting bolts with the potentiometer in this position then press * to complete the adjustment procedure.
DPCF01 1.0
13-31
http://vnx.su
Order of
operations
13
Function to check
Action
D34
(selector on
S8)
Bargraph
6. dlE
Use fiche n 60
fault test side
1
Fault test
Interpretation of
normally illuminated
bargraphs
1
Code present
7. dlE
3
Interpretation of
normally illuminated
bargraphs
G01*
Use fiche n 60
status test side
1
Code present
2
Advance corrector fed
4
Illuminated if command mode
G0** has been used since the
last dialogue took place
10
Fault warning light fed
10
Illuminated in preheating
phase
11
Injection computer may give
load lever position to other
computers (not used)
11
DPCF01 1.0
13-32
http://vnx.su
NOTES
Order of
operations
13
Function to check
Action
Bargraph
Computer
configuration
18
With AC
G50*3*
19
With AC
G50*8*
18
Without AC
G50*4*
Without AC
19
With conventional PAS
G50*9*
Absolute pressure
sensor
#16
Coolant temperature
sensor
#02
X = Ambient temperature
5 C
Air temperature
sensor
#03
X = Ambient temperature
5 C
X=0
#24
DPCF01 1.0
13-33
http://vnx.su
NOTES
13
Engine warm at idle speed after at least one operation of the engine cooling fan
assembly (air conditioning not selected).
Order of
operations
Function to check
Action
G01*
Bargraph
7. dlE
Use fiche n 60
status test side
20
2
No faults
Battery voltage
#04
DPCF01 1.0
13-34
http://vnx.su
NOTES
Order of
operations
13
Engine warm at idle speed after at least one operation of the engine cooling fan
assembly (air conditioning not selected).
Function to check
Interpretation of
normally illuminated
bargraphs
Action
Bargraph
Code present
2
Advance corrector fed
2
Illuminated if fast idle solenoid
valve is fed
3
5
Illuminated for post heating
Illuminated if altimetric
corrector is fed
11
Injection computer may give
load lever position to other
computers (not used)
11
13-35
http://vnx.su
NOTES
13
Engine warm at idle speed after at least one operation of the engine cooling fan
assembly (air conditioning not selected).
Order of
operations
Function to check
Action
Bargraph
After starting
phase for
40 seconds
X = 82
#24
After
40 seconds
3
X=0
#24
Computer
configuration
18
G50*3*
With AC
With AC
19
G50*8*
With PAS with pump
18
G50*4*
Without AC
Without AC
19
G50*9*
DPCF01 1.0
13-36
http://vnx.su
NOTES
13
Only consult these customer complaints after a complete check using the XR25.
Chart 1
Chart 2
Chart 3
Chart 4
Chart 5
Chart 6
DPCF01 1.0
13-37
http://vnx.su
NOTES
13
Use bornier El. 1332 for any operations on the computer connector.
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on another vehicle. If the XR25 is not the cause of the fault and dialogue is not established with another computer on the same vehicle, a faulty computer may be causing interference on the K and L fault finding lines.
Disconnect connections successively to determine which computer is at fault.
Check the ISO selector is on position S8, that you are using the latest XR25 cassette and the correct access
code (D34).
Check the battery voltage and carry out any necessary operations to ensure the correct voltage (U battery
> 10.5 volts).
Check the 15 Amp fuses on the engine connection unit have not blown (positions 3 and 4).
Check the connection and condition of the connections on the computer connector and the connection
R67 engine / dashboard.
Check the computer is correctly fed:
- Earth on track 2 of the computer connector (check the condition and tightness of the engine earth
strap and the engine earth on the gearbox housing).
- + after ignition feed on track 1 of the computer connector.
If fault finding is not established after these operations, replace the computer (consult the "Aid" section
for this operation).
AFTER REPAIR
13-38
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NOTES
13
Only consult this customer complaint after a complete check using the XR25.
AFTER REPAIR
13-39
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NOTES
13
Only consult this customer complaint after a complete check using the XR25.
Look for an open circuit or a short circuit to earth on the connection between track 11 on the injection
computer and track 20 on the BE connector for the air conditioning computer ("AC Inj. / fast idle" information).
This fault causes the absence of illumination of bargraph 9 LH side "air conditioning requested".
AFTER REPAIR
13-40
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NOTES
13
Only consult this customer complaint after a complete check using the XR25.
If no fault is shown by the XR25, ensure that the fault is not caused by a faulty immobiliser system.
AFTER REPAIR
13-41
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NOTES
13
Only consult this customer complaint after a complete check using the XR25.
If no fault is shown by the XR25, look for a short circuit to earth of the heater plug feed wiring or a plug
short circuit fault.
AFTER REPAIR
13-42
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NOTES
13
Only consult this customer complaint after a complete check using the XR25.
Measure the resistance of the altimetric corrector at the 10 track pump connector (between tracks 1 and
6).
Replace the altimetric corrector if the resistance is not approximately 15 ohms.
Ensure the continuity of the connection between track 1 on the pump connector, wiring side, and track 5
on the altimetric connector control relay (position H on the relay plate in the engine connection unit).
Ensure the presence of earth on track 6 of the pump connector, wiring side.
AFTER REPAIR
13-43
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MULTIPOINT INJECTION
FAULT FINDING
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
06
..............................................................
09
..................................................................
30
...........................................................
36
Customer complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
Checking conformity
63
.........................................................................
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INJECTION
Fault finding- Introduction
E7J 780
engine
17
Enter D13
9.NJ
COMPUTER IDENTIFICATION
The computer is not identified by reading a fault code but by reading the Part Number directly from the
computer. After having set up a dialogue with the computer:
ENTER
G70*
7700
XXX
XXX
The Part Number will then appear on the central display in three sequences.
Each sequence is displayed for approximately two seconds. The display is repeated twice .
After an operation on the injection system the computers memory can be erased by using the code G0** .
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E7J 780
engine
INJECTION
Fault finding - Introduction
17
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier Sus.
1228.
97434S
Bornier Sus. 1228 is a 55 track base with a printed circuit on which are 55 copper coated surfaces, numbered
from 1 to 55.
Using the wiring diagrams, the tracks connecting the components to be tested can be easily identified.
IMPORTANT :
All tests using bornier Sus. 1228 must be carried out with the battery disconnected.
The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 Volts be
applied to the test points.
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INJECTION
Fault finding - Introduction
E7J 780
engine
17
This phase is the essential starting point for any intervention on the vehicle.
There are several constraints to the treatment of the bargraphs :
- A priority in the order of treatment when several bargraphs are illuminated.
- The interpretation of a bargraph depending on whether it is constantly illuminated or flashing .
1 - Order of priority
A series of illuminated bargraphs corresponding to the sensors with the same 12 V or having the same
earth, indicates a fault in this source. These priorities are dealt with in the "NOTES" section of the
fault-finding of the bargraph concerned.
NOTE : If the customer complaint does not correspond to the fault bargraph which is flashing
(example : Air temperature sensor fault bargraph flashing, but no customer complaint) ignore
this memorised fault and erase it.
3 - No bargraphs illuminated
If no bargraphs are illuminated on the XR25, carry out a status and parameter check. This may help in
detecting a problem.
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E7J 780
engine
INJECTION
Fault finding - Introduction
17
The status and parameter check is aimed at checking the statuses and parameters which do not illuminate
any fault bargraphs if they are outside of permitted tolerance values . This phase allows :
- Faults to be found without the illumination of fault bargraphs which may correspond to a customer
complaint (example : absence of no load information causing an unstable idle speed).
- The correct operation of the injection to be checked and the risk of faults appearing shortly after the
repair to be eliminated.
This section contains fault-finding for statuses and parameters, under their test conditions
(example : fault finding for # 01 ignition on and fault finding for # 01 engine running).
If a status does not operate normally or a parameter is outside of permitted tolerance values, consult the
fault-finding page indicated in the "Fault-finding" column.
XR25
CHECK CORRECT
If the XR25 check is correct, but the customer complaint persists, the problem must be dealt with through
customer complaints.
Treatment of customer complaints
This section has fault charts, which suggest a series of possible causes of the problem.
These lines of enquiry must only be used in the following cases :
- No fault bargraph appears on the XR25.
- No faults are detected during the checking of statuses and parameters.
- The vehicle is not operating correctly
POST-REPAIR CHECK
This operation is a simple check of the repair (by a command, or by an XR25 command mode ...).
This makes it possible to check that the system upon which the intervention has been carried out is correct
electrically.
It is an introduction to the road test.
ROAD TEST
A road test is essential in order to guarantee the correct operation of the vehicle and to test the quality of the
repair. Its role is to make sure that no faults occur (or will occur) when driving.
In order to be significant, the road test is subject to special driving conditions.
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INJECTION
Fault finding - Introduction
E7J 780
engine
17
<
<
<
<
<
# 01
# 01
# 01
# 01
# 01
<
<
<
<
<
340 mbars
470 mbars
600 mbars
730 mbars
870 mbars
JF5111.0
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E7J 780
engine
INJECTION
Fault finding - XR25 fiche
17
FI21727-1
JF5111.0
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E7J 780
engine
INJECTION
Fault finding - XR25 fiche
17
N 27 SIDE 2/2
FI21727-2
JF5111.0
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INJECTION
Fault finding - XR25 fiche
E7J 780
engine
17
Illuminates when a dialogue has been established with the product computer. If it remains
extinguished:
- the code does not exist,
- there is a fault in the tool, the computer or the line
REPRESENTATION OF THE FAULTS (always on a coloured background)
If illuminated, indicates a fault on the tested product, the associated text defines the fault.
If extinguished, indicates that the fault has not been found on the tested product.
either
or
Engine running
Extinguishes when the function or condition given on the fiche is no longer performed.
Illuminates when the function or condition given on the fiche is performed
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INJECTION
E7J 780
engine
17
XR25 CIRCUIT
XR25 aid:
NOTES
2
3
11
38
24
32
Earth
Earth
7 Diagnostic socket
15 Diagnostic socket
Fuse F6
15 A
Fuse F3
5A
Repair.
AFTER REPAIR
17-9
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INJECTION
E7J 780
engine
17
COMPUTER CIRCUIT
XR25 aid:
NOTES
Computer faulty
None
AFTER REPAIR
17-10
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INJECTION
E7J 780
engine
17
IMMOBILISER CIRCUIT
XR25 aid:
NOTES
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the wiring on track 37 of the computer.
Repair if necessary.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR
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INJECTION
E7J 780
engine
17
NOTES
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
Computer
20
46
2
1
Repair if necessary.
Check the resistance of the sensor. Replace it if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-12
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INJECTION
E7J 780
engine
17
NOTES
If BG 3RH is flashing, increase the engine speed to 2500 rpm for 5 minutes
If BG3RH becomes permanently illuminated, deal with the fault.
Check the connection and the condition of the connector on the oxygen sensor.
Check, ignition on during the timed phase, for :
- earth on track B of the oxygen sensor,
- + 12 V after the fuel pump relay on track A of the oxygen sensor.
Repair if necessary.
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
17
C
Oxygen sensor
Repair if necessary.
The fault persists. Replace the oxygen sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
E7J 780
engine
17
NOTES
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
44
B1 Coolant temperature sensor
Computer
15
B2 Coolant temperature sensor
Repair if necessary.
Check the resistance of the sensor. Replace it if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-14
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INJECTION
E7J 780
engine
17
NOTES
12
B1
Repair if necessary.
The fault persists! Replace the sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-15
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INJECTION
E7J 780
engine
17
NOTES
Check that the pressure sensor is connected correctly both electrically and pneumatically.
Check the conformity of the pressure sensor pipe (it must not be holed or blocked...).
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
45
C Pressure sensor
Computer
44
A Pressure sensor
Computer
16
B Pressure sensor
Repair if necessary.
The fault persists! Replace the sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-16
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INJECTION
E7J 780
engine
17
NOTES
*25 = CO.0
*25 = CC.0
*25 = CO.0
*25 = CC.0
*25 = In
=>
=>
=>
CO or CC- line 33 or 34
CC- line 33 or 34 on the computer
sensor incorrectly connected
*25 = In
Check the target sensor has been correctly connected (the sensor connector must
not be inverted).
Repair if necessary.
The fault persists! Replace the sensor.
AFTER REPAIR
17-17
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INJECTION
E7J 780
engine
17
NOTES
If BG 6LH is flashing, erase the computer memory using G0**. Run the engine at
3000 rpm for 3 min. If BG 6LH becomes permanently illuminated or flashes, deal
with this fault. If BG 4LH or BG 5LH is also illuminated, check line 44 on the
computer.
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
8
2 Pinking sensor
Computer
44
1 Pinking sensor
Computer
31
Pinking sensor screening
Repair if necessary.
The fault persists! Replace the pinking sensor in question.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-18
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INJECTION
E7J 780
engine
17
NOTES
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
Computer
Computer
19
45
46
2
1
3
Throttle potentiometer
Throttle potentiometer
Throttle potentiometer
Repair if necessary.
Check the resistance of the throttle potentiometer.
The fault persists! Replace the throttle potentiometer.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-19
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INJECTION
E7J 780
engine
17
NOTES
If BG 8LH is flashing, erase the computer memory using G0**. Try to start the
engine. If BG 6LH is now permanently illuminated or flashing, deal with this fault. In
certain cases, BG 13RH is illuminated, which must be ignored if ADAC is not present.
Check the presence of 12 volts on track L1 on the fuel pump relay mounting.
If necessary, repair the line to the 15 A fuse.
Check the insulation, continuity and that there is no interference resistance on the line:
Computer
48
Repair if necessary.
L2
If the fuel pump relay still does not click, replace the fuel pump relay.
Check the presence of 12 volts on track L3 on the fuel pump relay mounting.
If necessary, repair the line to the 30 A fuse.
AFTER REPAIR
17-20
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INJECTION
E7J 780
engine
17
11
INJECTOR CIRCUIT
XR25 aid:
NOTES
*11 = XX.CO
*11 = XX.CC
When the ignition is switched on and during the timed phase, check for 12 V on track 1 of the faulty
injector.
If necessary, repair the line from track 1 injector to track L5 fuel pump relay.
Connect the bornier in place of the computer and check the insulation and continuity of the line :
Computer
Computer
30
4
2
2
Injectors 1 and 4
Injectors 2 and 3
Repair if necessary.
The fault persists! Replace the faulty injector.
NOTE : Check the insulation and continuity of the lines for the other injectors and also check the
resistance of these injectors.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
E7J 780
engine
17
11
AT
XR25 aid:
NOTES
INJECTION CIRCUIT
None
None
Ignore the illumination of this bargraph as the vehicle does not have an automatic transmission.
AFTER REPAIR
17-22
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INJECTION
E7J 780
engine
17
13
MEMORY CIRCUIT
XR25 aid:
NOTES
None
This bargraph only illuminates when the computer feed has been cut (disconnection of the battery, the
computer, ...).
Check the computer feed hygiene:
Computer
24
Fuse
15 A
F6
Computer
32
Fuse
5A
F3
Repair if necessary.
Turn the engine.
Switch the ignition off.
Switch the ignition on.
Enter dialogue with the computer.
Erase the computer memory using G0**.
NOTE : memorised faults are erased. It would therefore be useful to carry out a road test to check there
are no faults on the injection system.
AFTER REPAIR
17-23
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INJECTION
E7J 780
engine
17
13
ADAC CIRCUIT
XR25 aid:
NOTES
AFTER REPAIR
17-24
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INJECTION
E7J 780
engine
17
14
NOTES
If BG 14LH is flashing, erase the computer memory using G0**. Try to start the
engine (if the engine will not start, keep trying with the starter motor). If BG 14LH
becomes permanently illuminated or flashes, deal with this fault.
Check the insulation, continuity and that there is no interference resistance on the line:
Computer
40
B idle speed regulation stepping motor
Computer
35
A idle speed regulation stepping motor
Computer
9
D idle speed regulation stepping motor
Computer
36
C idle speed regulation stepping motor
Repair if necessary.
NOTE : This operation can be carried out without having to remove the throttle body.
Check the resistance of the idle speed regulation stepping motor.
Check the idle speed regulation valve if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-25
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INJECTION
E7J 780
engine
17
14
NOTES
If BG 14RH is flashing, erase the computer memory using G0**. Start the engine. If
BG 14RH becomes permanently illuminated when the engine is running, deal with
this fault.
42
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
E7J 780
engine
17
15
COMPUTER
XR25 aid:
NOTES
AC CONNECTION CIRCUIT
Check that the vehicle has air conditioning and if it is not fitted with air
conditioning, deal with the other bargraphs first.
Engine running, select the air conditioning function.
Connect the bornier in place of the computer and check the insulation and continuity of line 51 on the
computer.
Repair if necessary.
If the fault persists, refer to the air conditioning fault finding.
AFTER REPAIR
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INJECTION
E7J 780
engine
17
15
EGR CIRCUIT
XR25 aid:
None
None
NOTES
Ignore the illumination of this bargraph as the vehicle is not fitted with EGR.
AFTER REPAIR
17-28
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INJECTION
E7J 780
engine
17
16
COMPUTER
XR25 aid:
NOTES
*16 = XX.CO
*16 = XX.CC
29
28
3
3
Coil 2-3
Coil 1-4
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
Engine stopped, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue
with XR25
D13
(selector on
S8)
Bargraph
Fault finding
1
Fault test
9.NJ
Use fiche 27
1
Deal with
fault
bargraph
Code present
Change to
status test
10.NJ
None
G01*
Status test
Battery
voltage
# 04
19
Computer
configuration
Immobiliser
19
Ignition on
Computer configured to
manual gearbox
Computer configured to
automatic transmission
DIAG 1
See Fiche
"Reminder C"
to configure
vehicle
DIAG 12
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Fault finding
2
No load
# 17
Throttle
position
potentiometer
.
Accelerator
pedal
slightly
depressed
16 < X < 50
2
DIAG 2
2
Full load
# 17
Pressure sensor
Coolant
temperature
sensor
Air
temperature
sensor
X =Atmospheric pressure
# 01
DIAG 9
# 02
X = Engine temperature
5 C
DIAG 3
# 03
X = Temperature under
bonnet 5 C
DIAG 4
DIAG 17
10
Fan assembly
G17*
11
Fault warning
light
Switch
ignition on
DIAG 19
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
17
Carry out the actions below if the engine does not start.
NOTES
Order of
operations
Function to be
checked
Flywheel signal
sensor
Action
Bargraph
Ignition
Fuel pressure
Fault finding
3
Starter
Illuminated if TDC
information is detected
DIAG 5
G10*
DIAG 6
Connect
Optima
Station
Starting test.
Complete guide on
Optima Station
Fuel pump
2
Connect
pressure
gauge to
fuel inlet
and activate
starter
motor
Injector
command
Starter
Engine
compression
Connect
Optima
Station
Complete guide on
Optima Station
Flywheel
Connect
Optima
Station
Oscilloscope.
Complete guide on
Optima Station
Use Optima
5800 Station
Fuel pressure,
see Workshop
Repair
Manual or
section
DIAG 11
Use Optima
5800 Station
Use Optima
5800 Station
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
NOTES
Order of
operations
Function to be
checked
Action
Charging
circuit
# 04
Throttle
potentiometer
No load
Idle speed
regulation
Bargraph
Anti-pinking
circuit
Pressure circuit
X = atmospheric pressure
# 35
6
# 05
Fuel pressure
DIAG 2
DIAG 7
DIAG 8
300 X 400 mb
# 16
DIAG 1
# 01
Fault finding
# 13 (at
3500 rpm,
no load)
Richness
regulation
2 % < X < 15 %
# 12
# 21
# 06
3
17
Connect a
pressure
gauge to the
gallery and
activate the
starter
motor
DIAG 9
DIAG 10
See also
DIAG 15
Fuel pressure,
see Workshop
Repair
Manual or
section
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Fault finding
9
AC selected
Illuminated when AC
selected
10
Illuminated when AC
requests compressor
operation
DIAG 16
AC
10
Illuminated when
injection authorises
operation of compressor
# 06
830 < X < 930 rpm
Power assisted
steering
pressostat
13
Turn wheels
to full lock
DIAG 18
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
17
NOTES
Order of
operations
Function to be
checked
Vehicle speed
information
Action
Bargraph
# 18
Fault finding
X = speed read on
speedometer in km/h
DIAG 13
Programming
2
Adaptive
richness
# 30
64 X 192
# 31
64 X 192
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
0.97 < < 1.03
2500 rpm
after driving
3
Emission of
pollutants
At idle
speed, wait
for
stabilisation
DIAG 14
DIAG 15
see also
DIAG 10
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
BATTERY VOLTAGE
DIAG 1
NOTES
XR25 aid:
Ignition on
At idle speed
NOTE:
The battery and the charging circuit may be checked using the OPTIMA 5800 station (measurement does
not require the battery to be disconnected, which retains the memories of the computers).
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
E7J 780
engine
DIAG 2
NOTES
17
Fiche n 27
# 17 outside tolerances
# 17 does not vary when throttle moves
Status BG 2LH or 2RH, incorrect illumination
None
NOTES
19
45
46
2
1
3
Throttle potentiometer
Throttle potentiometer
Throttle potentiometer
Repair if necessary.
If the fault is still present, replace the throttle potentiometer.
# 17 is fixed
NOTES
None
Check the resistance of the throttle potentiometer when the throttle butterfly is moved.
If the resistance varies, check the electrical lines of the sensor.
If the resistance does not vary, check that the sensor is connected mechanically to the throttle.
If necessary, replace the sensor.
# 17 outside tolerances
NOTES
None
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
17
Fiche n 27
COOLANT TEMPERATURE
DIAG 3
NOTES
XR25 aid:
# 02 = Engine temperature 5 C
If the value read is incoherent, check the sensor is correctly following the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer
15
B2 Coolant temperature sensor
Computer
44
B1 Coolant temperature sensor
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
17
Fiche n 27
AIR TEMPERATURE
DIAG 4
NOTES
XR25 aid:
If the value read is incoherent, check the sensor is correctly following the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer
20
2
Air temperature sensor
Computer
46
1
Air temperature sensor
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
TDC DETECTION
DIAG 5
NOTES
XR25 aid:
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
FUEL PUMP
DIAG 6
XR25 aid:
NOTES
Repair if necessary.
Check the insulation and continuity of the wiring:
Fuel pump relay
Impact sensor
L5
Impact sensor
C1 Fuel pump
Repair if necessary.
Check the hygiene and presence of earth on track C2 of the fuel pump.
If + 12 V is not reaching the fuel pump, replace the fuel pump relay.
If + 12 V is reaching the fuel pump, replace the fuel pump.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
17
Fiche n 27
DIAG 7
NOTES
# 06 < Minimum
NOTES
# 06 > Maximum
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
17
Fiche n 27
ANTI-PINKING CIRCUIT
DIAG 8
NOTES
XR25 aid:
The pinking sensor should give a signal which is variable and not zero, to prove that it is recording the
mechanical vibrations of the engine.
If the signal is zero:
- Check the sensor is correctly screwed in.
- Check the insulation and continuity of the wiring:
Computer
8
2
Pinking sensor
Computer
44
1
Pinking sensor
Computer
2
Pinking sensor screening
If necessary, replace the sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
17
Fiche n 27
PRESSURE CIRCUIT
DIAG 9
XR25 aid:
NOTES
# 01 not coherent
ignition on
# 01 < Minimum at idle
speed
# 16 not coherent
AFTER REPAIR
Start the status and parameter check again from the beginning.
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17-44
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
RICHNESS REGULATION
DIAG 10
XR25 aid:
NOTES
17
Oxygen sensor
Repair if necessary.
Check the sealing of the canister bleed valve (a leak can disrupt the richness considerably).
Check the sealing of the exhaust pipe upstream from the oxygen sensor.
Check the sealing of the inlet manifold.
If the vehicle has only been driven in town, the sensor is contaminated (try driving under load).
Check the fuel pressure.
If the idle speed is unstable, check the valve clearances.
Check the injectors (flow and shape of the jet).
If necessary, replace the oxygen sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
INJECTOR
DIAG 11
NOTES
XR25 aid:
2 injectors
2 injectors
Repair if necessary.
During command mode operation, check for + 12 Volts on track 1 of the faulty injector.
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
IMMOBILISER
DIAG 12
NOTES
XR25 aid:
Check the insulation and continuity of the wiring for track 37 on the injection computer.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
VEHICLE SPEED
DIAG 13
NOTES
XR25 aid:
Repair.
The fault persists! Replace the speed sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
ADAPTIVE RICHNESS
DIAG 14
NOTES
XR25 aid:
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
E7J 780
engine
17
Fiche n 27
EMISSION OF POLLUTANTS
DIAG 15
NOTES
0.97 1.03
at 2500 rpm.
XR25 aid:
None
NOTES
0.97 1.03
at 2500 rpm.
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
E7J 780
engine
17
Fiche n 27
DIAG 15
CONT
NOTES
> 1.03
at 2500 rpm.
NOTES
None
< 0.97
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm. CO >
0.3 % at 2500 rpm.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
AIR CONDITIONING
DIAG 16
NOTES
XR25 aid:
Check the insulation and continuity of the lines for track 5 and track 51 on the injection computer.
Repair if necessary.
Refer to the fault finding for the air conditioning.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
17
Fiche n 27
ANTIPERCOLATION RELAY
DIAG 17
NOTES
XR25 aid:
The fan assembly must operate when command mode G17* is used.
There is not 12 V
on track 1
There is 12 V
on track 1
Fan assembly relay in place, check, during operation of the command mode,
for 12 V on track 5 of the fan assembly relay.
There is not 12 V
on track 5
There is 12 V
on track 5
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
DIAG 18
NOTES
XR25 aid:
None
Check the correct operation of the power assisted steering (oil level, ...).
Check the insulation and continuity of the line for track 13 on the injection computer.
Check the power assisted steering pressostat is correctly connected.
Repair if necessary.
If all these points are correct, replace the power assisted steering pressostat.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
DIAG 19
NOTES
XR25 aid:
None
AFTER REPAIR
Start the status and parameter check again from the beginning.
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E7J 780
engine
NOTES
INJECTION
Fault finding - Customer complaints
17
Only refer to this customer complaint after a complete check using the XR25.
STARTING FAULTS
Chart 1
Chart 2
Chart 3
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E7J 780
engine
Chart 1
NOTES
INJECTION
Fault finding - Fault charts
17
STARTING FAULTS
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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INJECTION
Fault finding - Fault charts
E7J 780
engine
Chart 2
NOTES
17
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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INJECTION
Fault finding - Fault charts
E7J 780
engine
17
Chart 2
CONT
NOTES
Only refer to this customer complaint after a complete check using the XR25.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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INJECTION
Fault finding - Fault charts
E7J 780
engine
Chart 3
NOTES
17
Only refer to this customer complaint after a complete check using the XR25.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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INJECTION
Fault finding - Fault charts
E7J 780
engine
17
Chart 3
SUITE
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
JF5111.0
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INJECTION
Fault finding -Aid
E7J 780
engine
17
14.5
A-D
= 52
B - C = 52
35
Primary
1-3 ; 2-3 = 1
1-2
= 0.5
Secondary
10 k
3 to 15
220
Fuel pressure
CO
0.3 % maximum
HC
CO2
14.5 % minimum
Lambda
Value for:
full load
1-2 = 2200
1-3 = 4460
2-3 = 5340
Sensor resistance
Temperature in C
20
40
80
90
7470
to
11970
3060
to
4045
1315
to
1600
6700
to
8000
2600
to
3000
1100
to
1300
270
to
300
200
to
215
JF5111.0
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Action
D13
(selector on
S8)
Bargraph
9.NJ
Use fiche n 27
fault test side
1
Fault test
Interpretation of
normally illuminated
bargraphs
1
Code present
2
3
Immobiliser
10.NJ
G01*
Use fiche n 27
status test side
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Interpretation of
normally illuminated
bargraphs
Code present
2
No load recognition
3
Illuminated if immobiliser
active
4
+ after ignition information
received
12
19
automatic transmission
(G50*1*)
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
2
6
Throttle position
potentiometer
No load
# 17
16 < X < 50
Accelerator
pedal slightly
depressed
Full load
# 17
Absolute pressure
sensor
# 01
X = Local atmospheric
pressure
Coolant temperature
sensor
# 02
X = Ambient temperature
5 C
Air temperature
sensor
# 03
X = Ambient temperature
5 C
10
# 12
11
12
Engine speed
Canister bleed
# 06
X = 0 rpm
# 23
X = 0.7 %
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17-65
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected).
Order of
operations
Function to be
checked
Action
Bargraph
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Battery voltage
# 04
if in # 04
then # 06
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
17
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected).
Function to be
checked
Interpretation of
normally illuminated
bargraphs
Action
Bargraph
Code present
2
No load recognition
3
Engine speed information
received
4
+ after ignition information
received
6
Idle speed regulation active
6
Richness regulation active
7
Fuel pump active
JF5111.0
17-67
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
4
(cont)
17
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected).
Function to be
checked
Interpretation of
normally illuminated
bargraphs (cont)
Action
Bargraph
12
19
Idle speed
automatic transmission
(G50*1*)
Without air
conditioning
operating
# 06
X = 750 50 rpm
# 12
2 % < X < 15 %
9
Air
conditioning
selected
10
Illuminated depending on
status of air conditioning
X = 880 50 rpm
# 06
17-68
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
17
Engine warm, at idle speed, after fan assembly has operated at least once.
Function to be
checked
Anti-pinking noise
measurement
Manifold pressure
Richness regulation
Action
Bargraph
# 13
(3500 rpm, no
load)
X is variable and
approximately 350 50 mb
(this pressure varies with
altitude)
# 01
no consumers
Stable engine
speed of 2500
rpm then idle
speed
# 05
# 35
# 21
7
10
Canister bleed
# 23
11
PAS pressostat
# 06
13
X = 850 rpm
JF5111.0
17-69
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INJECTION
Fault finding - Checking conformity
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Canister bleed
# 23
Vehicle speed
information
# 18
Pinking sensor
11
Vehicle under
load and
engine speed
2000 rpm
X = variable and not zero
# 13
0X7
(if there is a sensor fault, the
advance is retarded
systematically by 3 , which is
not visible using # 15 )
# 15
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E7J 780
engine
NOTES
INJECTION
Fault finding - Checking conformity
17
Order of
operations
Function to be
checked
Adaptive richness
Action
Bargraph
After
programming
phase
# 30
64 X 192
(average value after erasing
the memory: 128)
# 31
64 X 192
(average value after erasing
the memory: 128)
JF5111.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding- Introduction
17
Enter D13
9.NJ
COMPUTER IDENTIFICATION
The computer is not identified by reading a fault code but by reading the Part Number directly from the
computer. After having set up a dialogue with the computer:
ENTER
G70*
7700
XXX
XXX
The Part Number will then appear on the central display in three sequences.
Each sequence is displayed for approximately two seconds. The display is repeated twice .
After an operation on the injection system the computers memory can be erased by using the code G0** .
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Introduction
17
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier MS
1048.
89024S3
Bornier MS 1048 is a 35 track base with a printed circuit on which are 35 copper coated surfaces, numbered
from 1 to 35.
Using the wiring diagrams, the tracks connecting the components to be tested can be easily identified.
IMPORTANT :
All tests using bornier MS 1048 must be carried out with the battery disconnected.
The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 Volts be
applied to the test points.
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Introduction
17
This phase is the essential starting point for any intervention on the vehicle.
There are several constraints to the treatment of the bargraphs :
- A priority in the order of treatment when several bargraphs are illuminated.
- The interpretation of a bargraph depending on whether it is constantly illuminated or flashing .
1 - Order of priority
A series of illuminated bargraphs corresponding to the sensors with the same 12 V or having the same
earth, indicates a fault in this source. These priorities are dealt with in the "NOTES" section of the
fault-finding of the bargraph concerned.
NOTE : If the customer complaint does not correspond to the fault bargraph which is flashing
(example : Air temperature sensor fault bargraph flashing, but no customer complaint) ignore
this memorised fault and erase it.
3 - No bargraphs illuminated
If no bargraphs are illuminated on the XR25, carry out a status and parameter check. This may help in
detecting a problem.
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Introduction
17
The status and parameter check is aimed at checking the statuses and parameters which do not illuminate
any fault bargraphs if they are outside of permitted tolerance values . This phase allows :
- Faults to be found without the illumination of fault bargraphs which may correspond to a customer
complaint (example : absence of no load information causing an unstable idle speed).
- The correct operation of the injection to be checked and the risk of faults appearing shortly after the
repair to be eliminated.
This section contains fault-finding for statuses and parameters, under their test conditions
(example : fault finding for # 01 ignition on and fault finding for # 01 engine running).
If a status does not operate normally or a parameter is outside of permitted tolerance values, consult the
fault-finding page indicated in the "Fault-finding" column.
XR25
CHECK CORRECT
If the XR25 check is correct, but the customer complaint persists, the problem must be dealt with through
customer complaints.
Treatment of customer complaints
This section has fault charts, which suggest a series of possible causes of the problem.
These lines of enquiry must only be used in the following cases :
- No fault bargraph appears on the XR25.
- No faults are detected during the checking of statuses and parameters.
- The vehicle is not operating correctly
POST-REPAIR CHECK
This operation is a simple check of the repair (by a command, or by an XR25 command mode ...).
This makes it possible to check that the system upon which the intervention has been carried out is correct
electrically.
It is an introduction to the road test.
ROAD TEST
A road test is essential in order to guarantee the correct operation of the vehicle and to test the quality of the
repair. Its role is to make sure that no faults occur (or will occur) when driving.
In order to be significant, the road test is subject to special driving conditions.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Introduction
17
<
<
<
<
<
# 01
# 01
# 01
# 01
# 01
<
<
<
<
<
385 mbars
510 mbars
635 mbars
760 mbars
970 mbars
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D7F 710
engine 35 tracks
INJECTION
Fault finding - XR25 fiche
17
FI21727-1
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D7F 710
engine 35 tracks
INJECTION
Fault finding - XR25 fiche
17
FI21727-2
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D7F 710
engine 35 tracks
INJECTION
Fault finding - XR25 fiche
17
Illuminates when a dialogue has been established with the product computer. If it remains
extinguished:
- the code does not exist,
- there is a fault in the tool, the computer or the line
REPRESENTATION OF THE FAULTS (always on a coloured background)
If illuminated, indicates a fault on the tested product, the associated text defines the fault.
If extinguished, indicates that the fault has not been found on the tested product.
either
or
Engine running
Extinguishes when the function or condition given on the fiche is no longer performed.
Illuminates when the function or condition given on the fiche is performed
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D7F 710
engine 35 tracks
INJECTION
17
Bargraph 1 RH extinguished
XR25 CIRCUIT
XR25 aid:
NOTES
4
16
34
9
10
18
26
20
Earth
Earth
Earth
7 Diagnostic socket
15 Diagnostic socket
5 Main relay
2 Main relay
2 Fuel pump relay
AFTER REPAIR
17-83
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D7F 710
engine 35 tracks
INJECTION
17
COMPUTER CIRCUIT
XR25 aid:
NOTES
Computer faulty
None
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
IMMOBILISER CIRCUIT
XR25 aid:
NOTES
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the wiring on track 30 of the computer.
Repair if necessary.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR
17-85
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
Computer
2
15
2
1
Repair if necessary.
Check the resistance of the sensor. Replace it if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-86
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
If BG 3RH is flashing, increase the engine speed to 2500 rpm for 5 minutes
If BG 3RH becomes permanently illuminated, deal with the fault.
Check the connection and the condition of the connector on the oxygen sensor.
Check, ignition on during the timed phase, for :
- earth on track B of the oxygen sensor,
- + 12 V after the fuel pump relay on track A of the oxygen sensor.
Repair if necessary.
Check for the presence of earth on track 4 on the injection computer.
Repair if necessary.
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
22
C
Oxygen sensor
Repair if necessary.
The fault persists. Replace the oxygen sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
15
1
Coolant temperature sensor
Computer
6
2
Coolant temperature sensor
Repair if necessary.
Check the resistance of the sensor. Replace it if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-88
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
B1
Repair if necessary.
The fault persists! Replace the sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-89
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
Check that the pressure sensor is connected correctly both electrically and pneumatically.
Check the conformity of the pressure sensor pipe (it must not be holed or blocked...).
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
5
C Pressure sensor
Computer
15
A Pressure sensor
Computer
23
B Pressure sensor
Repair if necessary.
The fault persists! Replace the sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-90
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
*25 = CO.0
*25 = CC.0
*25 = CO.0
*25 = CC.0
*25 = In
=>
=>
=>
CO or CC- line 13 or 31
CC- line 13 or 31 on the computer
sensor incorrectly connected
*25 = In
Check the target sensor has been correctly connected (the sensor connector must
not be inverted).
Repair if necessary.
The fault persists! Replace the sensor.
AFTER REPAIR
17-91
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
For certain faults BG 6LH will only illuminate permanently at 3000 rpm. for 1
minute. If BG 4LH or BG 5LH or BG 3LH or BG 6RH is also illuminated, check line 15
on the computer.
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
1
2 Pinking sensor
Computer
15
1 Pinking sensor
Computer
16
Pinking sensor screening
Repair if necessary.
The fault persists! Replace the pinking sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-92
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
If BG 6RH is flashing and BG 3LH is fixed, deal with BG 3G. If BG 5LH is also
illuminated, check line 5 on the computer. If BG 4LH or BG 5LH or BG 6LH or BG
3LH is also illuminated, check line 15 on the computer .
3
5
15
C
B
A
Throttle potentiometer
Throttle potentiometer
Throttle potentiometer
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-93
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
AFTER REPAIR
17-94
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D7F 710
engine 35 tracks
INJECTION
17
11
INJECTOR CIRCUIT
XR25 aid:
NOTES
*11 = XX.CO
*11 = XX.CC
Check the resistance of the valve for the two faulty injectors.
Replace the injector/s if necessary.
When the ignition is switched on and during the timed phase, check for 12 V on track 1 of the faulty
injector.
If necessary, repair the line from track 1 injector to track 5 fuel pump relay.
Connect the bornier in place of the computer and check the insulation and continuity of the line :
Computer
Computer
33
32
2
2
Injectors 1 and 4
Injectors 2 and 3
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
17-95
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D7F 710
engine 35 tracks
INJECTION
17
11
AT
XR25 aid:
NOTES
INJECTION CIRCUIT
None
None
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
None
19
Instrument panel
Repair.
AFTER REPAIR
17-97
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D7F 710
engine 35 tracks
INJECTION
17
13
MEMORY CIRCUIT
XR25 aid:
NOTES
None
This bargraph only illuminates when the computer feed has been cut (disconnection of the battery, the
computer, ...).
Check the computer feed hygiene:
Computer
Main relay
18
3
5 Main relay
Fuse
Computer
Main relay
26
1
2 Main relay
Fuse
Computer
Fuel pump relay
20
1
Repair if necessary.
Turn the engine.
Switch the ignition off and wait for the loss of dialogue between the XR25 and the computer.
Switch the ignition on.
Enter dialogue with the computer.
Erase the computer memory using G0**.
NOTE : memorised faults are erased. It would therefore be useful to carry out a road test to check there
are no faults on the injection system.
AFTER REPAIR
17-98
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D7F 710
engine 35 tracks
INJECTION
17
14
NOTES
None
AFTER REPAIR
17-99
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D7F 710
engine 35 tracks
INJECTION
17
14
NOTES
None
24
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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D7F 710
engine 35 tracks
INJECTION
17
15
COMPUTER
XR25 aid:
NOTES
AC CONNECTION CIRCUIT
None
None
AFTER REPAIR
17-101
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D7F 710
engine 35 tracks
INJECTION
17
16
COMPUTER
XR25 aid:
NOTES
*16 = XX.CO
*16 = XX.CC
17
35
2
1
Coil
Coil
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter checks
Engine cold, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue
with XR25
D13
(selector on
S8)
Bargraph
Fault finding
1
Fault test
9.NJ
1
1
Use fiche 27
Code present
Change to
status test
G01*
10.NJ
Deal with
fault
bargraph
None
Status test
Battery
voltage
# 04
DIAG 1
19
Computer configured to
manual gearbox
4
Computer
configuration
19
Computer configured to
automatic transmission
Immobiliser
(if option)
Ignition on
See Fiche
"Reminder C"
to configure
vehicle
DIAG 12
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter checks
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Fault finding
2
No load
# 17
Throttle
position
potentiometer
.
Accelerator
pedal
slightly
depressed
10 < X < 50
2
DIAG 2
2
Full load
# 17
10
11
Pressure sensor
Coolant
temperature
sensor
Air
temperature
sensor
Fan assembly
Fault warning
light
X =Atmospheric pressure
# 01
# 02
X = Engine temperature
5 C
# 03
X = Temperature under
bonnet 5 C
G17*
Switch
ignition on
DIAG 9
DIAG 3
DIAG 4
DIAG 16
DIAG 18
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter checks
17
Carry out the actions below if the engine does not start.
NOTES
Order of
operations
Function to be
checked
Flywheel signal
sensor
Action
Bargraph
Ignition
Fuel pressure
Fault finding
3
Starter
Illuminated if TDC
information is detected
DIAG 5
G10*
DIAG 6
Connect
Optima
Station
Starting test.
Complete guide on
Optima Station
Fuel pump
2
Connect
pressure
gauge to
fuel inlet
and activate
starter
motor
Injector
command
Starter
Engine
compression
Connect
Optima
Station
Complete guide on
Optima Station
Flywheel
Connect
Optima
Station
Oscilloscope.
Complete guide on
Optima Station
Use Optima
5800 Station
Fuel pressure,
see Workshop
Repair
Manual or
section
DIAG 11
Use Optima
5800 Station
Use Optima
5800 Station
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter checks
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
NOTES
Order of
operations
Function to be
checked
Charging
circuit
Throttle
potentiometer
Idle speed
regulation
Anti-pinking
circuit
Pressure circuit
Action
Bargraph
# 06
DIAG 1
DIAG 2
# 12
4 % < X < 14 %
# 13 (at
3500 rpm,
no load)
DIAG 8
270 X 430 mb
X = atmospheric pressure
# 35
6
# 05
Fuel pressure
Fault finding
2
No load
# 16
Richness
regulation
# 04
# 01
17
Connect a
pressure
gauge to the
fuel inlet
and activate
the starter
motor
DIAG 9
DIAG 10
See also
DIAG 15
Fuel pressure,
see Workshop
Repair
Manual or
section
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter checks
NOTES
17
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
Order of
operations
Function to be
checked
Action
Power assisted
steering
pressostat
Turn wheels
to full lock
Bargraph
13
Fault finding
DIAG 17
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter checks
17
NOTES
Order of
operations
Function to be
checked
Vehicle speed
information
Action
Bargraph
# 18
Fault finding
X = speed read on
speedometer in km/h
DIAG 13
Programming
2
Adaptive
richness
Emission of
pollutants
# 30
106 X 150
# 31
106 X 150
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
0.97 < < 1.03
2500 rpm
after driving
DIAG 14
DIAG 15
see also
DIAG 10
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
At idle
speed, wait
for
stabilisation
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
BATTERY VOLTAGE
DIAG 1
NOTES
XR25 aid:
Ignition on
At idle speed
NOTE:
The battery and the charging circuit may be checked using the OPTIMA 5800 station (measurement does
not require the battery to be disconnected, which retains the memories of the computers).
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
THROTTLE POTENTIOMETER
XR25 aid:
DIAG 2
NOTES
17
Fiche n 27
# 17 outside tolerances
# 17 does not vary when throttle moves
Status BG 2LH or 2RH, incorrect illumination
None
NOTES
3
5
15
C
B
A
Throttle potentiometer
Throttle potentiometer
Throttle potentiometer
Repair if necessary.
# 17 is fixed
NOTES
None
Check the resistance of the throttle potentiometer when the throttle butterfly is moved.
If the resistance varies, check the electrical lines of the sensor.
If the resistance does not vary, check that the sensor is connected mechanically to the throttle.
If necessary, replace the sensor.
# 17 outside tolerances
NOTES
None
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
COOLANT TEMPERATURE
DIAG 3
NOTES
XR25 aid:
# 02 = Engine temperature 5 C
If the value read is incoherent, check the sensor is correctly following the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer
6
2
Coolant temperature sensor
Computer
15
1
Coolant temperature sensor
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
AIR TEMPERATURE
DIAG 4
NOTES
XR25 aid:
If the value read is incoherent, check the sensor is correctly following the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer
2
2
Air temperature sensor
Computer
15
1
Air temperature sensor
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
TDC DETECTION
DIAG 5
NOTES
XR25 aid:
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
FUEL PUMP
DIAG 6
XR25 aid:
NOTES
Repair if necessary.
Check the insulation and continuity of the wiring:
Fuel pump relay
Impact sensor
Impact sensor
C1 Fuel pump
Repair if necessary.
Check the hygiene and presence of earth on track C2 of the fuel pump.
If + 12 V is not reaching the fuel pump, replace the fuel pump relay.
If + 12 V is reaching the fuel pump, replace the fuel pump.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
Fiche n 27
DIAG 7
NOTES
# 06 < Minimum
NOTES
# 06 > Maximum
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
Fiche n 27
ANTI-PINKING CIRCUIT
DIAG 8
NOTES
XR25 aid:
The pinking sensor should give a signal which is variable and not zero, to prove that it is recording the
mechanical vibrations of the engine.
If the signal is zero:
- Check the sensor is correctly screwed in.
- Check the insulation and continuity of the wiring:
Computer
1
2
Pinking sensor
Computer
15
1
Pinking sensor
Computer
16
Pinking sensor screening
If necessary, replace the sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
Fiche n 27
PRESSURE CIRCUIT
DIAG 9
XR25 aid:
NOTES
# 01 not coherent
ignition on
# 01 < Minimum at idle
speed
# 16 not coherent
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
RICHNESS REGULATION
DIAG 10
NOTES
XR25 aid:
Check the sealing of the canister bleed valve (a leak can disrupt the richness considerably).
Check the sealing of the exhaust pipe upstream from the oxygen sensor.
Check the sealing of the inlet manifold.
If the vehicle has only been driven in town, the sensor is contaminated (try driving under load).
Check the fuel pressure.
If the idle speed is unstable, check the valve clearances.
Check the injectors (flow and shape of the jet).
If necessary, replace the oxygen sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
INJECTOR
DIAG 11
NOTES
XR25 aid:
2 injectors
2 injectors
Repair if necessary.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
Fiche n 27
IMMOBILISER
DIAG 12
NOTES
XR25 aid:
17
Check the insulation and continuity of the wiring for track 30 on the injection computer.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
VEHICLE SPEED
DIAG 13
NOTES
XR25 aid:
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27 side 2/2
ADAPTIVE RICHNESS
DIAG 14
NOTES
XR25 aid:
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
Fiche n 27
EMISSION OF POLLUTANTS
DIAG 15
NOTES
XR25 aid:
None
NOTES
0.97 1.03
at 2500 rpm
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
DIAG 15
CONT
NOTES
> 1.03
at 2500 rpm
NOTES
None
< 0.97
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm., CO >
0.3 % at 2500 rpm.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
Fiche n 27
ANTIPERCOLATION RELAY
DIAG 16
NOTES
XR25 aid:
The fan assembly must operate when command mode G17* is used.
There is not 12 V
on track 1
There is 12 V
on track 1
Fan assembly relay in place, check, during operation of the command mode,
for 12 V on track 5 of the fan assembly relay.
There is not 12 V
on track 5
There is 12 V
on track 5
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
DIAG 17
NOTES
XR25 aid:
None
Check the correct operation of the power assisted steering (oil level, ...).
Check the power assisted steering pressostat is correctly connected.
Check the insulation and continuity of the line for track 7 on the injection computer.
Repair if necessary.
If all these points are correct, replace the power assisted steering pressostat.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
DIAG 18
NOTES
XR25 aid:
None
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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NOTES
INJECTION
Fault finding - Customer complaints
17
Only refer to this customer complaint after a complete check using the XR25.
STARTING FAULTS
Chart 1
Chart 2
Chart 3
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Fault charts
17
STARTING FAULTS
Chart 1
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Fault charts
Chart 2
NOTES
17
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
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INJECTION
Fault finding - Fault charts
17
Chart 2
CONT
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Check the
engine
compression
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Fault charts
Chart 3
NOTES
17
Only refer to this customer complaint after a complete check using the XR25.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Fault charts
17
Chart 3
CONT
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding -Aid
17
14.5
A - D= 100
B - C = 100
35
Primary
Secondary
8 k
= 1.5
= 0.6
3 to 15
no load A-B
A-C
B-C
220
Fuel pressure
CO
0.3 % maximum
HC
CO2
14.5 % minimum
Lambda
Value for:
= 1300
= 1360
= 2300
full load
A-B= 1300
A-C= 2350
B-C = 1260
Sensor resistance
Temperature in C
20
40
80
90
5000
to
7000
1700
to
3300
500
to
1550
6700
to
8000
2600
to
3000
1100
to
1300
270
to
300
200
to
215
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Checking conformity
Engine cold, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
D13
(selector on
S8)
Bargraph
9.NJ
Use fiche n 27
fault test side
1
Fault test
Interpretation of
normally illuminated
bargraphs
1
Code present
2
3
Immobiliser
10.NJ
G01*
Use fiche n 27
status test side
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Interpretation of
normally illuminated
bargraphs
Code present
2
No load recognition
3
Illuminated if immobiliser
active
4
+ after ignition information
received
5
Locking relay control effective
12
Illuminates after erasing the
memory to indicate that the
operation has been carried out
correctly
12
19
automatic transmission
(G50*1*)
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
2
6
Throttle position
potentiometer
No load
# 17
10 < X < 50
2
Accelerator
pedal slightly
depressed
2
Full load
# 17
Absolute pressure
sensor
# 01
Coolant temperature
sensor
# 02
X = Ambient temperature
5 C
Air temperature
sensor
# 03
X = Ambient temperature
5 C
10
11
12
Engine speed
Canister bleed
# 12
# 06
X = 0 rpm
# 23
X = 0.7 %
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Checking conformity
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once
Order of
operations
Function to be
checked
Action
Bargraph
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Battery voltage
# 04
if in # 04
then # 06
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D7F 710
engine 35 tracks
INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Engine warm, at idle speed, after fan assembly has operated at least once
Function to be
checked
Interpretation of
normally illuminated
bargraphs
Action
Bargraph
Code present
2
No load recognition
3
Engine speed information
received
4
+ after ignition information
received
6
Idle speed regulation active
6
Richness regulation active
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INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
4
(cont)
17
Engine warm, at idle speed, after fan assembly has operated at least once
Function to be
checked
Interpretation of
normally illuminated
bargraphs (cont)
Action
Bargraph
12
19
automatic transmission
(G50*1*)
Idle speed
# 06
4 % < X < 14 %
# 12
Anti-pinking noise
measurement
X = 740 50 rpm
# 13
(3500 rpm, no
load)
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INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
Engine warm, at idle speed, after fan assembly has operated at least once
Function to be
checked
Action
Bargraph
Manifold pressure
# 01
no consumers
Richness regulation
Stable engine
speed of 2500
rpm then idle
speed
17
X is variable and is
approximately
270 X 430 mb
(this pressure varies with
altitude)
6
# 05
# 35
# 21
11
10
Canister bleed
# 23
13
11
PAS pressostat
X = 800 rpm
# 06
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INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
10.NJ
G01*
Use fiche n 27
status test side
20
No fault present
2
Canister bleed
# 23
Vehicle speed
information
# 18
Pinking sensor
11
Vehicle under
load and
engine speed
2000 rpm
# 13
# 15
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NOTES
INJECTION
Fault finding - Checking conformity
17
Order of
operations
Function to be
checked
Adaptive richness
Action
Bargraph
After
programming
phase
# 30
106 X 150
(average value after erasing
the memory: 128)
# 31
106 X 150
(average value after erasing
the memory: 128)
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MULTIPOINT INJECTION
FAULT FINDING
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152
..............................................................
155
..................................................................
175
...........................................................
181
Customer complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
201
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207
Checking conformity
208
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D7F 710
engine 55 tracks
INJECTION
Fault finding- Introduction
17
Enter D13
9.NJ
COMPUTER IDENTIFICATION
The computer is not identified by reading a fault code but by reading the Part Number directly from the
computer. After having set up a dialogue with the computer:
ENTER
G70*
7700
XXX
XXX
The Part Number will then appear on the central display in three sequences.
Each sequence is displayed for approximately two seconds. The display is repeated twice .
After an operation on the injection system the computers memory can be erased by using the code G0** .
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INJECTION
Fault finding - Introduction
17
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier Sus
1228.
97434S
Bornier Sus 1228 is a 55 track base with a printed circuit on which are 55 copper coated surfaces, numbered
from 1 to 55.
Using the wiring diagrams, the tracks connecting the components to be tested can be easily identified.
IMPORTANT :
All tests using bornier Sus 1228 must be carried out with the battery disconnected.
The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 Volts be
applied to the test points.
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INJECTION
Fault finding - Introduction
17
This phase is the essential starting point for any intervention on the vehicle.
There are several constraints to the treatment of the bargraphs :
- A priority in the order of treatment when several bargraphs are illuminated.
- The interpretation of a bargraph depending on whether it is constantly illuminated or flashing .
1 - Order of priority
A series of illuminated bargraphs corresponding to the sensors with the same 12 V or having the same
earth, indicates a fault in this source. These priorities are dealt with in the "NOTES" section of the
fault-finding of the bargraph concerned.
NOTE : If the customer complaint does not correspond to the fault bargraph which is flashing
(example : Air temperature sensor fault bargraph flashing, but no customer complaint) ignore
this memorised fault and erase it.
3 - No bargraphs illuminated
If no bargraphs are illuminated on the XR25, carry out a status and parameter check. This may help in
detecting a problem.
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INJECTION
Fault finding - Introduction
17
The status and parameter check is aimed at checking the statuses and parameters which do not illuminate
any fault bargraphs if they are outside of permitted tolerance values . This phase allows :
- Faults to be found without the illumination of fault bargraphs which may correspond to a customer
complaint (example : absence of no load information causing an unstable idle speed).
- The correct operation of the injection to be checked and the risk of faults appearing shortly after the
repair to be eliminated.
This section contains fault-finding for statuses and parameters, under their test conditions
(example : fault finding for # 01 ignition on and fault finding for # 01 engine running).
If a status does not operate normally or a parameter is outside of permitted tolerance values, consult the
fault-finding page indicated in the "Fault-finding" column.
XR25
CHECK CORRECT
If the XR25 check is correct, but the customer complaint persists, the problem must be dealt with through
customer complaints.
Treatment of customer complaints
This section has fault charts, which suggest a series of possible causes of the problem.
These lines of enquiry must only be used in the following cases :
- No fault bargraph appears on the XR25.
- No faults are detected during the checking of statuses and parameters.
- The vehicle is not operating correctly
POST-REPAIR CHECK
This operation is a simple check of the repair (by a command, or by an XR25 command mode ...).
This makes it possible to check that the system upon which the intervention has been carried out is correct
electrically.
It is an introduction to the road test.
ROAD TEST
A road test is essential in order to guarantee the correct operation of the vehicle and to test the quality of the
repair. Its role is to make sure that no faults occur (or will occur) when driving.
In order to be significant, the road test is subject to special driving conditions.
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INJECTION
Fault finding - Introduction
17
<
<
<
<
<
# 01
# 01
# 01
# 01
# 01
<
<
<
<
<
385 mbars
510 mbars
635 mbars
760 mbars
970 mbars
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INJECTION
Fault finding - XR25 fiche
17
FI21727-1
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INJECTION
Fault finding - XR25 fiche
17
FI21727-2
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INJECTION
Fault finding - XR25 fiche
17
Illuminates when a dialogue has been established with the product computer. If it remains
extinguished:
- the code does not exist,
- there is a fault in the tool, the computer or the line
REPRESENTATION OF THE FAULTS (always on a coloured background)
If illuminated, indicates a fault on the tested product, the associated text defines the fault.
If extinguished, indicates that the fault has not been found on the tested product.
either
or
Engine running
Extinguishes when the function or condition given on the fiche is no longer performed.
Illuminates when the function or condition given on the fiche is performed
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INJECTION
17
Bargraph 1 RH extinguished
XR25 CIRCUIT
XR25 aid:
NOTES
18
2
3
11
38
1
40
48
Earth
Earth
Earth
7 Diagnostic socket
15 Diagnostic socket
5 Main relay
2 Main relay
2 Fuel pump relay
AFTER REPAIR
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INJECTION
17
COMPUTER CIRCUIT
XR25 aid: computer faulty
NOTES
None
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INJECTION
17
IMMOBILISER CIRCUIT
XR25 aid:
NOTES
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the wiring on track 37 of the computer.
Repair if necessary.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR
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INJECTION
17
NOTES
Connect the bornier in place of the computer and check the insulation and continuity of the line.
Computer
Computer
20
46
2
1
Repair if necessary.
Check the resistance of the sensor. Replace if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
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INJECTION
17
NOTES
Check the connection and the condition of the connector on the oxygen sensor.
Check, ignition on during the timed phase, for :
- earth on track B of the oxygen sensor,
- + 12 V after the fuel pump relay on track A of the oxygen sensor.
Repair if necessary.
Check for the presence of earth on track 18 of the injection computer.
Repair if necessary.
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer 17
C Oxygen sensor
Repair if necessary.
The fault persists. Replace the oxygen sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
17
NOTES
If BG 6LH or BG 5LH is also illuminated , check line 44 of the computer. For certain
faults, BG 4LH is only permanently illuminated when the engine is running.
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer 44
1 Coolant temperature sensor
Computer 15
2 Coolant temperature sensor
Repair if necessary.
Check the resistance of the sensor. Replace it if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
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INJECTION
17
NOTES
12
B1
Repair if necessary.
The fault persists! Replace the sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
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INJECTION
17
NOTES
Check that the pressure sensor is connected correctly both electrically and pneumatically.
Check the conformity of the pressure sensor pipe (it must not be pierced or blocked...).
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
45
C Pressure sensor
Computer
44
A Pressure sensor
Computer
16
B Pressure sensor
Repair if necessary.
The fault persists! Replace the sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
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INJECTION
17
NOTES
*25 = CO.0
*25 = CC.0
*25 = CO.0
*25 = CC.0
*25 = In
=>
=>
=>
*25 = In
Check the target sensor has been correctly connected (the sensor connector must
not be inverted).
Repair if necessary.
The fault persists! Replace the sensor.
AFTER REPAIR
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INJECTION
17
NOTES
For certain faults BG 6LH will only illuminate permanently at 3000 rpm. for 1
minute. If BG 4LH or BG 5LH is also illuminated, check line 44 of the computer.
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the line:
Computer
54
2 Pinking sensor
Computer
44
1 Pinking sensor
Computer
2
Pinking sensor screening
Repair if necessary.
The fault persists! Replace the pinking sensor.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
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INJECTION
17
NOTES
19
45
46
C
B
A
Throttle potentiometer
Throttle potentiometer
Throttle potentiometer
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
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INJECTION
17
NOTES
AFTER REPAIR
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INJECTION
17
11
INJECTOR CIRCUIT
XR25 aid:
NOTES
*11 = XX.CO
*11 = XX.CC
Check the resistance of the value for the two faulty injectors.
Replace the injector/s if necessary.
When the ignition is switched on and during the timed phase, check for 12 V on track 1 of the faulty
injector.
If necessary, repair the line from track 1 injector to track 5 fuel pump relay.
Connect the bornier in place of the computer and check the insulation and continuity of the line :
Computer
Computer
30
4
2
2
Injectors 1 and 4
Injectors 2 and 3
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
17
11
AUTOMATIC TRANSMISSION
XR25 aid:
INJECTION CIRCUIT
None
None
NOTES
Ignore this bargraph, as this vehicle is not fitted with automatic transmission.
AFTER REPAIR
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INJECTION
17
NOTES
None
43
Instrument panel
Repair.
AFTER REPAIR
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INJECTION
17
13
MEMORY CIRCUIT
Loss of computer feed.
XR25 aid:
NOTES
None
This bargraph only illuminates when the computer feed has been cut (disconnection of the battery, the
computer, ...).
Check the computer feed hygiene:
Computer
Main relay
1
3
Computer
Main relay
40
Computer
Fuel pump relay
48
1
5 Main relay
Fuse
2 Main relay
Fuse
2 Fuel pump relay
Fuse
Repair if necessary.
Run the engine.
Switch the ignition off and wait for the loss of dialogue between the XR25 and the computer.
Switch the ignition on.
Enter dialogue with the computer.
Erase the computer memory using G0**.
NOTE :
Memorised faults are erased. It would therefore be useful to carry out a road test to check
there are no faults on the injection system.
AFTER REPAIR
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INJECTION
17
14
NOTES
None
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INJECTION
17
14
NOTES
None
42
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
17
15
COMPUTER
XR25 aid:
NOTES
Fiche n 27 side 1/
AC CONNECTION CIRCUIT
Check that the vehicle has air conditioning, if not, ignore this bargraph.
Connect the bornier in place of the computer and check the insulation and continuity of line 51 of the
computer.
Repair if necessary.
If the fault persists, consult the air conditioning fault finding section.
AFTER REPAIR
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INJECTION
Fault finding - Interpretation of XR25 bargraphs
16
COMPUTER
XR25 aid:
NOTES
17
Fiche n 27 side 1
*16 = XX.CO
*16 = XX.CC
29
28
2
1
Coil
Coil
Repair if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
Fault finding - Status and parameter checks
Engine stopped, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue
with XR25
D13
(selector
on S8)
Bargraph
Fault finding
1
Fault test
9.NJ
Use fiche 27
1
Deal with
fault
bargraph
Code present
Change to
status test
10.NJ
None
G01*
Status test
Battery
voltage
# 04
19
Computer
configuration
Immobiliser
(if option)
19
Ignition on
3
Computer configured to
manual gearbox
Computer configured to
automatic transmission
DIAG 1
See Fiche
Reminder C
to configure
the vehicle
DIAG 12
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INJECTION
Fault finding - Status and parameter checks
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Fault finding
2
No load
# 17
Throttle
position
potentiometer
.
Accelerator
pedal
slightly
depressed
10 < X < 50
2
DIAG 2
Pressure sensor
Coolant
temperature
sensor
Air
temperature
sensor
10
Fan assembly
11
Fault warning
light
Full load
# 17
# 01
X = Atmospheric
pressure
DIAG 9
# 02
X = Engine temperature
5 C
DIAG 3
# 03
X = Temperature under
bonnet 5 C
DIAG 4
G17*
DIAG 17
Switch
ignition on
DIAG 19
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INJECTION
Fault finding - Status and parameter checks
17
Carry out the actions below if the engine does not start.
NOTES
Order of
operations
Function to be
checked
Flywheel signal
sensor
Action
Bargraph
Fault finding
Fuel pump
Ignition
Fuel pressure
Starter
Illuminated if TDC
information detected
DIAG 5
G10*
DIAG 6
Connect
Optima
Station
Connect
pressure
gauge to
fuel inlet
and activate
starter
motor
Injection
command
Starter
Engine
compression
Connect
Optima
Station
Flywheel
Connect
Optima
Station
Complete guide on
Optima Station
Oscilloscope.
Complete guide on
Optima Station
Use Optima
5800 Station
Fuel pressure,
see Workshop
Repair
Manual or
section
DIAG 11
Use Optima
5800 Station
Use Optima
5800 Station
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Fault finding - Status and parameter checks
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
NOTES
Order of
operations
Function to be
checked
Action
Charging
circuit
# 04
Throttle
potentiometer
Idle speed
regulation
Anti-pinking
circuit
Pressure circuit
Bargraph
No load
# 21
# 13 (at
3500 rpm,
no load)
Fuel pressure
# 35
# 05
Connect a
pressure
gauge to the
fuel gallery
and activate
the starter
motor
Fault finding
DIAG 1
DIAG 2
# 16
Richness
regulation
Illuminated(does not
flash!)
# 12
# 01
# 06
3
17
DIAG 7
DIAG 8
270 X 430 V
X = atmospheric pressure
DIAG 9
DIAG 10
Fuel pressure,
see Workshop
Repair
Manual or
section
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INJECTION
Fault finding - Status and parameter checks
NOTES
Order of
operations
Function to be
checked
17
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
Action
Bargraph
Fault finding
9
Extinguished if fast idle is
not active
AC selected
10
10
Air
conditioning
# 06
Illuminated if the
injection authorises
compressor operation
DIAG 16
# 44
300 X 4000 W
9
800 X 900 rpm
# 06
Power assisted
steering
prestostat
# 44
10
Turn wheels
to full lock
13
300 X 4000 W
DIAG 18
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INJECTION
Fault finding - Status and parameter checks
17
NOTES
Order of
operations
Function to be
checked
Vehicle speed
information
Action
Bargraph
Fault finding
DIAG 13
# 30
106 X 150
DIAG 14
# 31
106 X 150
# 18
Programming
2
Adaptive
richness
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
0.97 < < 1.03
2500rpm
after driving
3
Emission of
pollutants
At idle
speed, wait
for
stabilisation
DIAG 15
see also
DIAG 10
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
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Fault finding - Status and parameter interpretation
DIAG 1
NOTES
BATTERY VOLTAGE
XR25 aid: Battery voltage ignition on, Minimum< # 04 < Maximum
Battery voltage idle speed, Minimum< # 04 < Maximum
17
Fiche n 27
Ignition on
At idle speed
NOTE:
The battery and the charging circuit may be checked using the OPTIMA 5800 station (measurement does
not require the battery to be disconnected, which retains the memories of the computers).
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
Fault finding - Status and parameter interpretation
DIAG 2
NOTES
THROTTLE POTENTIOMETER
XR25 aid:# 17 outside tolerances
# 17 does not vary when throttle moves
Status BG 2LH or 2RH, incorrect illumination
17
Fiche n 27
NOTES
None
# 17 is fixed
NOTES
None
Check the resistance of the throttle potentiometer when the throttle is activated.
If the resistance varies, check the electrical lines of the sensor.
If the resistance does not vary, check that the sensor is connected mechanically to the throttle.
If necessary, replace the sensor.
# 17 outside tolerances
NOTES
None
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
Fault finding - Status and parameter interpretation
DIAG 3
17
COOLANT TEMPERATURE
XR25 aid:# 02 = Engine temperature 5 C
NOTES
No fault bargraphs should be illuminated.
If the value read is inconsistent, check the sensor correctly follows the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer 15
2 Coolant temperature sensor
Computer 44
1 Coolant temperature sensor
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
Fault finding - Status and parameter interpretation
DIAG 4
17
Fiche n 27
AIR TEMPERATURE
NOTES
No fault bargraphs should be illuminated.
If the value read is incoherent, check the sensor correctly follows the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer
20
2 Air temperature sensor
Computer
46
1 Air temperature sensor
Repair.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 5
17
Fiche n 27
TDC DETECTION
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 6
Fiche n 27
FUEL PUMP
XR25 aid:
17
NOTES
No fault bargraphs should be illuminated.
Impact sensor
C1 Fuel pump
Check the hygiene and presence of earth on track C2 of the fuel pump.
If + 12 V is not reaching the fuel pump, replace the fuel pump relay.
If + 12 V is reaching the fuel pump, replace the fuel pump.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 7
17
Fiche n 27
NOTES
No fault bargraphs should be illuminated.
# 06 < Minimum
NOTES
# 06 > Maximum
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
DIAG 8
Fiche n 27
ANTI-PINKING CIRCUIT
XR25 aid:# 13 is not zero and variable for fast idle or under load
NOTES
No fault bargraphs should be illuminated.
The pinking sensor should give a signal which is variable and not zero, to prove that it is recording the
mechanical vibrations of the engine.
If the signal is zero:
- Check the sensor is correctly screwed in.
- Check the insulation and continuity of the wiring:
Computer
54
2 Pinking sensor
Computer
44
1 Pinking sensor
Computer
2
Pinking sensor screening
If necessary, replace the sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
DIAG 9
XR25 aid:
NOTES
# 01 not coherent
ignition on
# 01 < Minimum at idle
speed
# 16 not coherent
Fiche n 27
PRESSURE CIRCUIT
Check the insulation, the continuity and that there is no interference on the
line:
Computer
45
C Pressure sensor
Computer
44
A Pressure sensor
Computer
16
B Pressure sensor
Repair if necessary.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 10
NOTES
Fiche n 27
RICHNESS REGULATION
XR25 aid:
17
Check the sealing of the canister bleed valve (a leak can disrupt the richness considerably).
Check the sealing of the exhaust pipe upstream from the oxygen sensor.
Check the sealing of the inlet manifold.
If the vehicle has only been driven in town, the sensor is contaminated (try driving under load).
Check the fuel pressure.
If the idle speed is unstable, check the valve clearances.
Check the injectors (flow and shape of the jet).
If necessary, replace the oxygen sensor.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 11
NOTES
17
INJECTOR
Fiche n 27
XR25 aid : CO or CC - line 30 of the computer for injectors 1 and 4
CO or CC - line 4 of the computers for injectors 2 and 3
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 12
17
Fiche n 27
IMMOBILISER
NOTES
Check the insulation and continuity of the wiring for track 37 on the injection computer.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 13
17
Fiche n 27
VEHICLE SPEED
XR25 aid:
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
DIAG 14
ADAPTIVE RICHNESS
XR25 aid:Minimum < # 30 < Maximum
Minimum < # 31 < Maximum
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
17
DIAG 15
Fiche n 27
EMISSION OF POLLUTANTS
XR25 aid:
None
NOTES
No fault bargraphs should be illuminated.
NOTES
NOTES
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 15
17
Fiche n 27
Cont.
NOTES
No fault bargraphs should be illuminated.
NOTES
None
< 0.97
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm, CO >
0.3 % at 2500 rpm.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 16
17
Fiche n 27
AIR CONDITIONING
NOTES
No fault bargraphs should be illuminated.
Check the insulation and continuity of lines track 5 and track 51 of the injection computer.Repair if
necessary.Consult the air conditioning fault finding.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
17
DIAG 17
Fiche n 27
ANTIPERCOLATION RELAY
XR25 aid:
The fan assembly must operate when command mode G17* is used.
NOTES
No fault bargraphs should be illuminated.
There is not 12 V
on track 1
There is 12 V
on track 1
Fan assembly relay in place, check, during operation of the command mode,
for 12 V on track 5 of the fan assembly relay.
There is not 12 V
on track 5
There is 12 V
on track 5
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 18
17
Fiche n 27
NOTES
No fault bargraphs should be illuminated.
Check the correct operation of the power assisted steering (oil level, ...).
Check the insulation and continuity of the line for track 13 on the injection computer.
Check the power assisted steering pressostat is correctly connected.
Repair if necessary.
If all these points are correct, replace the power assisted steering pressostat.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Status and parameter interpretation
DIAG 19
17
Fiche n 27
XR25 aid:None
NOTES
No fault bargraphs should be illuminated.
AFTER REPAIR
Start the status and parameter check again from the beginning.
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D7F 710
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INJECTION
Fault finding - Customer complaints
17
NOTES
Only refer to this customer complaint after a complete check using the XR25.
STARTING FAULTS
Chart 1
Chart 2
Chart 3
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Fault charts
17
STARTING FAULTS
Chart 1
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
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INJECTION
Fault finding - Fault charts
17
Chart 2
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
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INJECTION
Fault finding - Fault charts
17
Chart 2
CONT
NOTES
Only refer to this customer complaint after a complete check using the XR25.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
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INJECTION
Fault finding - Fault charts
17
Chart 3
NOTES
Only refer to this customer complaint after a complete check using the XR25.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Fault charts
17
Chart 3
CONT
NOTES
Only refer to this customer complaint after a complete check using the XR25.
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
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D7F 710
engine 55 tracks
17
14.5
A-D
B-C
35
Primary =
Secondary
= 100
= 100
= 1.5
8 k
3 to 15
220
Fuel pressure
CO
0.3 % maximum
HC
CO2
14.5 % minimum
Oxygen
Value for:
full load
A-B= 1300
A-C= 2350
B-C = 1260
Sensor resistance
Temperature in C
Air temperature sensor
Resistance in ohms
Coolant temperature sensor
Resistance in ohms
20
40
80
90
5000
to
7000
1700
to
3300
500
to
1550
6700
to
8000
2600
to
3000
1100
to
1300
270
to
300
200
to
215
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Checking conformity
Engine cold, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
D13
(selector on
S8)
Bargraph
9.NJ
Use fiche n 27
fault test side
1
Fault test
Interpretation of
normally illuminated
bargraphs
1
Code present
2
3
Immobiliser
10.NJ
G01*
Use fiche n 27
status test side
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Interpretation of
normally illuminated
bargraphs
Code present
2
No load recognition
3
Illuminated if immobiliser
active
4
+ after ignition information
received
5
Locking relay control effective
9
Always illuminated if air
conditioning option available
12
19
19
Automatic
transmission(G50*1*)
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
2
6
Throttle position
potentiometer
No load
# 17
10 < X < 50
Accelerator
pedal slightly
depressed
Full load
# 17
X = Local atmospheric
pressure
Absolute pressure
sensor
# 01
Coolant temperature
sensor
# 02
X = Ambient temperature
5 C
Air temperature
sensor
# 03
X = Ambient temperature
5 C
10
# 12
11
12
Engine speed
Canister bleed
# 06
X = 0 rpm
# 23
X = 0.7 %
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D7F 710
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INJECTION
Fault finding - Checking conformity
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once(air
conditioning not selected)
Order of
operations
Function to be
checked
Action
G01*
Bargraph
10.NJ
Use fiche n 27
status test side
20
2
No fault present
Battery voltage
# 04
if in # 04
then # 06
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D7F 710
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INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Engine warm, at idle speed, after fan assembly has operated at least once(air
conditioning not selected)
Function to be
checked
Interpretation of
normally illuminated
bargraphs
Action
Bargraph
Code present
2
No load recognition
3
Engine speed information
received
4
+ after ignition information
received
5
Locking relay control effective
6
Idle speed regulation active
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D7F 710
engine 55 tracks
INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
4
(cont)
17
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected)
Function to be
checked
Interpretation of
normally illuminated
bargraphs (cont)
Action
Bargraph
12
Illuminates after erasing the
memory to indicate that the
operation has been carried out
correctly
19
Automatic
transmission(G50*1*)
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D7F 710
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INJECTION
Fault finding - Checking conformity
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected)
Order of
operations
Function to be
checked
Action
Bargraph
6
Without air
conditioning
# 06
X = 740 50 rpm
# 12
4 % < X < 14 %
# 44
X 300 W
With air
conditioning
and without
fast idle
request
10
# 06
# 44
X = 740 50 rpm
With air
conditioning
and fast idle
request
300 X 4000 W
9
# 06
10
# 44
X = 850 50 rpm
300 X 4000 W
Anti-pinking noise
measurement
# 13
(3500 rpm, no
load)
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D7F 710
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INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected)
Function to be
checked
Manifold pressure
Richness regulation
17
Action
Bargraph
X is variable and is
approximately
270 X 430 mb
(this pressure varies with
altitude)
# 01
no consumers
Stable engine
speed of 2500
rpm then idle
speed
# 05
# 35
# 21
11
10
Canister bleed
# 23
13
11
PAS pressostat
X = 800 rpm
# 06
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D7F 710
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INJECTION
Fault finding - Checking conformity
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Canister bleed
# 23
Vehicle speed
information
# 18
Pinking sensor
11
Vehicle under
load and
engine speed
2000 rpm
X = variable and not zero
# 13
0X6
(if there is a sensor fault, the
advance is retarded
systematically by 4 , which is
not visible using # 15 )
# 15
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D7F 710
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NOTES
INJECTION
Fault finding - Checking conformity
17
Order of
operations
Function to be
checked
Adaptive richness
Action
Bargraph
After
programming
phase
# 30
106 X 150
(average value after erasing
the memory : 128)
# 31
106 X 150
(average value after erasing
the memory : 128)
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FAULT FINDING
CONTENTS
Pages
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
.............................................................
04
.........................................................................
18
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Customer complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Checking conformity
http://vnx.su
ABS BOSCH
5.3
38
CONDITIONS FOR APPLICATION FOR THE TESTS DEFINED IN THIS FAULT FINDING
The tests described in this fault finding are only to be applied when the wording of the fault corresponds
exactly to the display on the XR25 kit.
If a fault is dealt with because there is a flashing bargraph, the conditions for confirming the existence of an
actual fault (and the need to apply the fault finding ) can be found in the "Notes" or at the beginning of the
bargraph interpretation.
If a bargraph is only interpreted when it is permanently illuminated, the application of the recommended
tests in the fault finding when the bargraph is flashing will not allow you to determine the origin of the
memorisation of this fault. In this case, only a test of the wiring and the connections of the component in
question must be carried out (the fault is simply memorised as it was not present at the time of testing).
NOTE : The ignition must have been switched off before the XR25 kit is used.
- XR25 kit.
-
Reminders : When there is intermittent fault memorisation, the ABS warning light will illuminate the next
time the vehicle is used until the car reaches 7.5mph (12 km/h). When the fault is memorised, a
counter relating to the fault is set at 40 . This value is reduced by one each time the ignition is
turned on if the fault is not present when the vehicle exceeds 7.5mph (12 km/h). When the
reading on the counter is equal to 1, it remains at 1 and the fault is not erased.
B76531.0
38-1
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ABS BOSCH
5.3
PRESENTATION OF
38
FICHE N 53
FI21753
B76531.0
38-2
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ABS BOSCH
5.3
38
Illuminated
- Supplementary information:
Certain bargraphs have a *. Command*.., when the bargraph is illuminated, allows supplementary
information on the type of fault or status arising to be displayed.
B76531.0
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 1, right hand side extinguished
Code present
NOTES
None.
Check that the XR25 kit is not the cause of the fault by trying to communicate with the computer of
another vehicle. If the XR25 kit is not at fault and it will not communicate with any other computer in the
same vehicle, it is possible that a faulty computer is corrupting fault finding lines K and L . Locate this
computer by disconnecting the lines one by one.
Check that the ISO interface is correctly in position S8 and that you are using the most recent XR25
cassette and the correct access code.
Check the battery voltage and carry out the necessary operations to obtain the correct voltage(9.4Volts<
U battery<17.4Volts)
Check the presence and condition of the ABS fuse on the connection unit of the passenger compartment
(10A).
Check the connection of the computer connector and the condition of its connection.
Check the connection and condition of the connection at the R36 dashboard / ABS connection.
Check the ABS earth wires (tighten the two earth screws above the ABS assembly).
Check that the computer is correctly fed :
- earth on track 19 of the 31 track connector,
- + after ignition feed on track 15 of the 31track connector.
If dialogue is still not established after these tests, replace the ABS computer.,
AFTER REPAIR
When communication is established, deal with any fault bargraphs which may be
illuminated.
B76531.0
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 1 left hand side illuminated
Power supply/computer
NOTES
None.
Check the condition and position of the 60A ABS fuse in the engine connection unit (white mounting).
Ensure continuity between this fuse and tracks 17 and 18 of the computer connector (presence of positive
before ignition feed on both tracks). Check the tightness and condition of the battery terminals.
Check the connections on the 31 track connector of the ABS computer.
Check the ABS earths (above the hydraulic assembly) and visually check all the ABS wiring.
Erase the computer memory, exit the fault finding (G13*) and switch off the ignition.
Carry out a new XR25 test. If the "power supply / computer" fault persists, replace the ABS computer.
AFTER REPAIR
38-5
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ABS BOSCH
5.3
38
Fiche n 53
2-3-4-5
Bargraphs 2, 3, 4 or 5 right or left hand side flashing
To confirm their presence and therefore the need to apply the fault finding
described below start command G20*. The fault is present if the bargraph
appears illuminated at the end of the command.
If bargraph 11 left hand side is also illuminated, deal with bargraph 11 left hand
side as a priority.
Check the ABS earths (tightening of the two screws above the hydraulic assembly).
Check the condition and position of the 60A ABS fuse in the engine connection unit (white mounting).
Check the connection and condition of the connections on the 31 track connector of the computer.
Erase the computer memory, exit the fault finding mode(G13*) switch off the ignition.
Switch on the ignition and carry out a new test with the XR25 kit, using command G20*.
If the fault "solenoid valve circuit"reappears, replace the ABS computer.
AFTER REPAIR
38-6
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ABS BOSCH
5.3
38
Fiche n 53
NOTES
None.
If the resistance is correct, check and ensure the continuity of the connection between the sensor
connector and the computer connector:
- between one track of the sensor connector and track 7 of the computer connector,
- between the other track of the sensor connector and track 6 of the computer connector.
Also check the insulation between these connections.
Carry out a visual inspection of the sensor wiring and check the quality of the connection on the 31 track
computer connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode(G13*) and switch off the ignition.
Switch the ignition on and replace the sensor if the fault reappears.
If the fault reappears after replacing the sensor, replace the computer.
AFTER REPAIR
38-7
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 6 Right hand side illuminated
NOTES
None.
If the resistance is correct , check and ensure the continuity of the connections between the sensor
connector and the computer connector :
- between one track of the sensor connector and track 3 of the computer connector,
- between the other track of the sensor connector and track 5 of the computer connector.
Also check the insulation between these connections.
Carry out a visual inspection of the sensor wiring and check the quality of the connections on the 31
track computer connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor, then erase the
computer memory.
Exit the fault finding mode(G13*) and switch off the ignition.
Switch the ignition on and replace the sensor if the fault reappears .
If the fault reappears after replacing the sensor, replace the computer.
AFTER REPAIR
38-8
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 7 left hand side illuminated
NOTES
None.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
connector and the computer connector :
- between one track of the sensor connector and track 8 of the computer connector (via track B of the
connector under the body R101),
- between the other track of the sensor connector and track 9 of the computer connector (via track A of
the connector under the body R101).
Also check the insulation between these connections.
Carry out a visual inspection of the sensor wiring and check the quality of the connections on the 31 track
computer connector.
If all checks are correct, reconnect the computer and wheel speed sensor, then erase the computer
memory.
Exit fault finding mode(G13*) and switch off the ignition.
Switch on the ignition and replace the sensor if the fault reappears.
If the fault reappears after replacing the sensor, replace the computer.
AFTER REPAIR
38-9
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 7 Right hand side illuminated
NOTES
None.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
connector and the computer connector :
- between one track of the sensor connector and track 1 of the computer connector (via track D of the
connector under the body R101),
-between the other track of the sensor connector and track 2 of the computer connector (via track C of
the connector under the body R101).
Also check the insulation between these connections.
Carry out a visual inspection of sensor wiring and check the quality of the connections on the 31 track
computer connector.
If all checks are correct, reconnect the computer and the wheel speed sensor, then erase the computer
memory.
Exit fault finding mode(G13*) and switch off the ignition.
Switch on the ignition and replace the sensor if the fault reappears.
If the fault reappears after replacing the sensor, replace the computer.
AFTER REPAIR
38-10
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ABS BOSCH
5.3
38
Fiche n 53
8
Bargraph 8 right or left hand side
flashing
NOTES
Even if they are present at time of testing, these faults will always be declared by
BG 8 flashing on the left or right hand side.
To confirm their presence and therefore the need to apply the fault finding below, carry out a road test. The fault is present if the bargraph illuminates during
the test.
If bargraphs 6 and 8 left hand side are both illuminated, deal with bargraph 6
first.
If bargraphs 6 and 8 right hand side are both illuminated, deal with bargraph 6
first.
Check the quality of the wheel speed sensor mounting (its position and that it is tightened to
recommended torque).Check the sensor / target air gap over one wheel revolution : 0.13 mm < air
gap< 1.96 mm. Check conformity of the target (condition, number of teeth=26)
Carry out a visual inspection of the sensor wiring and check the quality of the connections on the 31 track
computer connector.
If all checks are correct, reconnect the computer and the wheel speed sensor, then erase the computer
memory.
Leave fault finding mode(G13*) and carry out a road test. Replace the sensor if the fault reappears.
If the fault reappears after replacing the sensor, it may be caused by an operating fault on a solenoid
valve and it is therefore necessary to carry out the hydraulic check of the solenoid valves with the XR25 kit
with command G03* or G04* (consult the section "Aid"). If the ten unlocking/locking cycles do not occur
on one of the wheels, replace the hydraulic assembly.
If the hydraulic assembly is not at fault, replace the computer.
AFTER REPAIR
38-11
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ABS BOSCH
5.3
38
Fiche n 53
9
Bargraph 9 right or left hand side flashing
NOTES
Even if present at time of test, these faults will always be declared by BG9 flashing on the left or right hand side.
To confirm their presence and therefore the need to apply the fault finding below, carry out a road test.The fault is present if the bargraph illuminates during
the test.
If bargraphs 7 and 9 left hand side are both illuminated, deal with bargraph 7
first.
If bargraphs 7 and 9 right hand side are both illuminated, deal with bargraph 7
first.
Check the quality of the wheel speed sensor mounting (position and torque tightening).
Check the connection and condition of the sensor connections.
Check the connections at the intermediate connector under the body R101.
If the connector is correct , check the resistance of the sensor at its connector.
Replace the sensor if its resistance is not approximately 1.6 Kohms (1.6 Kohms 320 ohms).
Carry out a visual inspection of the sensor wiring and check the quality of the connections on the 31 track
computer connector.
If all checks are correct, reconnect the computer and the wheel speed sensor, then erase the computer
memory. Leave fault finding mode(G13*) and carry out a road test.
If the fault reappears, check the sensor/target air gap over one wheel rotation :
0.03 mm < air gap< 2.4 mm (test only possible on vehicle with 4 bar rear axle).
Check conformity of the target:condition, number of teeth = 26.
If all checks are correct, leave fault finding mode(G13*) and carry out a road test.
Replace the sensor if the fault reappears.
If the fault reappears after replacing sensor, it could be caused by a solenoid valve operating fault. It is
therefore necessary to carry out a hydraulic test of the solenoid valves with the XR25 kit with command
G05* or G06* (consult section"Aid"). If the ten unlocking/locking cycles do not occur on one of the
wheels, replace the hydraulic assembly.
If the hydraulic assembly is not at fault, replace the computer.
AFTER REPAIR
38-12
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ABS BOSCH
5.3
10
38
Fiche n 53
NOTES
1.dEF
NOTES
1.dEF
2.dEF
If bargraph 10 RH is flashing, confirm the presence of the fault and therefore the
need to apply fault finding below, using command G20* on the XR25 kit.
The fault is present if the bargraph re-illuminates at the end of the command.
Check the ABS earths (tightening of the two earth bolts above the hydraulic assembly).
Check/ ensure continuity between the ABS earth and track 16 of the computer connector.
Check locking of the two-track connector of the pump motor.
If all checks are correct, reconnect the computer and erase the memory with command G0**.
Leave fault finding mode(G13*) and carry out a road test.
Replace the computer if the fault reappears.
2.dEF
NOTES
None.
AFTER REPAIR
38-13
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ABS BOSCH
5.3
38
11
Fiche n 53
Bargraph 11 left hand side illuminated
NOTES
None.
Carry out operations necessary for obtaining correct voltage between tracks 19 and 17/18 of the 31-track
ABS computer connector (9.4 volts < correct voltage < 17.4 volts) :
- Check tightness and condition of battery terminals.
- Check the 60A fuse in the engine connection unit (white base).
- Ensure continuity between the 60A fuse and tracks 17 and 18 of the computer connector.
- Check the ABS earths (tightening of the two earth bolts above the hydraulic assembly).
- Check/ ensure continuity between the ABS earth and track 19 of the computer connector.
If all the checks are correct, reconnect the computer then erase its memory with command G0**.
Leave fault finding mode(G13*) and carry out a road test. Replace the computer if the fault reappears.
AFTER REPAIR
38-14
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ABS BOSCH
5.3
12
38
Fiche n 53
Press the brake pedal while observing right and left bargraph 13.
Are the positions "pedal released" and "pedal depressed" registered?
YES
Check the two brake light bulbs and the earth of the rear light units (no
earthing of track 14 across the bulbs when pedal is not depressed ).
NO
AFTER REPAIR
38-15
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ABS BOSCH
5.3
12
38
Fiche n 53
NOTES
Check the quality of wheel speed sensor mountings (position and that they are tightened to the
recommended torque).
Check the conformity of the targets :condition, number of teeth= 26.
AFTER REPAIR
38-16
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ABS BOSCH
5.3
38
13
Fiche n 53
Bargraph 13 right and left
Brake pedal
NOTES
Carry out checks only if illumination of the bargraph is not consistent with the
pedal position.
- Check the condition and adjustment of the brake light switch. Replace if necessary.
- Check the operation of the brake light switch contact (closed contact between tracks A3 and B1).
Replace the brake light switch if there is permanent continuity between the two tracks.
- Check and ensure insulation from 12 volts of the connection between track B1 of the brake light
switch connector and track 14 of the ABS computer connector .
Intermediate connectors :
Dashboard / ABS R36 on track 8.
Dashboard / rear left hand side R2 on track 7.
AFTER REPAIR
Carry out a road test followed by a check with the XR25 kit.
B76531.0
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ABS BOSCH
5.3
NOTES
38
Only carry out this conformity check after a complete XR25 check.
Order of
operations
Function to be checked
Action
XR25 dialogue
D11
(selector on
S8)
Bargraph
#12
2
Computer conformity
Acknowledgement that
brake pedal is not
pressed
Acknowledgement that
brake pedal is pressed
Ignition
13
Press brake
pedal
13
B76531.0
38-18
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ABS BOSCH
5.3
38
Bleeding of hydraulic circuits : G15*3* front left / G15*4* front right / G15*5* rear left / G15*6* rear
right
Apply the procedure described in the section "Bleeding the circuits" in the Workshop Repair Manual.
B76531.0
38-19
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ABS BOSCH
5.3
NOTES
38
Only consult this section after a complete check with the XR25 kit.
ABS warning light does not illuminate for 3 seconds after ignition switched on.
Chart 1
Chart 2
Chart 3
Chart 3
Chart 4
Pulling.
Chart 5
Wandering.
Chart 6
Unexpected ABS operation at low speed and little force applied to brake.
Chart 7
Chart 8
Chart 9
Chart 10
Spongy pedal.
Chart 11
Chart 12
Chart 13
Chart 14
Chart 15
OTHER CASES
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-20
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ABS BOSCH
5.3
38
Fault chart 1
Only consult this section after a complete check with the XR25 kit.
NOTES
yes
no
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-21
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ABS BOSCH
5.3
38
Fault chart 2
Only consult this section after a complete check with the XR25 kit.
NOTES
yes
no
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-22
http://vnx.su
ABS BOSCH
5.3
Fault chart 3
NOTES
38
Only consult this section after a complete check with the XR25 kit.
Check the voltage of the computer power supply : 9.5 volts < correct voltage < 17.5 volts.
If necessary, carry out the following operations :
- Check the battery charge (check the charging circuit if necessary).
- Check the tightness and condition of the battery terminals.
- Check the ABS earths (tightness of two earth bolts above the ABS assembly).
Disconnect the computer and check the condition and the positioning of the shunt in the 31 track
connector (between track 19 and track 21).
Check on the computer side, the condition of the shunt opening pin.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-23
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ABS BOSCH
5.3
Fault chart 4
NOTES
38
Only consult this section after a complete check with the XR25 kit.
Wheel locking on a vehicle equipped with ABS, or tyre squeal, considered by the customer
as locking, can be linked to a normal reaction of the system and should not be systematically
considered as a fault :
- locking is allowed below 3.75 mph ( 6 km/h) (the system will not provide regulation).
- Braking with ABS regulation under very bad road conditions (high degree of tyre squeal).
- -----------------------------------------
REMINDER:
On the other hand, if there really is wheel locking on one or more wheels, lift the vehicle so the wheels can
be turned, and check :
- a possible incorrect connection in the speed sensor connection.
Use operations #01, #02, #03 and #04 while turning the appropriate wheel and ensure the consistency of the results obtained .
If the value measured is zero, turn the other wheels to confirm a bad electrical connection of the sensors and repair the wiring.
- A possible incorrect connection of the hydraulic assembly pipes.
Use operations G03*, G04*, G05* and G06* while applying the brake and check for the ten cycles of
unlocking/locking on the wheel concerned (consult section "Aid").
If the ten cycles do not occur on the wheel tested, (wheel remains locked), see if they occur on another wheel (if a bad connection is confirmed: repair).
If the ten cycles do not occur on a wheel and the pipes are correctly connected, replace the hydraulic
assembly.
Check the condition of the ABS targets and that they conform.
Also check the sensor/target air gap by rotating each of the wheels :
Front 0.13 mm < air gap over one rotation < 1.96 mm.
Rear 0.03 mm < air gap over one rotation < 2.4 mm (check only possible on vehicles with four-bar
rear axles).
If the fault persists after these checks, replace the hydraulic assembly.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-24
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ABS BOSCH
5.3
Fault chart 5
38
PULLING
Only consult this section after a complete check with the XR25 kit.
NOTES
yes
no
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-25
http://vnx.su
ABS BOSCH
5.3
Fault chart 6
38
WANDERING
Only consult this section after a complete check with the XR25 kit.
NOTES
yes
no
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-26
http://vnx.su
ABS BOSCH
5.3
Fault chart 7
NOTES
38
Only consult this section after a complete check with the XR25 kit.
It is possible to feel brake pedal vibrations which are linked to reactions of the system in particular
situations :
- Crossing speed bumps.
- Rear inside wheel lifts on tight bends.
If the problem is different, check the speed sensors connectors ( micro-breaks) as well as the air gaps.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-27
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ABS BOSCH
5.3
Fault chart 8
NOTES
38
Only consult this section after a complete check with the XR25 kit.
Under poor road conditions, it is normal to feel jerky operation and vibration of the pedal and a higher
degree of tyre squeal than on a good road surface.
This results in a feeling that there is variation in efficiency, but this is normal.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-28
http://vnx.su
ABS BOSCH
5.3
Fault chart 9
NOTES
38
Only consult this section after a complete check with the XR25 kit.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-29
http://vnx.su
ABS BOSCH
5.3
Fault chart 10
NOTES
38
Only consult this section after a complete check with the XR25 kit.
Passage of air from the hydraulic assembly regulation channels to brake circuits.
Bleed the circuits according to the procedure recommended in the Technical Note (use of XR25 command
modes. These command modes are described in the section "Aid").
After the operation, carry out a road test with ABS regulation.
If the fault persists, carry out the preceding operation once or twice more.
If customer complaint is particularly serious and bleeding brings about no improvement, replace the
hydraulic assembly.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-30
http://vnx.su
ABS BOSCH
5.3
Fault chart 11
NOTES
38
SPONGY PEDAL
Only consult this section after a complete check with the XR25 kit.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-31
http://vnx.su
ABS BOSCH
5.3
Fault chart 12
NOTES
38
Only consult this section after a complete check with the XR25 kit.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-32
http://vnx.su
ABS BOSCH
5.3
Fault chart 13
NOTES
38
Only consult this section after a complete check with the XR25 kit.
- Assembly vibration: check the presence and condition of the rubber assembly mounting pads.
- Vibration of pipes : check that all pipes are well clipped into their fixing clips and that there is no contact
between pipes or between pipes and bodywork.
To determine the origin of the noise, it is possible to use functions G03*, G04*, G05* and G06* on the XR25
kit (consult section "Aid").
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-33
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ABS BOSCH
5.3
Fault chart 14
NOTES
38
Only consult this section after a complete check with the XR25 kit.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-34
http://vnx.su
ABS BOSCH
5.3
Fault chart 15
NOTES
38
Only consult this section after a complete check with the XR25 kit.
Ensure that the XR25 is not at fault by trying to communicate with a computer on another vehicle. If the
XR25 is not at fault and dialogue is not being established with another computer on the same vehicle, it is
possible that a faulty computer is disturbing diagnostic lines K and L. Proceed with successive disconnections to localise this computer.
Check that the ISO interface is in position S8, that you are using the most recent version of the XR25 kit
and the correct access code.
Check the battery voltage and carry out the operations necessary to obtain the correct voltage (9.4 volts
< U battery< 17.4 volts).
Check the presence and condition of the ABS fuse on the passenger compartment connection unit (10A).
Check the connection of the computer connector and the condition of its connections.
Check the connection and condition of the connections at the R36 dashboard / ABS connector.
Check the ABS earth leads (tighten the two earth bolts above the ABS assembly).
Check that the computer is receiving the proper power supply :
- earth on track 19 of the 31 track connector,
- +after ignition on track 15 of the 31 track connector.
Check that the diagnostic socket is receiving the correct power supply:
- + before ignition on track 16,
- earth on track 5.
Check continuity and insulation of the lines of the diagnostic socket / ABS computer connections:
- between track 12 of the computer connector and track 15 of the diagnostic socket,
- between track 11 of the computer connector and track 7 of the diagnostic socket.
If dialogue is still not established after these checks, replace the ABS computer.
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
B76531.0
38-35
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IMMOBILISER
FAULT FINDING
SUMMARY
Pages
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
04
..............................................................
..........................................................
14
...................................................................
15
25
26
Conformity check
............................................................................
34
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
http://vnx.su
IMMOBILISER
Fault finding - Introduction
82
ISO selector on S8
Enter D56
n.56
PRECAUTION :
When carrying out the test using a multimeter, avoid using a test pin on connectors where the test pin is
of a size which could damage the clips and lead to a poor contact.
After repairing the immobiliser system, enter G0** on the keyboard of the XR25 kit to proceed with
erasing the memorised fault.
v0406.0
82-1
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IMMOBILISER
Fault finding- XR25 Fiche
PRESENTATION
OF XR25
82
FICHE N 56
FI21756
v0406.0
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IMMOBILISER
Fault finding- XR25 Fiche
82
DESCRIPTION OF BARGRAPHS
Illuminates when dialogue is established with the product computer, if it remains extinguished :
- the code does not exist,
- there is a line , computer or tool fault.
REPRESENTATION OF FAULTS (always on coloured background)
Illuminated, indicates a fault on the part tested, the associated text defines the fault.
or
Engine running
Extinguished when operation or condition specified on the fiche is no longer met.
Illuminated when operation or condition specified on the fiche is met.
v0406.0
82-3
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IMMOBILISER
82
side extinguished
Fiche n 56
NOTES
Check that lines K and L are not being disrupted by another computer.
AFTER REPAIR
When communication is established, deal with any fault bargraphs which may
be illuminated.
Carry out a conformity check.
v0406.0
82-4
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IMMOBILISER
Fault finding- Interpretation of XR25 Bargraphs
82
Fiche n 56
NOTES
NONE
NOTE : In the diesel version, incorrect configuration of the decoder unit does not prevent proper
operation of the immobiliser. Nevertheless, if there is a fault, the immobiliser warning light will
not illuminate.
AFTER REPAIR
82-5
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IMMOBILISER
82
Fiche n 56
NOTES
YES
NO
Repair the electrical wiring between track A7 of the 18 track decoder unit
connector and the passenger compartment fuse board.
AFTER REPAIR
82-6
http://vnx.su
IMMOBILISER
Fault finding- Interpretation of XR25 Bargraphs
Bargraph 5 left hand
side illuminated
82
Fiche n 56
Check that the central locking switch is not permanently depressed as the result of
a mechanical fault .
NOTES
Decoder
unit
Central locking
B3 switch
A1
B2
B5
NO
YES
Change the central locking switch.
AFTER REPAIR
82-7
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IMMOBILISER
82
side illuminated
Fiche n 56
NOTES
Set the XR25 to pulse sensor mode (button "G", input on terminal "Vin").
Ignition on, check for pulses on track A6 of the 18 track decoder unit connector (test with the decoder
unit and the coded electronic unit of the solenoid valve connectors connected).
Ignition on, if there are no pulses, change the decoder unit.
Switch on the ignition for 30 consecutive seconds, then switch off the ignition and wait until the
immobiliser warning light flashes (immobiliser active).
Switch on the ignition again and check that bargraph 8 left hand side is permanently illuminated.
Is Bargraph 8 left hand side permanently illuminated ?
YES
NO
AFTER REPAIR
82-8
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IMMOBILISER
82
Fiche n 56
NOTES
Before beginning the fault finding, switch on the ignition for longer than 30
consecutive seconds, then switch off the ignition.
For the diesel version, if bargraphs 6 right and 6 left are illuminated, check the impact switch.
Ensure that the connector of the coded electronic unit of the solenoid valve is properly connected.
Check the condition of the electrical wiring between track A6 of the decoder unit and track 8 of the
coded solenoid valve connector and check the 12 Volts supply and earth.
Repair if necessary.
Set the XR25 to pulse sensor mode (button "G", input on terminal "Vin").
Ignition on, check for pulses on track A6 of the decoder unit connector (test with decoder unit and
solenoid valve coded electronic unit connectors connected).
Are there any pulses?
YES
NO
AFTER REPAIR
82-9
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IMMOBILISER
Fault finding- Interpretation of XR25 Bargraphs
side illuminated
82
Fiche n 56
CODED LINE
NOTES
NONE.
For petrol vehicles, if bargraph 6 right hand side is illuminated, check the impact switch.
Check the continuity and insulation from earth and from 12 volts of the wiring between track A6 of the
18 track decoder unit connector and track ** of the injection computer .
Repair the wiring if necessary.
Set the XR25 to pulse sensor mode (button "G", input on terminal "Vin").
Ignition on, check for pulses on track A6 of the decoder unit connector (test with decoder unit and
solenoid valve coded electronic unit connectors connected).
Are there any pulses ?
YES
NO
AFTER REPAIR
82-10
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IMMOBILISER
Fault finding- Interpretation of XR25 Bargraphs
Fiche n 56
NOTES
82
*27 =
cc.1
co.0
None.
Check the continuity and insulation with earth and 12 volts of the wiring between :
18 track decoder unit connector
(A2
4)
antenna ring
YES
NO
AFTER REPAIR
82-11
http://vnx.su
IMMOBILISER
Fault finding- Interpretation of XR25 Bargraphs
11
82
Fiche n 56
NOTES
Check if locking or unlocking the doors is possible by testing with the other key. If locking or unlocking of
the vehicle doors is possible, replace the battery in the first key.
On the infrared transmitter connector, check for + 12 V before ignition feed between tracks B2 and A3.
Is this voltage present ?
YES
Set the XR25 to pulse sensor mode (button "G", input on terminal "Vin").
Check for pulses on track B2 of the infrared transmitter by pressing the PLIP (test
with the decoder unit and infrared transmitter connectors connected).
Are there any pulses when the PLIP is pressed?
NO
YES
NO
decoder unit
B1
B2
PLIP
B2
B3
central locking
A1
button
B5
Are they insulated from earth ?
AFTER REPAIR
YES
NO
82-12
http://vnx.su
IMMOBILISER
Fault finding- Interpretation of XR25 Bargraphs
11
side remains
extinguished
82
Fiche n 56
NOTES
Only consult the fault finding which follows if, when the PLIP is pressed BG 11 left
illuminates for 3 seconds and BG 11 right remains extinguished.
Check that the keys belong to the vehicle.
There is a desynchronisation between the PLIP code and the decoder unit code if bargraph 11 right
hand side remains extinguished when the PLIP is pressed (but bargraph 11 left hand side illuminates for
approximately 3 seconds before extinguishing) and locking or unlocking of the vehicle doors with the
PLIP is not possible.
Apply the procedure for resynchronising the PLIPs .
AFTER REPAIR
82-13
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IMMOBILISER
82
NOTES
Only consult these customer complaints after a complete check using the XR25
COMMUNICATION
Fault
Chart
1
Fault
Chart
2
Fault
Chart
3
Fault
Chart
4
Fault
Chart
5
Fault
Chart
6
NO
XR25/DECODER UNIT
v0406.0
82-14
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
Fault Chart 1
NOTES
82
Lines K and L are shared between several computers, which can disrupt them. If
the fault persists, it would be prudent to check that they are not disrupting lines K
and L.
Ensure that the XR25 is not the cause of the fault by trying to communicate with another computer on the
vehicle (air conditioning computer, injection computer ...).
Check that the ISO selector is on position S8 , that you are using the latest XR25 cassette and and the correct
access code (D56).
Check the battery voltage (U > 10.5 volts). Recharge the battery if necessary.
If there is still no dialogue between the XR25 and the decoder unit , replace the decoder unit .
AFTER REPAIR
When communication has been established, deal with any illuminated fault
bargraphs.
Carry out a conformity check.
v0406.0
82-15
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 2
None.
NOTES
no
no
no
no
yes
Check the condition of the antenna ring fuse.
Is the fuse in good condition?
yes
Switch on the ignition and check that
bargraph 4 RH is illuminated.
Is bargraph 4RH illuminated?
yes
Switch on the ignition (positive after ignition
feed) and check that
bargraph 19RH is extinguished.
Is bargraph 19RH extinguished ?
yes
AFTER REPAIR
82-16
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 2
CONT 1
yes
no
Check the key recognition function.
Try to start the vehicle with the second key.
Can the vehicle be started?
yes
no
no
Test the memory of the unit by entering #65
If "0" is displayed , test OK
If "1" is displayed ,fault .
Is "0" displayed on the screen ?
yes
Is the antenna ring correctly mounted on the
ignition switch ?
no
yes
AFTER REPAIR
82-17
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 2
CONT 2
2
2
4
masse
+AVC
A2
decoder
bornier
no
yes
no
yes
Switch off the ignition and wait until the
immobiliser warning light flashes
(immobiliser active ). Set the XR25 to pulse
sensor mode (button "G",
input on terminal "Vin").
When switching on the ignition again, check
for a pulse on track A2 of the decoder unit
(test with decoder unit and antenna ring
connectors connected).
Is there a pulse?
yes
Replace the key.
AFTER REPAIR
82-18
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 3
Check that decoder unit programming has been correctly carried out.
NOTES
no
no
no
no
yes
Check that bargraph 3RH is extinguished .
Is bargraph 3RH extinguished ?
yes
Check that bargraph 5LH is extinguished .
Is Bargraph 5LH extinguished ?
yes
Check continuity and insulation from earth
of the wiring between track A5 of the 18
track decoder unit connector and the
instrument panel .
Is the wiring in good condition?
yes
AFTER REPAIR
82-19
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 3
CONT
no
yes
AFTER REPAIR
82-20
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 4
None.
NOTES
no
yes
yes
no
Check continuity and insulation from earth
and 12 volts of the wiring between
track A6 of the 18 track decoder unit
connector and track 19 (or 43 depending on
engine) of the injection computer.
Is the wiring in good condition ?
no
yes
AFTER REPAIR
82-21
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 4
CONT
yes
no
Replace the decoder unit or refer to the
Workshop Repair Manual, section "replacing
decoder and key kit".
AFTER REPAIR
82-22
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 5
None.
NOTES
no
no
yes
XR25 still connected , check whether
BG 2RH is illuminated on the following
injection fiches:
on the Safrane:
-fiche n 27 side 1/2
on the Laguna :
- fiche n 13 (depending on the engine)
- fiche n 27 side 1/2 (depending on the
engine)
- fiche n 28 (depending on the engine) Is BG
2RH illuminated on these injection fiches?
yes
Refer to the chart for BG 2RH injection fiche
in the section "Fault finding - Interpretation
of XR25 bargraphs ".
AFTER REPAIR
82-23
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
82
Fault Chart 6
None.
NOTES
no
yes
There is a problem with the impact switch.
AFTER REPAIR
82-24
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IMMOBILISER
82
NOTES
NO
Only consult these customer complaints after a complete check using the XR25
Chart
1
Chart
2
Chart
3
Chart
4
Chart
5
Chart
6
v0406.0
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
Fault Chart 1
NOTES
NO XR25/COMPUTER
82
COMMUNICATION
Lines K and L are shared between several computers, which can disrupt them. If
the fault persists, it would be prudent to check that they are not disrupting lines K
and L.
Ensure that the XR25 is not the cause of the fault by trying to communicate with another computer on the
vehicle (air conditioning computer, injection computer ...).
Check that the ISO selector is on position S8 , that you are using the latest XR25 cassette and the correct
access code (D56).
Check the battery voltage (U > 10.5 volts). Recharge the battery if necessary.
If there is still no dialogue between the XR25 and the decoder unit , replace the decoder unit .
AFTER REPAIR
When communication has been established, deal with any illuminated fault
bargraphs.
Carry out a conformity check.
v0406.0
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
82
Fault Chart 2
None.
NOTES
no
no
no
yes
Check the condition of the antenna ring.
Is the fuse in good condition?
yes
Switch on the ignition and check that
bargraph 4RH is illuminated .
Is Bargraph 4RH illuminated?
yes
Switch on the ignition and check that
bargraph 19RH is extinguished .
Is Bargraph 19RH extinguished ?
no
yes
AFTER REPAIR
82-27
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
82
Fault Chart 2
CONT 1
yes
no
Check the key recognition function.
Try to start the vehicle with the second key.
Can the vehicle be started?
yes
no
no
no
yes
AFTER REPAIR
82-28
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
82
Fault Chart 2
CONT 2
2
3
4
earth
+AVC
A2
decoder
bornier
no
yes
no
yes
Switch off the ignition and wait until the
immobiliser warning light flashes
(immobiliser active ). Set the XR25 to pulse
sensor mode (button "G",
input on terminal "Vin").
When turning on the ignition again, check for
a pulse on track A2 of the decoder unit (test
with decoder unit and antenna ring
connectors connected).
Is there a pulse?
yes
Replace the key.
AFTER REPAIR
82-29
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
82
Fault Chart 3
None.
NOTES
A6
decoder
bornier
no
no
yes
Set the XR25 to pulse sensor mode (button
"G", input on terminal "Vin"). Ignition on,
check for pulses on track A6 of the decoder
unit connector (test with decoder unit and
solenoid valve coded electronic unit
connectors connected).
Are there any pulses?
yes
XR25 connected , use fiche n 56.
Carry out a mechanical check of the solenoid
valve .
-- Ignition off, enter G23*.
- Switch on the ignition. The valve should
open and close several times in 30 seconds
(listen).
Does the valve open and close for
approximately 30 seconds ?
no
yes
Replace the decoder unit .
AFTER REPAIR
82-30
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IMMOBILISER
82
Fault Chart 4
None.
NOTES
no
yes
AFTER REPAIR
no
82-31
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
82
Fault Chart 5
Check that decoder unit programming has been properly carried out.
NOTES
no
no
no
no
yes
AFTER REPAIR
82-32
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
82
Fault Chart 6
None.
NOTES
no
yes
There is a problem with the impact switch.
AFTER REPAIR
82-33
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IMMOBILISER
Fault finding - Checking conformity
NOTES
82
Order of
operations
Function to be
checked
Action
D56
(selector on
S8)
Bargraph
n.56
1
2
Code present
X X X
Conformity of decoder
unit
G70*
Interpretation of
bargraphs normally
illuminated
v0406.0
82-34
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IMMOBILISER
Fault finding - Checking conformity
NOTES
Order of
operations
Function to be
checked
Action
Bargraph
Configuration of the
computer petrol/diesel
9
6
82
Forced protection
mode
Immobiliser status
10
Illuminated if immobiliser
active : switch off the ignition
and wait approximately 10
seconds for the BG 10LH to
illuminate.
Extinguished if immobiliser
inactive.
v0406.0
82-35
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IMMOBILISER
Fault finding - Checking conformity
NOTES
Order of
operations
Function to be
checked
Action
Bargraph
9
9
10
10
82
11
11
Reception of the
infrared signal from
the PLIP
11
v0406.0
82-36
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IMMOBILISER
Fault finding - Checking conformity
NOTES
Order of
operations
12
13
14
15
82
Function to be
checked
Action
Bargraph
Reception of door
lock/unlock
information from the
central door locking
button
14
Sending of
lock/unlock
information by the
decoder unit to the
locking micromotors.
14
Sending electric
window raise
information
Not used
15
16
Reception of "doors
open" information
v0406.0
82-37
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IMMOBILISER
Fault finding - Checking conformity
NOTES
Order of
operations
16
Function to be
checked
Action
Bargraph
17
Information on
programming or
resynchronisation of
PLIP in progress
Illuminated if programming or
resynchronisation in progress
(PLIP).
17
17
Programming not
carried out for PLIP
information
18
Programming of 1st
key information
19
Programming not
carried out for key
information
19
19
20
Programming not
confirmed for key
information
21
82
Illuminated if programming
not carried out (PLIP).
18
Not used.
Illuminated if programming
not carried out (key).
Illuminated if programming
not confirmed (key).
G60* : changes to 1 when
setting is completed.
Sending of
information is blocked
Enter security code
20
v0406.0
82-38
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IMMOBILISER
Fault finding - Aid
82
ADDITIONAL CHECKS
To use this function, enter G on the XR25 , then the number of the command followed by a star.
03
04
Forced protection mode : activates the immobiliser function even if the key is correct, which allows
starting prevention to be checked. Bargraph 9 left should illuminate.
This command must be entered when the ignition is off and the immobiliser function is active.
IMPORTANT : switching the ignition off cancels this command.
05
Immobiliser warning light command (illuminates immobiliser warning light for 3 seconds ).
08
09
13
22
Configuration :
- G 22 * 1 * = configuration for petrol vehicles (Bargraph 3RH should be extinguished).
- G 22 * 2 * = configuration for diesel vehicles (Bargraph 3RH should be illuminated).
23
32
39
Transponder line.
v0406.0
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IMMOBILISER
Fault finding - Aid
82
ADDITIONAL CHECKS
40
Entering the security code (Bargraph 10 left should be illuminated and the ignition turned on).
This command mode can be used to enter the security code but does not permit decoding of the
injection computer or of the coded solenoid valve.
Enter the number of the vehicles security code on the XR25 and validate with "*".
If the code number is correct, "bon" is displayed on the XR25 and bargraph 10 left extinguishes.
If the code number is incorrect, "Fin" is displayed on the XR25 and bargraph 10 left remains
illuminated.
IMPORTANT : 3 attempts may be made to enter the code. If, after the 3rd attempt, the code
remains invalid,you must wait for approximately 15 minutes before trying again (the ignition must
be switched on and off again between each attempt.)
47
70
43
26
27
65
Test E2 Prom.
95
v0406.0
82-40
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IMMOBILISER
Fault finding - Aid
82
To remove the clips and the wiring tabs of the two decoder unit connectors, the kit El. 1263 MUST be
used.The connector and the wiring could be irreparably damaged if this tool is not used.
Use the black tool to unclip the modules.
Use the brown tool to remove the clips.
96031R
v0406.0
82-41
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AIRBAG ANDPRETENSIONERS
FAULT FINDING
SUMMARY
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
05
.............................................................
07
.........................................................................
22
Checking conformity
...................................................................
23
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
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88
The checks defined in this fault finding should only be applied to a vehicle when the fault bargraph is
illuminated, indicating that the fault is present on the vehicle at the time of checking. Only a computer
fault will require replacement of the computer, whether the bargraph is permanently illuminated or
flashing .
If the fault is not present but simply memorised, the bargraph flashes and application of the checks
recommended in the fault finding section will not allow the origin of the fault to be found. In this case,
only a check of the wiring and the connection of the component in question must be carried out (it is
possible to test the wiring concerned in fault finding mode to try to obtain permanent illumination of the
bargraph ).
AND
SYSTEMS
REMINDER:
When carrying out an operation on the airbag/seat belt pretensioner systems , it is essential to lock the
computer with the XR25 command G80* to avoid all risk of triggering at the wrong time (all firing lines
will be inhibited). This operating mode will be indicated by illumination of the warning light on the
instrument panel.
Never carry out any measuring operations on the airbag and pretensioners trigger lines with equipment
other than the XRBAG.
Before using a dummy ignition module, ensure that its resistance is between 1.8 and 2.5 ohms.
Only 30 track connector computers with airbag(s) function are able to be tested with the XR25.
Computers with the pretensioner function only must be checked with the XRBAG by following the checks
described in the fault finding section.
The ignition must be switched off, then on again to make the warning light extinguish following erasure
of the memory using the command G0**.
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88
DI8811.1
A
B
C
D
H
Independent unit
Driver seat
Passenger seat
Pretensioners
+ 12 V
Earth
PRETENSIONERS
Measuring point
Correct Value
C0, C1 and C3
1.6 to 4.6
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88
DI8812.3
A
B
C
D
E
Central unit
Driver seat
Passenger seat
Pretensioners
Drivers airbag ignition module
CT
A1
A3
A2
B1
B2
Rotary switch
+12 Volts
Earth
Warning light
Diagnostic socket
AIRBAG
PRETENSIONERS
Measuring point
Correct value
Measuring point
Correct value
C0, C2 and C4
2 to 9.4
C0, C1 and C3
1.6 to 4.6
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88
DI8813.2
A
B
C
D
E
G
Central unit
Drivers seat
Passengers seat
Pretensioners
Drivers airbag ignition module
Passengers airbag ignition module
CT
A1
A3
A2
B1
B2
Rotary switch
+12 Volts
Earth
Warning light
Diagnostic socket
AIRBAG
Measuring point
Correct value
Driver
C0, C2 and C4
2 to 9.4
Passenger
C0 and C4
1.6 to 4.6
PRETENSIONERS
Measuring point
Correct value
C0, C1 and C3
1.6 to 4.6
88-4
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OF
XR25
88
FICHE N 49
FI21749
1EC761.0
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88
MEANING OF BARGRAPHS
If illuminated, indicates a fault on the product tested. The associated text defines
the fault.
This bargraph could be :
- Illuminated
: fault present.
- Flashing
: fault memorised.
- Extinguished
: fault absent or not found.
Indefinite
illuminated when the operation or the condition specified on the
fiche is met.
Extinguished
ADDITIONAL SPECIFICATIONS
Certain bargraphs have a *. The command *.., when the bargraph is illuminated,
allows additional information on the type of fault or status to be displayed.
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88
NOTES
Fiche n 49
Code present
The computers which only control the operation of the seat belt pretensioners do
not have XR25 fault finding (check to be carried out with XRBAG).
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on
another vehicle .
Check that the ISO selector is in position S8, that the latest XR25 cassette and the correct access code are
being used.
Check the battery voltage and carry out the operations necessary to obtain the correct voltage (10.5 volts
< U battery< 16 volts).
If dialogue is still not established after these various checks, replace the airbag computer (consult the
section on "Aid" for this operation).
AFTER REPAIR
1EC761.0
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NOTES
or flashing
88
Fiche n 49
Computer
None
Replace the airbag computer (consult the section "Aid" for this operation).
AFTER REPAIR
None
1EC761.0
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88
Voltage supply
XR25 aid:
NOTES
I.dEF - 2.dEF
Fiche n 49
*02 :
1.dEF
2.dEF
3.dEF
dEF
:
:
:
:
Use the 30 track adaptor of the XRBAG to operate on the computer connector .
NOTES
None
Carry out the operations necessary to obtain the correct computer power supply :
10.5 volts 0.1 < correct voltage< 16 volts 0.1.
- Check the battery charge.
- Check the charge circuit.
- Check the tightness and condition of the battery terminals.
- Check the computer earth .
3.dEF
NOTES
None
dEF
NOTES
None
The dEF display on the kit indicates the minimum memorisation of 2 of the 3 faults declared by the
display 1.dEF , 2 . d E F and 3.dEF (bargraph flashing ).
Operation:
- Check the battery charge.
- Check the charge circuit.
- Check the tightness and condition of the battery terminals.
- Condition of the computer connections.
- Check the computer earth .
- Condition / position of the fuse.
AFTER REPAIR
88-9
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88
NOTES
Fiche n 49
*05 :
CC : Short-circuit
CO : Open circuit
Never carry out measurements on the trigger lines with equipment other than the
XRBAG.
Reconnect the rotary switch below the steering wheel, disconnect the computer connector and fit the 30
track adaptor.
The XRBAG tool MUST be used for checking resistance on the wire marked B on the adaptor.
If the value obtained is not correct, check the 30 track connector connection (tracks 10 and 11) and
replace the wiring if necessary.
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
Reconnect the drivers airbag ignition module and remount the steering wheel cushion.
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
carry out another check with the XR25 and, if there is no fault, unlock the
computer using command G81*.
Destroy the airbag cushion if it has been replaced (tool El. 1287).
1EC761.0
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88
NOTES
Fiche n 49
*25 :
Never carry out measurements on the trigger lines with equipment other than the
XRBAG.
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
Reconnect the drivers airbag ignition module and remount the steering wheel cushion.
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
Destroy the airbag cushion if it has been replaced (tool El. 1287).
1EC761.0
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88
Bargraph 6
Fiche n 49
NOTES
*06 :
CC : Short circuit
CO : Open circuit
Never carry out measurements on the trigger lines with equipment other than the
XRBAG. On this vehicle "line 1" corresponds to the single trigger line of the
passengers airbag module .
YES
If the value obtained is correct at wire C on the adaptor, check the condition of the
computer connection .
NO
If the value obtained is not correct at wire C on the adaptor, check the 30 track
connector connection (tracks 6 and 7).
If the value remains incorrect, switch off the ignition and remove the dashboard to
gain access to the wiring of the passengers airbag module . Disconnect the ignition
module of the passengers airbag module, connect a dummy ignition module to the
ignition module , then use the XRBAG to measure the resistance on the wire marked C
on the adaptor.
If the value obtained is correct , replace the passengers airbag module .
If the value obtained is not correct, replace the airbag wiring.
Reconnect the computer and the ignition module of the passengers airbag module , then switch on the
ignition again.
Carry out an XR25 check.
If the kit still indicates the presence of a line 1 passengers airbag fault and and the checks carried out
show no evidence of a fault, replace the airbag computer (consult the section "Aid" for this operation).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
Destroy the airbag cushion if it has been replaced (tool El. 1287).
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88
NOTES
Fiche n 49
*27 :
Never carry out measurements on the trigger lines with equipment other than the
XRBAG. On this vehicle "line 1" corresponds to the single trigger line of the
passengers airbag module .
YES
It the value obtained is correct at wire C on the adaptor, check the condition of the
computer connection .
NO
If the value obtained is not correct at the adaptor wire, check the 30 track connector
connection (tracks 6/7).
If the value remains incorrect , replace the airbag wiring.
Reconnect the computer and the ignition module of the passengers airbag module , then switch on the
ignition again.
Carry out an XR25 check.
If the kit still indicates the presence of a passengers airbag line fault and the checks carried out show no
evidence of a fault, replace the airbag computer (consult the section "Aid" for this operation).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
Destroy the airbag cushion if it has been replaced (tool El. 1287).
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88
Bargraph 8
Fiche n 49
NOTES
*08 :
CC : Short circuit
CO : Open circuit
Never carry out measurements on the trigger lines with equipment other than the
XRBAG.
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
Reconnect the ignition module of the drivers pretensioner .
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
Destroy the pretensioner if it has been replaced (tool El. 1287).
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NOTES
Fiche n 49
*28 :
CC : Short circuit
CO : Open circuit
Never carry out measurements on the trigger lines with equipment other than the
XRBAG.
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
Reconnect the ignition module of the passengers pretensioner .
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
Destroy the pretensioner if it has been replaced (tool El. 1287).
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88
NOTES
Fiche n 49
*29 :
Never carry out measurements on the trigger lines with equipment other than the
XRBAG.
The XRBAG tool MUST be used for measuring insulation appropriate to the type of fault at point C1 (seat
connector) of the drivers pretensioner line.
If the value obtained is not correct , replace the wiring between points C1 and C3 (seat wiring).
Then carry out the same measurement on the passengers pretensioner line (if not a drivers side fault ).
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
Reconnect the ignition modules of the seat belt pretensioners.
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
Destroy the pretensioner(s) if it has been replaced (tool El. 1287).
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10
NOTES
Bargraph 10
Fiche n 49
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
1EC761.0
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10
NOTES
Fiche n 49
Use the 30 track XRBAG adaptor to carry out operations on the computer
connector .
NOTES
None
If the checks carried out have not proven the existence of a fault, disconnect the computer connector and
fit the 30 track XRBAG adaptor . Use the XRBAG in testing mode to check the operation of the warning
light on the instrument panel from the grey adaptor wire.
If it is possible to illuminate the warning light using the XRBAG, replace the airbag computer (consult
the section "Aid" for this operation).
If it is impossible to operate the warning light , repeat the preceding checks.
NOTES
None
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the
ignition. Carry out another XR25 check and if there is no fault, unlock the
computer using command G81*.
1EC761.0
88-18
http://vnx.su
14
NOTES
88
Fiche n 49
Computer locked
None
This bargraph 14 left hand side allows computer locked status to be seen .
When it is illuminated, all trigger lines are inhibited, preventing the release of the airbags and the seat
belt pretensioners.
This bargraph is normally illuminated in two situations :
- The computer is new (it is sold in locked mode).
- The XR25 computer locking command has been used during an operation on the vehicle
(G80*).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the
ignition. Carry out another XR25 check and if there is no fault, unlock the
computer using command G81*.
1EC761.0
88-19
http://vnx.su
14
NOTES
88
Fiche n 49
None
Consult the Techline if this bargraph is illuminated in other situations (no fault, no impact, ...).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
1EC761.0
88-20
http://vnx.su
17-18-19
NOTES
88
Fiche n 49
Computer configuration
None
Bargraphs 17, 18 and 19 left hand side allow the computer configuration to be visualised and to ensure
that it is correct for the vehicle.
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the
ignition.
Carry out another XR25 check .
1EC761.0
88-21
http://vnx.su
88
Only carry out this conformity check after a complete XR25 check.
Order of
operations
Operation to be
checked
Action
XR25 dialogue
D49
(selector on
S8)
I.Ab
#02
22
Computer Conformity
Computer
Configuration
Warning light
operation - check
computer
initialisation
Bargraph
17 / 18 / 19
Switch on the
ignition
1EC761.0
88-22
http://vnx.su
88
NOTES
None
With the ignition switched off, disconnect the computer connector and fit the 30 track XRBAG adaptor.
Switch on the ignition and check the computer power supply between the terminals marked earth and
+after ignition feed.
Carry out the operations necessary to ensure a voltage between 10.5 volts and 16 volts.
The XRBAG tool MUST be used for checking resistance and tests for leaks to positive and to earth on the
adaptor wires marked D and E .
If the values obtained on the 2 circuits are correct,there is no fault on the seat belt pretensioner circuit.
Reconnect the computer .
If one of the values obtained is not correct, check the 30 track connector connection (tracks 3 / 4 for wire
D and 1/2 for wire E) and replace the wiring if necessary .
The XRBAG tool MUST be used for checking resistance and tests for leaks to positive and to earth at
point C1 of the pretensioner at fault (wire D : Passenger and E : Driver ).
If all values obtained are correct, replace the wiring between points C0 and C1, then carry out the test
again using the adaptor to check that the repair has been successful.
The XRBAG tool MUST be used for checking resistance and tests for leaks to positive and to earth at
point C3 ( Pretensioner ignition module ).
If all values obtained are correct, replace the wiring between points C1 and C3 (seat wiring), then carry
out the test again at the adaptor to check that the repair has been successful.
If one of the values is not correct at C3, replace the seat belt pretensioner, then carry out the test again
using the adaptor to check that the repair has been successful.
AFTER REPAIR
1EC761.0
88-23
http://vnx.su
88
The airbag computers are sold in locked mode to avoid all risk of release at the wrong time (all
trigger lines are inhibited). This operational mode is indicated by the illumination of the warning
light on the instrument panel.
When replacing the airbag computer, follow this procedure :
- Ensure that the ignition is switched off.
- Replace the computer.
- Carry out an XR25 check.
- Unlock the computer using command G81*, only when no fault is declared.
1EC761.0
88-24
http://vnx.su
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRF1000
http://vnx.su
Engine and
peripherals
Contents
Page
13 FUEL SUPPLY -
DIESEL EQUIPMENT
10-1
10-1
10-2
10-3
10-4
10-9
10-25
10-29
10-30
11-1
11-11
11-29
12 FUEL MIXTURE
Specifications
Throttle body
Inlet manifold
Exhaust manifold
Inlet-exhaust manifolds
Page
12-1
12-7
12-15
12-18
12-20
Fuel supply
Fuel cut off in case of an impact
Injector gallery
Fuel filter
Pump flow
Fuel pressure
Antipercolation device
Diesel equipment
General
Specifications
Location of components
Advance solenoid valve
Altimetric corrector
Fast idle LDA
Coded solenoid valve
Load potentiometer
Computer configuration
Injector with sensor (needle
lift)
Injection warning light
Pre-postheating control
Fast idle control
Injection/air conditioning
programming
Computer
Defect modes
Pump
Pump -Timing
Idle speed settings
http://vnx.su
13-1
13-2
13-6
13-7
13-8
13-12
13-13
13-14
13-16
13-19
13-22
13-25
13-26
13-28
13-29
13-31
13-32
13-33
13-35
13-36
13-36
13-37
13-38
13-39
13-41
13-46
Contents
Page
17 IGNITION - INJECTION
14 ANTIPOLLUTION
Test for the presence of lead
Fuel vapour rebreathing
Oil vapour rebreathing
Exhaust gas recirculation
(EGR)
Page
(continued)
14-1
14-2
14-7
14-11
Injection/air conditioning
programming
Idle speed correction
Adaptive idle speed
correction
Richness regulation
Adaptive richness correction
17-17
17-18
17-19
17-20
17-22
16 STARTING - CHARGING
Alternator
Starter
16-1
16-7
17 IGNITION - INJECTION
Ignition
Static ignition
Plugs
Injection
General
Location of components
Centralised coolant temperature
management
Injection fault warning light
Immobiliser function
Computer configuration depending
on gearbox type
17-1
17-3
17-4
17-8
17-13
17-14
17-15
17-16
19-1
19-2
19-3
19-4
19-7
Exhaust
General
Exhaust pipe assembly
19-12
19-15
Fuel tank
Tank
Sender unit
Pump and sender unit assembly
19-17
19-29
19-30
Engine suspension
Suspended engine mountings
19-32
http://vnx.su
Type
Quantity
Components
Coat
Loctite FRENBLOC
Locking and sealing resin
Coat
Loctite FRENETANCH
Locking and sealing resin
Coat
Coat
RHODORSEAL
5661
10
Identification
Vehicle type
Engine
Manual
gearbox
Capacity
(cm 3)
Bore
(mm)
Stroke
(mm)
F/K C0A
D7F 710
JB1
1 149
69
76.8
F/K C0C
E7J 780
JB3
1 390
75.8
77
F/K C0D
F/K C0E
F8Q 662
F8Q 630
JB1
1 870
80
93
Ratio
9 .65/1
9 .5/1
2 1.5 /1
D7F
E7J
F8Q
Mot. E
Mot. F (D)
10-1
http://vnx.su
10
OIL CONSUMPTION =
10-2
http://vnx.su
22 mm long socket
CHECKING
ENGINE CHECKING
The oil pressure should be checked when the engine is warm (approximately 80C).
D engine
Idling
4 000 rpm
0.8 bar
3.5 bars
E engine
Idling
3 000 rpm
1 bar
3 bars
F engine
1 000 rpm
3 000 rpm
87363R1
USE
D engine
E engine
F engine
C+F
C+E+F
B+F
10-3
http://vnx.su
1.2 bars
3.5 bars
10
D7F engine
10
B. Vi.
31-01
Mot.
1202
Mot.
1273
Mot.
1311-06
Mot.
1379
T. Av. 476
EQUIPMENT REQUIRED
Load positioner
18
2.5
Wheel bolt
Left-hand suspended mounting bolt
on gearbox
9
6.2
2.1
6.2
6.2
13034S
REMOVAL
Drain:
- the cooling circuit (bottom hose of the
radiator),
- the gearbox oil,
- the engine oil if necessary.
Remove:
- the battery,
- the bonnet,
- the wheels,
- the air intake pipe,
- the expansion bottle and fix it to the engine.
10-4
http://vnx.su
D7F engine
10-5
http://vnx.su
10
D7F engine
10
13085R
93912R1
92661R1
Disconnect:
- the accelerator cable,
- the canister pipe,
- the brake servo vacuum pipe,
- the hoses between the radiator and the
engine block, on the engine block side,
13084R
10-6
http://vnx.su
D7F engine
Remove:
- the computer support plate.
- the power assisted steering pipe mountings
on the engine,
- the power assisted steering pump belt (see
section 07),
- the power assisted steering pulley,
- the power assisted steering bolts.
10
12924R2
99893S
Remove:
- the gearbox side support,
12924R1
10-7
http://vnx.su
D7F engine
10
12924R3
10-8
http://vnx.su
D7F engine
10
B. Vi.
31-01
Mot.
1040-01
Mot.
1202
Mot.
1311-06
Mot.
1379
T. Av. 476
T. Av. 1233-01
18
3.7
6.2
10.5
2.5
9
6.2
6.2
6.2
2.5
13034S
Drain:
- the cooling circuit (disconnect the bottom
hose of the radiator),
- the gearbox oil if necessary,
- the engine oil if necessary.
REMOVAL
Remove:
- the battery,
- the wheels,
- the air intake pipe,
- the upper radiator mountings,
- the expansion bottle and fix it to the engine,
- the power assisted steering fluid reservoir,
and secure it onto the engine.
10-9
http://vnx.su
D7F engine
Disconnect:
- the accelerator cable,
- the canister pipe,
- the brake servo pipe,
- the heater hoses,
- the oxygen sensor connector,
- the fuel pipes.
10
Remove:
- the shock absorber base bolts,
- the steering shaft yoke bolt.
97390-1R
10-10
http://vnx.su
D7F engine
10
10621R
93912R2
92442-1R2
10267R1
10-11
http://vnx.su
D7F engine
98755R
10-12
http://vnx.su
10
D7F engine
10
Use tool T. Av. 1233-01 to position the engine and transmission assembly in relation to the body.
Refitting is the reverse of removal.
Tighten the suspended engine mounting bolts and nuts to the recommended torque.
12924R4
10-13
http://vnx.su
E7J engine
10
Mot. 1040-01
Mot. 1159
Mot. 1202
Mot. 1448
Mot. 1311-06
6.2
10.5
6.2
4.4
6.2
18
Wheel bolt
REMOVAL
12994R1
Drain:
- the cooling circuit through the bottom hose
of the radiator,
- the gearbox and the engine if necessary.
Remove:
- the bonnet,
- the front wheels,
- the tie-rods between sub-frame and body,
10-14
http://vnx.su
E7J engine
10
Disconnect:
- the wiring connections and the hoses on the
thermostat support,
- the hoses on the expansion bottle,
- the brake servo pipe,
- the heater hoses (there are two types of assembly to be disconnected, as shown in the
diagrams below),
12988R
13085R
13084R
13088R2
10-15
http://vnx.su
E7J engine
10
In order to prevent any risk of damage to the rotary switch beneath the steering wheel, the following instructions should be observed:
Before disconnecting the steering column and
the rack, the steering wheel MUST be immobilised with the wheels straight, using a "steering wheel lock", throughout the operation.
If there is any doubt that the rotary switch is
properly centred, the steering wheel must be
removed in order to apply the centring method
described in section 88 "Air bag".
REMINDER: this kind of work must only be carried
out by properly trained and qualified staff.
13034R
99024R2
97390S1
10-16
http://vnx.su
E7J engine
10
13086R
99310R
12993-1R3
13359R
10-17
http://vnx.su
E7J engine
10
REFITTING
98755R1
Fill:
- the engine and gearbox with oil, if necessary,
the cooling circuit and bleed it (see section 19
"Filling - bleeding").
10-18
http://vnx.su
F8Q engine
10
Mot. 1040-01
Mot. 1159
Mot. 1202
Mot. 1448
Mot. 1311-06
6.2
10.5
6.2
18
Wheel bolt
REMOVAL
12994R1
Drain:
- the cooling circuit through the bottom hose
of the radiator,
- the gearbox and the engine if necessary.
Remove:
- the bonnet,
- the front wheels,
- the tie-rods between sub-frame and body,
10-19
http://vnx.su
F8Q engine
10
Unclip the fuel pipes from the air filter unit and
the timing cover and unclip the diesel filter from
its support and move the assembly to one side.
12988R
13083-1R
10-20
http://vnx.su
F8Q engine
10
13088R1
11734R
Disconnect:
- the hoses on the expansion bottle,
- the brake servo pipe,
- the heater hoses (there are two types of assembly to be disconnected, as shown in the
diagrams below),
11733R
13085R
10-21
http://vnx.su
F8Q engine
10
Remove:
- the upper mountings of the radiator and attach it to the engine,
- the nut and the eccentric bolt of the steering
shaft yoke, after pushing back the guard.
13084R
In order to prevent any risk of damage to the rotary switch beneath the steering wheel, the following instructions should be observed:
Before disconnecting the steering column and
the rack, the steering wheel MUST be immobilised with the wheels straight, using a "steering wheel lock", throughout the operation.
If there is any doubt that the rotary switch is
properly centred, the steering wheel must be
removed in order to apply the centring method
described in section 88 "Air bag".
13034R
10-22
http://vnx.su
F8Q engine
10
13086R1
99024R2
99310R
13086R
10-23
http://vnx.su
F8Q engine
10
REFITTING
12993-1R3
Fill:
- the engine and gearbox with oil, if necessary,
the cooling circuit and bleed it (see section 19
"Filling - bleeding").
98755R1
10-24
http://vnx.su
D7F engine
99900S
10-25
http://vnx.su
10
E7J / F8Q
engines
10
Mot. 1233-01
6.2
10.5
1
1.5
3
6.2
Wheel bolt
REMOVAL
Remove:
- the front wheels,
- the nut and the eccentric bolt of the steering
shaft yoke, after pushing back the guard,
97390S1
10-26
http://vnx.su
E7J / F8Q
engines
10
12993-1R3
Gradually lower the sub-frame with the aid of the threaded rods Mot. 1233-01 until
dimensions X1 and X2 are reached approximately.
13507R
E7J engine
X 1 = 9 cm
F8Q engine
X 2 = 12 cm
X 1 = 7 cm
10-27
http://vnx.su
X 2 = 9 cm
E7J / F8Q
engines
99179S
Do not forget to replace the two half-moon gaskets on each side of the sump.
F8Q engine
Fit a new after-sales gasket.
Refitting is the reverse of removal.
10-28
http://vnx.su
10
D7F engine
10
Mot. 1054
TDC pin
Mot. 1273
Mot. 1289-03
Mot. 1355
Mot. 1374
Mot. 1379
REFITTING
Refit the new seal onto the crankshaft output without damaging it when passing the timing
sprocket drive groove.
2 + 90
REPLACEMENT
REMOVAL
99788R
Refit the new timing belt (see the method described in section 11 "Timing belt").
99787R
Screw the body of the tool into the seal using nut
(1), then use bolt (2) to extract the seal.
10-29
http://vnx.su
D7F engine
10
Mot. 1054
TDC pin
Mot. 1273
Mot. 1355
Mot. 1379
REFITTING
2 + 90
6.2
6.2
REMOVAL
Remove:
- the timing belt (see method described in
section 11 "Timing belt"),
- the oil level sensor with the aid of a 19 mm
half-moon wrench,
- the oil dipstick,
- the crankshaft pulley and sprocket,
- the engine flywheel guard.
99790R
98964S
10-30
http://vnx.su
D7F engine
99788R
10-31
http://vnx.su
10
D7F engine
Mot. 1054
TDC pin
Mot. 1135-01
Mot. 1273
Mot. 1379
Mot. 1386
TIGHTENING TORQUES
(in daN.m)
2 + 90
6.2
6.2
REMOVAL
10267R
Remove :
- the front right hand wheel,
- the belt from the alternator and the power
assisted steering pump if fitted (see section
07),
- the crankshaft accessories pulley.
11-1
http://vnx.su
11
D7F engine
11
12924S1
DI1041R
99795R
11-2
http://vnx.su
D7F Engine
11
REFITTING
10881R
10072S
10479R1
11-3
http://vnx.su
D7F Engine
11
Fit tool Mot. 1273 and note the tension measurement, which should be 203 US (fitting tension),
or simply adjust by varying the position of the
tension wheel using Mot. 1135-01 and repeat the
tensioning process in (b).
Turn the engine at least twice (never in the opposite direction to normal operation).
Insert the pin in the engine at TDC, then remove
the pin .
IMPORTANT
Insert the pin in the engine at TDC then remove the pin.
Using tool Mot. 1386, apply a pretensioning
torque of 1 daN.m between the crankshaft
sprocket and the water pump.
12924S1
10881R
11-4
http://vnx.su
E7J Engine
11
Mot. 591-02
Index pin
Mot. 591-04
Mot. 1135-01
Mot. 1273
EQUIPMENT REQUIRED
Wheel bolts
Crankshaft pulley bolts
Tension wheel nut
9
2 + 68 6
Remove :
- the front right wheel along with the mudguard,
- the suspended engine mounting cover,
13359R
13370S
11-5
http://vnx.su
E7J Engine
11
13362S
13506R
11-6
http://vnx.su
E7J Engine
11-7
http://vnx.su
11
F8Q Engine
11
Mot. 1054
TDC pin
Mot. 1273
EQUIPMENT REQUIRED
Remove :
- the accessories belt,
- the suspended engine mounting cover.
Wheel bolts
Crankshaft pulley bolt
9
2 + 115 15
5
6.2
4.4
REMOVAL
13086R1
13370S
11-8
http://vnx.su
F8Q Engine
11
Remove :
- the timing covers,
12518R
13095S
12419R
11-9
http://vnx.su
F8Q Engine
11
REFITTING
13094R
13096R
Fit tool Mot. 1273 and tension the belt until the
fitting value is reached (see section 07 "Timing
belt tension").
11-10
http://vnx.su
D7F Engine
11
Mot. 591-04
Mot. 1202
Mot. 1273
Mot. 1379
EQUIPMENT REQUIRED
Remove:
- the timing belt (see method described in
section 11 "Timing belt"),
- the dipstick,
- the brake servo pipe,
- the air filter,
- the accelerator cable,
- the fuel supply and return pipes level with the
timing belt cover on the cylinder head
2 + 90
6.2
6.2
Wheel bolts
REMOVAL
11-11
http://vnx.su
D7F Engine
99894R1
99940R
11-12
http://vnx.su
11
D7F Engine
Remove :
- the mounting bolts (5) for the throttle body retaining bracket on the
cylinder head,
- the mounting nuts (3) for the manifold on the cylinder head
- the mounting bolts (4) of the manifold on the valve rocker cover
- the inlet manifold, throttle body and injector gallery assembly.
99937R1
11-13
http://vnx.su
11
D7F Engine
CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
11
92076S
11-14
http://vnx.su
D7F Engine
99902S
10072S
11-15
http://vnx.su
11
D7F Engine
Partly refit the suspended engine mounting timing cover on the engine using two bolts.
Inlet
Exhaust
11
0.05
0.15
99905S
Remove the tool retaining the engine on the subframe, Mot. 1379.
NOTE : tightening the inlet manifold :
- progressively hand tighten the six nuts until
the inlet manifold comes into contact with the
cylinder head, then tighten them to a torque
of 1.5 daN.m,
- fit the upper bolts and tighten them to a torque of 0.9 daN.m.
10072S
11-16
http://vnx.su
E7J Engine
11
Mot. 588
Retaining bracket
Mot. 591-02
Index
Mot. 591-04
Mot. 1159
Mot. 1202
Mot. 1273
Mot. 1311-06
EQUIPMENT REQUIRED
5
2 + 68 6
6.2
cover
Nut for suspended engine mounting cover 4.4
Wheel bolts
DEPOSE
99024R2
11-17
http://vnx.su
E7J Engine
99310R
Remove :
- the connector along with the pipe on the absolute pressure sensor,
- the stepping motor connector,
13338S
13339S
11
11-18
http://vnx.su
E7J Engine
11
13365S
13360R
13364R1
11-19
http://vnx.su
E7J Engine
11
92062R
13336-1R1
CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
Remove :
- the cylinder head bolts except for (F) which
must simply be loosened, then pivot the cylinder head around the bolt.
92106R
11-20
http://vnx.su
E7J Engine
ADJUSTMENT OF
NECESSARY)
11
VALVE ROCKERS
(IF
"Tilt" method
REFITTING
(special notes)
0.10
0.25
98713R1
11-21
http://vnx.su
E7J Engine
11
78373R
11-22
http://vnx.su
F8Q Engine
11
Mot. 251-01
Mot. 252-01
Mot. 591-02
Index
Mot. 591-04
Mot. 1054
TDC pin
Mot. 1159
Mot. 1202
Mot. 1273
Mot. 1311-06
EQUIPMENT REQUIRED
REMOVAL
99024R2
11-23
http://vnx.su
F8Q Engine
11
99461R
99310R
Remove :
- the exhaust downpipe,
- the hoses and connectors of the cylinder head
coolant pipe housing outlet,
- the connection at (1) using tool Mot. 1311-06,
Disconnect connector (6) from the diesel fuel filter, remove it from its support and move the diesel fuel filter pipe assembly to one side.
13097R
11-24
http://vnx.su
F8Q Engine
11
13083-1R1
11734R
11-25
http://vnx.su
F8Q Engine
11
Remove :
- the accessories belt tensioning system,
- the cylinder head bolts.
Release the cylinder head by setting aside the
lower part of the lower camshaft housing,
without causing the cylinder head to pivot, since
this is centred by the two dowels at ( C ).
11733R
99173-1R
13093R
11-26
http://vnx.su
F8Q Engine
11
CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
99180S
11-27
http://vnx.su
F8Q Engine
11
Refit the cylinder head gasket selected previously. This is centred by two dowels at (C).
99173-1R
99173R
11-28
http://vnx.su
F8Q Engine
SPECIAL TOOLING
Mot. 1366-01
11
REQUIRED
2.7
2.5
2.5
86911-1S
Remove the air filter housing along with the cylinder head cover.
Compare the two dimensions noted to the recommended dimensions, and replace the adjusters if necessary .
Inlet:
0.10
Exhaust :
0.25
11-29
http://vnx.su
F8Q Engine
11
It is vital to turn the engine in the opposite direction to normal operation (in order to avoid the
locking of the engine), until the valve comes into
contact with tool Mot. 1366-01 (rotate camshaft
by 90 in the relation to the fully open position).
Extract the valve adjuster using a screwdriver and
a magnetic tool.
11231R
98895R1
REFITTING
11232-1R
11-30
http://vnx.su
FUEL MIXTURE
Specifications
D7F engine
12
Engine
Vehicle
Gearbox
Type Suffix
XC0A
JB1
D7F
710
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
Ratio
69
76.8
1149
9.65/1
Suffix
D7F
710
C61
EU 96
Engine
Type
Catalytic
converter
Depollution
standard
Engine
speed
[rpm]
74050
Fuel***
[minimum octane
rating]
Pollutant emission **
CO (%) (1)
CO 2 (%)
HC (ppm)
0.5 max
14.5 min
100 max
Lambda ()
0.97<<1.03
*
**
***
For a coolant temperature above 80C and after stable speed of 2500 rpm, for about 30 seconds. Test to
be carried out after return to idle speed.
For legal values refer to your country specification.
OR 91 unleaded compatible.
Temperature in C ( 1)
20
40
80
90
5000 to 7000
1700 to 3300
800 to 1550
6700 to 8000
2600 to 3000
1100 to 1300
270 to 300
200 to 215
12-1
http://vnx.su
D7F engine
DESCRIPTION
Computer
FUEL MIXTURE
Specifications
MAKE/TYPE
SAGEM or
MAGNTI MARLLI
Injection
Fuel filter
Fuel pump
Tracks
Resistance
1-2
1.5
1 - 4 |1 - 3
2 -3 | 2 - 4
3-4
0.6
HT - HT
8 K
Resistance 220
EYQUEM : RFC50LZ2E
NGK : BKR5EK
Gap: 0.9 mm
Tightening torque: 2.5 to 3 daN.m
WALBRO
Pressure regulator
Regulated pressure
Zero vacuum :
Vacuum of 500 mbars :
Solenoid injectors
Plugs
SPECIAL NOTES
Ignition
TDC sensor
12
SIEMENS
Voltage:
Resistance :
12-2
http://vnx.su
12 Volts
14.5 1
3 0.2 bars
2.5 0.2 bars
D7F engine
DESCRIPTION
Throttle body
FUEL MIXTURE
Specifications
12
MAKE/TYPE
SPECIAL NOTES
MAGNETI MARELLI
diameter 36 mm
873 633
AIR PAX
Throttle position
potentiometer
Voltage: 5 V
Resistance :
-
Diagnostic function
Voltage:
Resistance :
BOSCH
FICHE n 27
CODE D13
SELECTOR S8
Track
No load
Full load
AB
AC
BC
1300
1360
2300
1300
2350
1260
12 Volts
35 5
Voltage at 850 C
Rich mixture > 625 mvolts
Lean mixture : 0 to 80 mvolts
Heating resistance, tracks A-B : 3 to 15
Tightening torque : 5 daN.m
Throttle potentiometer:
Regulated idle speed :
Full load :
Idle speed R.C.O. :
10 # 17 50
185 # 17 240
4 % # 12 14 %
12-3
http://vnx.su
FUEL MIXTURE
Specifications
E7J engine
12
Engine
Vehicle
Gearbox
Type Suffix
XC0C
Manual
E7J
780
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
Ratio
75.8
77
1390
9.5/1
Suffix
E7J
780
C63
EU 96
Engine
Type
Catalytic
converter
Depollution
standard
Engine
speed
[rpm]
75050
Fuel***
(minimum octane
rating)
Pollutant emission **
CO (%) (1)
CO 2 (%)
HC (ppm)
0.5 max
14.5 min
100 max
Lambda ()
0.97<<1.03
*
**
***
For a coolant temperature above 80C and after stable speed of 2500 rpm, for about 30 seconds. Test to
be carried out after return to idle speed.
For legal values refer to your country specification.
OR 91 unleaded compatible.
Temperature in C ( 1)
Air temperature sensor
Type CTN
Resistance in Ohms
Coolant temperature sensor
Type CTN
Resistance in Ohms
20
40
80
90
7470 to
11970
3060 to 4045
1315 to 1600
6700 to 8000
2600 to 3000
1100 to 1300
270 to 300
200 to 215
12-4
http://vnx.su
E7J engine
DESCRIPTION
Computer
Injection
FUEL MIXTURE
Specifications
MAKE/TYPE
SPECIAL NOTES
55tracks
SIEMENS
FENIX 5
Ignition
-
TDC sensor
Plugs
Fuel filter
Fuel pump
Tracks
Resistance
1-2
0.5
1-3
2 -3
HT - HT
10 K
Resistance 220
EYQUEM : RFC52LS
CHAMPION : RC10PYC
Gap: 0.9 mm
Tightening torque: 2.5 to 3 daN.m
WALBRO
Pressure regulator
Regulated pressure
Zero vacuum :
Vacuum of 500 mbars :
Solenoid injectors
12
SIEMENS
Voltage:
Resistance :
12-5
http://vnx.su
12 Volts
14.5 1
3 0.2 bars
2.5 0.2 bars
E7J engine
DESCRIPTION
Throttle body
FUEL MIXTURE
Specifications
12
MAKE/TYPE
PIERBURG
SPECIAL NOTES
diameter 41 mm
714 227
Throttle position
potentiometer
Voltage: 5 V
Resistance :
-
Diagnostic function
DELCO REMY
Voltage:
Resistance :
Track
no load
full load
1-2
1-3
2-3
5440
4500
2160
2200
4460
5340
12 Volts
35 5
Voltage at 850 C
Rich mixture > 625 mvolts
Lean mixture : 0 to 80 mvolts
Heating resistance, tracks A-B : 3 to 15
Tightening torque : 4.5 daN.m
NGK
FICHE n 27
CODE D13
SELECTOR S8
Throttle potentiometer:
Regulated idle speed :
Full load :
Idle speed R.C.O. :
16 # 17 50
185 # 17 243
2 % # 12 15 %
12-6
http://vnx.su
D7F engine
FUEL MIXTURE
Throttle body
12
1
1
12-7
http://vnx.su
E7J engine
FUEL MIXTURE
Throttle body
12
REMOVAL
13338R
REFITTING
13339R1
Disconnect:
- the accelerator cable,
- the connectors :
of the stepping motor (2),
of the throttle potentiometer (3).
12-8
http://vnx.su
D7F engine
FUEL MIXTURE
Inlet manifold
12
1.7
12-9
http://vnx.su
E7J engine
FUEL MIXTURE
Inlet manifold
Lower the vehicle.
12
REMOVAL
Remove:
- the air filter,
- the injector gallery (see section 13).
Lift the vehicle.
Remove the strut (1) (to gain access to the bolt
fixing the strut on the right-hand side of the vehicle, remove the mudguard and the right-hand
wheel).
13339R2
13130R
13335-1R
12-10
http://vnx.su
FUEL MIXTURE
Inlet manifold
E7J engine
12
13338R1
12-11
http://vnx.su
D7F engine
FUEL MIXTURE
Exhaust manifold
12
2.5
1
2.2
12-12
http://vnx.su
E7J engine
FUEL MIXTURE
Exhaust manifold
12
REMOVAL
13239R2
REFITTING
12-13
http://vnx.su
F8Q engine
FUEL MIXTURE
Inlet/Exhaust manifolds
12
REMOVAL
PRO12.1
Special note
To remove nut (C) located above the starter motor, use a small ratchet (6.35 mm square) and a
universal joint.
13047-1R1
Remove, from above, the two nuts fixing the exhaust downpipe to the manifold.
Slacken, without removing it, the nut on the
clamp connecting the downpipe to the exhaust
pipe.
Tilt the exhaust downpipe towards the gearbox.
13047R
12-14
http://vnx.su
F8Q engine
FUEL MIXTURE
Inlet/exhaust manifolds
REFITTING
12-15
http://vnx.su
12
FUEL SUPPLY
Fuel cut off in case of an impact
OBJECTIVE
13
OPERATING PRINCIPLE
DESCRIPTION
The system consists simply of an inertia switch (1),
which:
- detects the impact,
- and thus cuts off the electrical circuit.
THE
SWITCH
13051R
This is fitted:
in petrol engines, between track 1 of the
pump relay (236) and the + 12 V supply ,
13-1
http://vnx.su
FUEL SUPPLY
Injector gallery
D7F Engine
Mot. 1311-06
IMPORTANT: during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
REMOVAL
Disconnect :
- the battery,
- the pressure measurement pipe (1) of the
pressure regulator,
- the fuel return pipe (2),
- the electrical connector of the injectors (3)
99937R3
13-2
http://vnx.su
13
D7F Engine
FUEL SUPPLY
Injector gallery
13
99375R
10046R
99461R1
13-3
http://vnx.su
DF7 Engine
FUEL SUPPLY
Injector gallery
13
REFITTING
10047R
PRC13.1
13-4
http://vnx.su
E7J Engine
FUEL SUPPLY
Injector gallery
IMPORTANT: during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
13
REMOVAL
99373R
13244R
13-5
http://vnx.su
FUEL SUPPLY
Fuel filter
Petrol
engines
13
Mot. 1265
LOCATION
96420R3
REPLACEMENT
IMPORTANT : during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
REMOVAL
13-6
http://vnx.su
FUEL SUPPLY
Pump flow
Petrol
engines
13
Mot. 1265
96093R2
IMPORTANT
12839S
If the fuel flow is low, check the pump feed voltage (approximately 10 % reduction in flow for a
voltage drop of 1 Volt)
13-7
http://vnx.su
FUEL SUPPLY
Fuel pressure
DF7 Engine
13
Mot. 1311-01
Mot. 1311-05
Mot. 1311-06
IMPORTANT : during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
99375R
99939S
99934R1
13-8
http://vnx.su
DF7 Engine
FUEL SUPPLY
Fuel pressure
13
99938-1R
13-9
http://vnx.su
FUEL SUPPLY
Fuel pressure
EF7 Engine
13
Mot. 1311-01
Mot. 1311-05
IMPORTANT : during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
13244-1R
99376R
13-10
http://vnx.su
E7J Engine
FUEL SUPPLY
Fuel pressure
13
12839S
13-11
http://vnx.su
FUEL SUPPLY
Antipercolation device
E7J Engine
13
When the ignition is switched off, the coolant temperature monitoring mode begins.
Monitoring mode
no
yes
no
yes
The monitoring mode is left 2 minutes after switching off the ignition in cases where the coolant
temperature is not greater than or equal to 101C or once the coolant temperature falls below 92C.
13-12
http://vnx.su
no
DIESEL EQUIPMENT
General
13
The use of electronic injection in Diesel engines has allowed the operational power of these engines to be
optimised, thus reducing the emission rate of pollutant gases.
The system consists of a computer, which receives information from:
- the coolant temperature sensor,
- the air temperature sensor,
- the engine speed sensor,
- the vehicle speed sensor,
- the load potentiometer,
- the injection start sensor, which forms part of the injector of cylinder n 3 (injector with sensor).
It controls :
- the injection pump :
the altimetric corrector (F8Q 630) via a relay
the advance solenoid valve.
- the cold engine starting system (heater plugs and pre-postheating unit),
- the exhaust gas recycling system (EGR),
- the diesel injection fault warning light,
- the preheating warning light,
- the solenoid valve controlling the fast idle speed LDA,
- the relay controlling the power assisted steering electric pump assembly (for vehicles with air conditioning), the pump assembly is supplied once the engine speed exceeds 650 rpm.
It carries out a self diagnosis procedure which may be visualised through the XR25 .
SPECIAL FEATURES
13-13
http://vnx.su
DIESEL EQUIPMENT
Specifications
13
Engine
Vehicles
Gearbox
Type Suffix
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
Ratio
Catalytic
converter
Depollution
standard
XC0D
JB
F8Q
662
80
93
1 870
21.5/1
C67
EU96
XC0E
JB
F8Q
630
80
93
1 870
21.5/1
C67
EU96
Vehicles
Idle speed
SMOKE OPACITY
no load
maximum
full load
maximum
Homologation value
Legal maximum
XC0D
825 50
4 600 100
4 100 100
1.05 m -1 (35 %)
2.5 m
-1
(64 %)
XC0E
825 50
4 600 100
4 100 100
1.11 m -1 (36 %)
2.5 m
-1
(64 %)
Temperature in C ( 1)
Air temperature sensor
Siemens CTN type
Resistance in Ohms
Coolant temperature sensor
Siemens CTN type
Resistance in Ohms
20
40
80
90
7470 to
11970
3060 to 4045
1315 to 1600
3060 to 4045
1315 to 1600
300 to 370
210 to 270
13-14
http://vnx.su
DIESEL EQUIPMENT
Specifications
DESCRIPTION
Computer
Injection
Injection pump
MAKE/TYPE
SPECIAL NOTES
LUCAS
Indirect
LUCAS DIESEL
8448B171 A/231A
(F8Q 630)
8448B152 B/241B
(F8Q 662)
Pump setting (obtain TDC
point using 8 mm pin)
Injector holders
13
Dimension ( X ) on pump
LUCAS DIESEL
LUCAS DIESEL
LDCR020011AA1
Injectors
LUCAS DIESEL
RDN OSDC 6902
Opening pressure : +5
- 5 130 bars
Maximum pressure difference: 8 bars
Voltage: 12 volts
Resistance : 46 5
Injector pipes
interior : 2.5 mm
Length: 330 5 mm
Plugs
BERU
Pencil type plug
Resistance : 0.8
Tightening torque : 2 daN.m
TDC sensor
Resistance : 220
Voltage: 12 V
Resistance : 46
Advance corrector
Voltage: 12 V
Resistance : 11.5
Load potentiometer
Voltage : 5 V
Resistance : (in K , approximately )
Track
(10 track connector)
5-4
3-4
3-5
Altimetric corrector
Fault finding
no load
full load
4.5
5.6
2.8
4.5
2.8
5.6
Voltage : 12 V
Resistance : 15.5
Fiche n 43
Code D34
Selector S8
13-15
http://vnx.su
DIESEL EQUIPMENT
Location of components
13
12874
1
2
3
4
5
6
7
8
9
10
11
12
13
14
13-16
http://vnx.su
DIESEL EQUIPMENT
Location of components
12
14
13
11
9
8
3
2
13
12872R
19
12869-1R
6
5
16
4
12871R
13083R
13-17
http://vnx.su
DIESEL EQUIPMENT
Location of components
20
13
EGR valve
87970R
17
18
13047-1R
13048R
12839S
13-18
http://vnx.su
DIESEL EQUIPMENT
Advance solenoid valve (1)
13
10314-1R
Mot. 997-01
REMOVAL
13-19
http://vnx.su
DIESEL EQUIPMENT
Advance solenoid valve
13
13342R
10579R1
Passage of connector
13-20
http://vnx.su
DIESEL EQUIPMENT
Advance solenoid valve
13
REFITTING
ITB191917
13127R
13-21
http://vnx.su
F8Q 662
DIESEL EQUIPMENT
Altimetric corrector
13
13129R
Mot. 997-01
Mot. 1140
Altimetric corrector
REMOVAL
13-22
http://vnx.su
F8Q 662
DIESEL EQUIPMENT
Altimetric corrector
13
13342R
10579R2
Connector passage
13-23
http://vnx.su
F8Q 662
DIESEL EQUIPMENT
Altimetric corrector
13
REFITTING
13128R
13-24
http://vnx.su
DIESEL EQUIPMENT
Fast idle speed LDA
13
13043R
13044R
13-25
http://vnx.su
DIESEL EQUIPMENT
Coded solenoid valve
13
10314R3
10713R1
10315R2
99780-1R
13-26
http://vnx.su
DIESEL EQUIPMENT
Coded solenoid valve
On this type of vehicle, the replacement of the
solenoid valve and of the coded electronic unit (A)
requires the removal of the injection pump from
the engine.
REMOVAL
With the pump on the bench, remove the protective fittings at (B).
These are secured by shear bolts which may be removed either :
- using a small cold chisel or a punch and hitting
on the conical heads of bolts (C), (D) and (E)
to loosen them,
- using tool Mot. 1372 for bolt (F), drilling it
using the 4 mm diameter drill (drilling depth
approximately 4 mm) and the large diameter
drilling guide tube on the fitting side (2).
Use extractor (3) and its handle to remove it .
REFITTING
Location of bolts :
D
C and F : 6 x 40 mm ; torque =
E
: 5 x 33 mm ; torque =
1.2
daN.m
0.55 daN.m
13-27
http://vnx.su
13
DIESEL EQUIPMENT
Load potentiometer
13
In the factory, vehicles are programmed with the full load position. (memorising the voltage delivered by the
potentiometer in the full load position). This value is used to adjust the load potentiometer after it has been
replaced. It is therefore essential, if the diesel injection computer has to be replaced during the vehicles lifetime , to carry out this programming (G31*).
If it is necessary to replace the load potentiometer, in order to adjust it we compare the voltage delivered by
the potentiometer in full load position, with the value memorised. The new potentiometer is said to be correctly adjusted when the two voltages are equal. This is displayed on the XR25. G32* indicates the difference in voltage between the value memorised and the one from the potentiometer. The adjustment is correct if this value is equal to 0 in the full load position.
The potentiometer and the computer cannot be replaced at the same time (if necessary, replace the potentiometer first and then the computer).
REPLACEMENT OF THE LOAD POTENTIOMETER (operation to be carried out by two people)
Remove the three terminals for the load potentiometer from the 10 track pump connector (see method
described in section 13 "Advance solenoid valve").
Remove the two bolts mounting the faulty potentiometer, extract this, and fit the new potentiometer .
Hand tighten the two bolts mounting the potentiometer but do not lock them - it should be possible to turn
the potentiometer body .
Connect the XR25, and switch on the ignition.
Set the selector to S8.
Enter code
then
Press down on the accelerator pedal (full load position). Do not act directly on the load lever.
Holding the full load position, turn the potentiometer body until the value 0 appears on the XR25 display (if
you are too far from the 0 value, the screen will display HL , which means "Hors Limite"= "Off limits". Just
to turn the potentiometer body to obtain the display of a decimal value).
Tighten the two bolts mounting the potentiometer in the full load position, when the value read is 0.
13-28
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DIESEL EQUIPMENT
Computer configuration
PROGRAMMING
13
Enter code
When the display flashes "PF", press the accelerator pedal down as far as it will go.
The programming is complete when
the screen displays the following
wording:
then
13-29
http://vnx.su
DIESEL EQUIPMENT
Computer configuration
13
COMPUTER CONFIGURATION IN RELATION TO THE PAS (POWER ASSISTED STEERING PUMP ASSEMBLY)
IMPORTANT : according to the above explanations, only two types of combination are possible for the illumination of bargraphs 18 and 19.
Vehicle with AC
and PAS pump assembly
18
18
CA
19
19
DA
NOTE : if the computer has been replaced, remember to carry out the programming of the load potentiometer full load position (see "Load potentiometer " section ).
13-30
http://vnx.su
DIESEL EQUIPMENT
Injector with sensor (needle lift)
13
PRM1315
1
2
3
4
5
Plunger rod
Spacer
Injector
Spring
Winding
13-31
http://vnx.su
DIESEL EQUIPMENT
Injection warning light
13
OPERATING PRINCIPLE OF THE DIESEL INJECTION WARNING LIGHT ON THE INSTRUMENT PANEL
On switching on the ignition, the diesel injection fault warning light is illuminated.
gine begins to run.
Fault in a component of the injection assembly
Faults in the following components may cause the warning light to illuminate :
- injector with sensor
- advance solenoid valve,
- engine speed sensor ,
- load lever potentiometer,
- pre-postheating (according to version).
13-32
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DIESEL EQUIPMENT
Pre-postheating control
The pre-postheating function is controlled by the
computer, which controls the preheating plug relay housing.
13
b) Fixed preheating
After the preheating warning light has
extinguished (variable preheating), the
plugs remain fed for 8 seconds before the
engine is started.
1) Ignition - Preheating
The preheating process is divided in two
phases :
a) Variable preheating
This is dependent on the coolant temperature, on the battery voltage and on altitude (internal computer sensor) when the
ignition is switched on (the preheating
warning light illuminates).
13041S
Maximum preheating limit (battery voltage lower than 9.3 volts and altitude higher than 2 000 m).
Minimum preheating limit (battery
voltage greater than 10.5 volts altitude
lower than 350 m).
13-33
http://vnx.su
DIESEL EQUIPMENT
Pre-postheating control
13
time (s)
For an idle speed and load lever
position
180
- 20
20
40
60
Coolant temperature C
13-34
http://vnx.su
DIESEL EQUIPMENT
Fast idle speed control
The fast idle speed function is controlled by the
computer via a solenoid valve operating the diaphragm (versions with or without air conditioning).
The fast idle speed control becomes operational :
- if, on switching on the ignition, the coolant
temperature is below 10C,
F8Q 662
Coolant
Fast idle speed
temperature
cut-off
on switching
temperature
ignition on (C)
(C)
10
5
0
- 10
- 20
-
F8Q 630
Fast idle speed
cut-off
temperature
(C)
20
20
30
40
50
11
15
20
25
30
NOTE :
- Fast idle speed operational :
solenoid valve not operated,
cable loose, and not tensioned.
- Nominal idle sped :
solenoid valve operated
cable tensioned
SPECIAL FEATURES : once the AC has been
selected on the instrument panel, the fast idle
speed function is activated.
13-35
http://vnx.su
13
DIESEL EQUIPMENT
Injection/air conditioning programming
13
During certain stages of operation, the diesel injection computer stops the compressor from functioning.
Engine start programming
After the engine has started running, the compressor is prevented from functioning for 3 seconds.
Performance return programming
If the full load position is detected, the AC compressor is prevented from functioning for 8 seconds.
Stalling prevention programming
If the engine speed is lower than 650 rpm., the compressor is automatically cut off. It will only be allowed to
function again if the engine speed exceeds 775 rpm.
13-36
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DIESEL EQUIPMENT
Computer
13
CONNECTION
PRM1316
1 -<-
Computer supply
14-->-
2 -----
Computer earth
15 -->-
3 -----
Sensor earth
16 -->-
4 -->-
17 -->-
5 -->-
18 -->-
6 -->-
19 -->-
AC prevention control
7 -<--
20 -->-
8 -<--
9 -->-
21 -----
10 -<--
22
Not used
11 -<--
AC status
23 -<--
12 -<--
24 -<--
13 -><-
25 -<--
13-37
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DIESEL EQUIPMENT
Defect modes
13
If there is a fault with one of the components listed below, the computer enters "defect mode", which means
that replacement values are used to ensure engine operation.
Set values (for replacement)
Faulty
component
Advance
corrector
Coolant sensor
Running time
function
Air sensor
Temperature
= 22C
Pre-postheating
time
EGR function
AC function
Cut
Running time
function
Cut
Cut
20 % load lever
position
Preheating : 30C
Postheating :
80C
Postheating:
30 % load lever
position
Load
potentiometer
Altitude sensor
Altitude
= 900 m
Altitude
= 900 m
Cut
Battery
16 V < U < 6 V
Ubatt = 13.5V
Not controlled
TDC sensor
Minimum
advance
Solenoid valve
fully open
position
Cut
Speed
= 2 000 rpm
Speed
= 2 000 rpm
Needle lift
sensor
Defect mode
advance
(Carto soft
F8Q 662)
Maximum
advance
(F8Q 630)
Vehicle speed
sensor
Position :
V = 175 km/h
Position :
V = 175 km/h
Position :
V = 175 km/h
Heater plugs
relay housing
Cut
Postheating :
Not controlled
until ignition is
switched off
then on again
13-38
http://vnx.su
DIESEL EQUIPMENT
Pump
13
Mot. 1054
TDC pin
Mot. 1200
Pump-pulley retaining tool
Mot. 1317
4.5
2.2
REMOVAL
99183R
DI1302-1
13-39
http://vnx.su
DIESEL EQUIPMENT
Pump
Remove :
- the fuel supply pipe (A),
- the fuel return pipe (B),
- the pump connector (C),
- the accelerator cable (D),
- the vacuum pipe (E) connected to the fast
idle speed LDA,
- the high pressure wiring loom using tool Mot.
1383,
13
12410R
Clean the pump shaft very thoroughly, using solvent to eliminate all trace of grease.
Refit the pump.
Tighten the three bolts mounting the pump .
Pretighten the central nut of the pump to 2
daN.m.
IMPORTANT : it is vital to carry out a pretightening operation before the final tightening; tighten the central pump nut to a torque of 4.5
daN.m.
Carry out the timing operations (see "Pump Timing").
12869R
13-40
http://vnx.su
DIESEL EQUIPMENT
Pump - Timing
13
Mot.
Mot.
Mot.
Mot.
Mot.
Mot.
1054
1079
1200
1317
135
1359
TDC pin
91258R2
13-41
http://vnx.su
DIESEL EQUIPMENT
Pump - Timing
-
13
Timing pin
Dial gauge support
30 mm dial gauge
12419R
Turn the engine in its operating direction (clockwise from timing end).
91285R
be-
DI1303-1
13-42
http://vnx.su
DIESEL EQUIPMENT
Pump - Timing
MODIFICATION OF TOOL
13
Mot. 1358
98694R2
12275S
12411R
12338R
13-43
http://vnx.su
DIESEL EQUIPMENT
Pump - Timing
13
91258R2
12312R2
A
B
C
Timing pin
Dial gauge support
30 mm dial gauge
91285R
13-44
http://vnx.su
DIESEL EQUIPMENT
Pump - Timing
13
Turn the engine in its operating direction (clockwise from timing end).
12419R
13-45
http://vnx.su
DIESEL EQUIPMENT
Adjusting idle speed
It is vital to make these adjustments when the engine is warm, and after the engine cooling fan
has operated at least twice.
13
ADJUSTMENT
12870R
1
2
3
4
5
13-46
http://vnx.su
Petrol
engine
ANTIPOLLUTION
Test for the presence of lead
14
This test can only be carried out using a lead testing kit supplied by NAUDER.
To obtain a testing kit, contact your local After Sales Head Office.
Part numbers :
93703S
METHOD
a - Test conditions :
- Engine stationary.
- Exhaust pipes warm.
- Do not test when the temperature is below 0C.
b - If necessary use a soft cloth to clean the inside of the exhaust pipe so any soot deposits are removed.
c - Wearing the gloves, take a test paper and moisten it slightly with distilled water (the paper is not
effective if it is too wet).
d - Press the damp paper onto the cleaned exhaust pipe immediately and hold it there firmly for about a
minute.
e - Remove the test paper and allow to dry. The test paper will turn red or pink if lead is present.
IMPORTANT : The test for lead should only be carried out on the exhaust pipe, never on the oxygen
sensor.
14-1
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ANTIPOLLUTION
Fuel vapour rebreathing
D7F Engine
14
99933R
1
2
3
4
R
Inlet manifold
Fuel vapour absorber (canister)
RCO control solenoid valve
Cylinder head
Pipe from fuel tank
PRC14.1
14-2
http://vnx.su
E7J Engine
ANTIPOLLUTION
Fuel vapour rebreathing
14
13123R
1
2
3
4
R
Inlet manifold
Fuel vapour absorber (canister)
RCO control solenoid
Throttle body
Pipe from fuel tank
14-3
http://vnx.su
ANTIPOLLUTION
Fuel vapour rebreathing
CONDITION FOR BLEEDING THE CANISTER
engine)
(E7J
14
14-4
http://vnx.su
ANTIPOLLUTION
Fuel vapour rebreathing
14
YES
YES
NO
NO
97393R6
1 Inlet manifold
2 Canister bleed solenoid valve
3 Canister
4 Fuel tank
14-5
http://vnx.su
ANTIPOLLUTION
Fuel vapour rebreathing
14
LOCATION-REMOVAL OF COMPONENTS
E7J Engine
REMOVAL
13242R2
D7F Engine
It is mounted at the front, on the lifting bracket.
13049R
99939-1R3
14-6
http://vnx.su
D7F Engine
ANTIPOLLUTION
Oil vapour rebreathing
14
CIRCUIT DIAGRAM
99932R
1
2
3
4
5
6
14-7
http://vnx.su
D7F Engine
ANTIPOLLUTION
Oil vapour rebreathing
14
PRC14.2
14-8
http://vnx.su
ANTIPOLLUTION
Oil vapour rebreathing
E7J Engine
14
CIRCUIT DIAGRAM
13335R
1
2
3
Cylinder head
Inlet manifold
Oil vapour rebreathing pipe connected
upstream from the throttle body (the circuit is
used for medium and high loads)
Oil vapour rebreathing pipe connected
downstream from the throttle body
CHECKING
14-9
http://vnx.su
ANTIPOLLUTION
Oil vapour rebreathing
F8Q Engine
14
13042R
1
2
3
4
Engine
Oil decanter
Air filter
Inlet manifold
14-10
http://vnx.su
F8Q Engine
ANTIPOLLUTION
Exhaust gas recirculation (EGR)
14
13046R
1
2
3
4
5
6
7
8
9
13045R
14-11
http://vnx.su
EGR valve
EGR solenoid (ON/OFF)
Vacuum pump
Engine
Exhaust manifold
Inlet manifold
Air filter
Injection computer
Coolant temperature sensor
F8Q Engine
ANTIPOLLUTION
Exhaust gas recirculation (EGR)
To remove the EGR solenoid (2), remove the air
filter .
12871R1
13047-1R2
SPECIAL NOTES
14-12
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14
F8Q Engine
ANTIPOLLUTION
Exhaust gas recirculation (EGR)
The EGR is controlled by the computer via an
ON/OFF solenoid valve.
The operation of the EGR solenoid valve is dependent upon the following parameters :
- the air temperature,
- the coolant temperature ,
- the altitude,
- the position of the load lever ,
- the vehicle speed ,
- the engine speed .
The EGR function is cut if :
- the air temperature < 16C or
- the coolant temperature < 45C or
- the engine speed/ load potentiometer value is
greater than a certain threshold .
The EGR is cut after operating at idle speed for 40
seconds (at zero vehicle speed).
Once the vehicle speed > 25 mph (40 km/h), the
EGR is operational again. It will be cut again after
40 seconds of operating at idle speed at zero vehicle speed.
XR 25 bargraph 14 RH is illuminated if the EGR
function is permitted. In order to determine if the
EGR is actually controlled, use #24. if the value is
different from 0, the EGR is activated .
14-13
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14
STARTING - CHARGING
Alternator
16
IDENTIFICATION
ENGINE
ALTERNATOR
CURRENT
D7F
80 A
E7J
VALEO
A 11 VI 87
75 A
F8Q
VALEO A 11 VI 88
75 A
CHECKING
Engine rpm
75 amps
80 amps
1000
46
54
2000
68
75
3000
71
80
4000
72
82
16-1
http://vnx.su
STARTING - CHARGING
Alternator
16
Check:
- all electrical connections are good.
- the bulb has not blown. (Earth the circuit and
the bulb should illuminate).
16-2
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STARTING - CHARGING
Alternator
16
FAULT FINDING
SPECIAL TOOLING REQUIRED
The OPTIMA 5800 diagnostic station allows the alternator to be checked by measuring the voltage and current delivered , with or without electrical consumers .
NOTE : the Amps clamp used for this station is of the inductive type (measurement range: 0 to 1 000 A). It
is fitted without disconnecting the battery, which allows the the computer memory and adaptive information to be saved.
Fit the Amps clamp directly at the alternator output, with the arrow pointing towards the alternator (any incorrect positioning is detected by the station).
The measurement is carried out in three stages :
- measurement of the battery voltage, ignition off,
- measurement of the regulated voltage and of the current supplied, without consumers,
- measurement of the regulated voltage and current supplied, with a maximum number of consumers.
On completion of the test, the values noted will lead to the following fault finding messages :
- Battery voltage, no load < 12.3 V = battery uncharged.
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 supply in relation to its specifications :
Engine
D7F
E7J
F8Q
Nominal current
70
75
75
53
51
55
Current (amps)
16-3
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STARTING - CHARGING
Alternator
16
16-4
http://vnx.su
STARTING-CHARGING
Alternator
D7F / E7J
Engines
16
Mot. 1273
REMOVAL
E7J Engine
13363R
10617R
16-5
http://vnx.su
STARTING-CHARGING
Alternator
F8Q Engine
16
Mot. 1273
REMOVAL
13188S
REFITTING
13092R
16-6
http://vnx.su
STARTING - CHARGING
Starter motor
IDENTIFICATION
ENGINE
STARTER MOTOR
D7F
VALEO D7 E1
Bosch 0001116001
E7J
D6 RA 73
F8Q
Bosch 0001108180
16-7
http://vnx.su
16
STARTING - CHARGING
Starter motor
16
FAULT FINDING
SPECIAL TOOLING REQUIRED
Checking of the starter motor is carried out using the OPTIMA 5800, by measuring the battery voltage and
the current absorbed in the engine starting phase. The following operation faults may be highlighted :
- a fault in the battery ( the voltage falls during the starting phase),
- locking of the starter motor (the current absorbed is too high),
- a fault in the engine starter gear (the current absorbed is too low).
In order to carry out the measurement, it is necessary to stop the vehicle from starting :
- for D7F and E7J engines : disconnect the engine speed sensor (located on the clutch housing ,
- for F8Q engines : disconnect the pump electrical solenoid and isolate the terminal.
NOTE :
- an open circuit on the engine speed sensor or the ignition creates a fault memorised by the injection
computer, this fault must then be erased from the memory using the XR25 (see " Injection" section),
- if the engine is fitted with an immobiliser, it is sufficient to lock the doors using the remote control.
16-8
http://vnx.su
D7F Engine
STARTING - CHARGING
Starter motor
REMOVAL
10076R
16-9
http://vnx.su
16
E7J Engine
STARTING - CHARGING
Starter motor
-
REMOVAL
16
13088S
the mounting (1) for the power assisted steering pipe, along with the strut at (A),
13087R
13336-1R
16-10
http://vnx.su
F8Q Engine
STARTING - CHARGING
Starter motor
16
REMOVAL
13087R1
REFITTING
16-11
http://vnx.su
IGNITION
Semi-static ignition
17
D7F Engine
PRESENTATION
99931-1R2
E7J Engine
17-1
http://vnx.su
IGNITION
Semi-static ignition
D7F Engine
17
D7F Engine
Electrical connector
Electrical connector
Track
Allocation
+anti-interference
condenser
+after ignition
coil control by
computer
Track
+after ignition
+anti-interference
condenser
Allocation
Test to be made
between tracks
Resistance
Test to be made
between tracks
Resistance
1 - 2
1.5
1 - 2
0.5
1 - 3
1 - 3
1 - 4
2 - 3
2 - 3
HT - HT
10 k
2 - 4
3 - 4
0.6
HT - HT
8 k
17-2
http://vnx.su
IGNITION
Spark plugs
D7F/E7J
Engines
Engine
D7F
E7J
17
Make
Type
EYQUEM
NGK
RFC 50 LZ 2E
BKR 5EK
EYQUEM
CHAMPION
RFC 52 LS
RC 10 PYC
D7F Engine
To disconnect the spark plug leads, use the tool (3), which is integrated to the plastic cover (4) on the cylinder head.
99894R1
99940R
NOTE : to remove the spark plugs, use the tool kit, Ele. 1382.
17-3
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D7F Engine
INJECTION
General
17
Semi-sequential multipoint injection. Injectors controlled two by two (injectors for cylinders 1 and 4 followed by injectors for cylinders 2 and 3).
FITTING A 2ND GENERATION ENGINE IMMOBILISER REQUIRES A SPECIAL PROCEDURE FOR REPLACING THE
COMPUTER.
17-4
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E7J Engine
INJECTION
General
17
Semi-sequential multipoint injection. Injectors are controlled two by two (injectors for cylinders 1 and 4
followed by cylinders 2 and 3).
Maximum speed :
- 6 200 rpm if 1st , 2nd or 3rd gears
- 6 000 rpm if 4th,or 5th gears.
FITTING A 2ND GENERATION ENGINE IMMOBILISER REQUIRES A SPECIAL PROCEDURE FOR REPLACING THE
COMPUTER.
17-5
http://vnx.su
D7F Engine
INJECTION
General
17
LOCATION OF COMPONENTS
13081
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Coil
Air filter
Oxygen sensor
Absolute pressure sensor
Throttle position potentiometer
Idle regulation stepping motor
Air temperature sensor
Injection computer
Inertia switch
Locking relay
Fuel pump relay
TDC sensor
Fuel vapour recycling solenoid valve
Coolant temperature sensor
Tool for removing spark plug leads
Pinking sensor
Power assisted steering pressostat
Pressure regulator
Anti-interference condenser
Fuel vapour absorber (canister)
17-6
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E7J Engine
INJECTION
General
17
LOCATION OF COMPONENTS
13082
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
17-7
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D7F Engine
8
9
INJECTION
Location of components
16 Pinking sensor
(tightening torque: 2.5 daN.m)
Injection computer
Inertia switch
13051R1
4
5
6
7
11311R1
11313R4
99939-1R2
17-8
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17
D7F Engine
INJECTION
Location of components
1 Coil
19 Anti-interference condenser
17
Oxygen sensor
(tightening torque : 5 daN.m)
99931-1R1
H Locking relay
K Fuel pump relay
12993R
13050R
12839S
17-9
http://vnx.su
E7J Engine
8
9
INJECTION
Location of components
Injection computer
Inertia switch
13240R
17
13239R
Pinking sensor
(tightening torque: 2.5 daN.m)
13336R
17-10
http://vnx.su
E7J Engine
1
14
16
18
INJECTION
Location of components
6 Throttle position potentiometer
11 TDC sensor
13242R1
4
5
7
17
13337R
13 Oxygen sensor
(tightening torque : 4.5 daN.m)
13339R
13243R
17-11
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INJECTION
Location of components
E7J engine
17
13241R
12839S
17-12
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INJECTION
Coolant temperature management
D7F Engine
17
244
259
Operating principle
Sensor 244 allows :
- the coolant temperature to be shown on the
instrument panel,
- the injection computer to receive constant information on the engine coolant temperature
.
11634R2
E7J Engine
13239R1
17-13
http://vnx.su
INJECTION
Injection fault warning light
17
17-14
http://vnx.su
INJECTION
Immobiliser function
17
All computers are supplied uncoded, but are capable of being programmed with a code.
When replacing the computer, the vehicle code must be programmed in and then a check must be made to
ensure that the immobiliser system is operational.
To do this, it is sufficient to carry out the following operations:
- turn the ignition on for a few seconds and turn it off again,
- remove the key to guarantee the immobiliser function.
CHECKING THE IMMOBILISER FUNCTION
Remove the key from the ignition switch. After 10 seconds the red immobiliser warning light will flash.
For special notes on testing an injection computer (test part), refer to section 82: "Immobiliser".
17-15
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INJECTION
Computer configuration depending on gearbox type
17
Each time the injection computer is replaced, it must be programmed with the type of gearbox (manual or
automatic) which is fitted in the vehicle. The computers are designed to function with either type of gearbox.
Method for configuring the computer
Connect the XR25
Select S8
Switch on the ignition
Enter D13 then
For vehicles fitted with manual gearbox :
Enter G50* 2*
For vehicles fitted with automatic transmission :
Enter G50* 1*
then
To ensure that the computer has memorised the data correctly, switch the ignition back on , using fault finding fiche n 27; the fault bargraph 20 LH should be extinguished, whilst the 19 LH or RH status bargraph
should be illuminated.
17-16
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INJECTION
Injection/air conditioning programming
17
between the air conditioning computer and the injection computer consists of a single wire (track 5).
This track carries two types of information :
- the fast idle speed request information . For this information to be transmitted to the injection
computer , two conditions must be fulfilled :
the air conditioning function must have been selected on the control panel ,
the pressure in the air conditioning circuit must be greater than a certain threshold.
If this information is transmitted, the fast idle speed is obtained (it is therefore normal that
sometimes, when the air conditioning is switched on, engine idling, there is no fast idle speed ).
- the Absorbed Power information. This information has no influence on the idle speed. It simply
informs the injection computer of the torque value taken up by the compressor; the computer, in
turn, acts on the idle speed regulation solenoid. The absorbed power may be visualised using the
XR25. When the air conditioning is switched on , #44 should be between 300 and 5 000 watts.
IMPORTANT: the value at #44 or idle speed is never equal to 0, whatever the status of the
compressor, off or on . The minimum value which may be read using #44 is approximately 300
watts.
between the the injection computer and the air conditioning computer consists of a single wire (track
51). This track carries the information regarding the authorisation or prevention of compressor
operation.
COMPRESSOR OPERATION
PROGRAMMING
During certain operating phases, the injection computer prevents the compressor from operating.
Programming when starting engine
The compressor is prevented from functioning for 10 seconds after starting the engine .
Recovery of performance ( D7F engine)
Depending on the torque required by the driver and on the power absorbed by the air conditioning
compressor, the injection computer stops or allows the operation of the compressor .
Anti-stalling function (D7F engine)
If the no load position is recognised , and the engine speed is lower than 600 rpm, and if the power absorbed
by the compressor is greater than 300 watts, the compressor disengages .
It engages again if:
- the no load position is recognised when the engine speed reaches 850 rpm.,
- if the no load position is not recognised when the engine speed reaches 1 800 rpm.
Thermal protection programming ( E7J engine )
The compressor does not engage in cases where the coolant temperature is greater than or equal to +
115C.
Over-revving protection (E7J engine )
The compressor is prevented from operating if the engine speed is greater than 5 900 rpm.
17-17
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INJECTION
Idle speed correction
CONNECTION BETWEEN THE
17
AND THE
INJECTION COMPUTER
The injection computer receives information from the power assisted steering pressostat . This varies
depending on the pressure present in the hydraulic circuit. The higher the pressure, , the more energy is
absorbed by the power assisted steering pump.
To compensate for this energy absorption, the injection computer increases the opening ratio of the idle
speed regulation stepping motor.
The information is received on track 13 of the injection computer. If the pressostat is closed , the computer
receives an earth . The idle speed is adjusted to 800 rpm for the D7F engine and 850 rpm for the E7J
engine .
IDLE SPEED CORRECTION DEPENDING ON THE BATTERY VOLTAGE
The objective of this correction is to compensate for the drop in voltage, due to consumer operation when
the battery is poorly charged To correct this, the idle speed is increased, allowing the alternator to rotate
faster and consequently increase the charging voltage.
The lower the voltage, the greater the degree of correction. Correction of the engine speed is therefore
variable. It begins when the voltage drops to below 12.7 Volts. Correction begins at the nominal engine
speed and may reach a maximum of 880 rpm for the D7F engine and 930 rpm for the E7J engine .
IDLE SPEED CORRECTION DEPENDING ON AIR CONDITIONING OPERATION
The injection computer increases the idle speed to 850 rpm. for the D7F engine and 880 rpm . for the E7J
engine , provided it receives the fast idle speed information from the air conditioning computer.
17-18
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INJECTION
Adaptive idle speed correction
17
PRINCIPLE
Under normal warm engine operating conditions , the R.C.O. idle speed value at #12 varies between a
high value and a low value, until the nominal idle speed is obtained .
It is possible that during variations in the operation of the vehicle (running in, engine wear..), that the
R.C.O. idle speed value could become close to the highest or lowest values.
The adaptive correction (#21) of the R.C.O. idle speed (#12) allows the slow variations in the engine air requirement to be corrected, so that the R.C.O. ( #12) is recentred to an average nominal value.
This correction only becomes effective if the coolant temperature is higher than 75C, 20 seconds after
starting the engine and if the nominal idle speed regulation phase has been reached.
VALUES FOR THE R.C.O. IDLE SPEED AND ITS ADAPTIVE CORRECTION
D7F 710
engine
E7J 780
engine
X = 740 rpm
X = 750 rpm
4 %X14 %
2 %X15 %
Limit value:
- minimum : - 4.3 %
- maximum :+3.9 %
Limit value:
- minimum : - 2.4 %
- maximum :+6.2 %
In the case of excess air (air leak or throttle stop incorrectly adjusted ..) the idle speed increases, and the
R.C.O.idle speed value at #12 decreases , in order to return to the nominal idle speed; the value of the
R.C.O.idle speed adaptive correction at #21 decreases to re-centre the R.C.O. idle speed at #12.
In the case of a lack of air (contamination, etc.), the process is inverted : the R.C.O. idle speed at #12 increases and the adaptive correction at #21 also increases, in order to re-centre the #12 to an average nominal value.
IMPORTANT : It is vital, after erasing the memory from the computer (disconnecting the battery), to let the
engine run at idle speed before returning the vehicle to the customer, so that the adaptive correction can be
correctly reset.
17-19
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INJECTION
Richness regulation
17
Reading #05 on the XR25 : the value read is the voltage sent to the computer by the oxygen sensor; it is expressed in volts (the value actually varies between 0 and 1 000 millivolts).
When the engine is in the loop phase, the voltage value should oscillate rapidly and should be between
5050 mV (lean mixture) and 850 50 mV (rich mixture) and vice versa.
The smaller the gap between the upper and lower values, the poorer the information from the sensor (the
gap is usually at least 500 mV).
RICHNESS CORRECTION (#35)
The value given under # 35 on the XR25 represents the average value of richness corrections made by the
computer depending on the richness of the burnt mixture as seen by the oxygen sensor (the oxygen sensor actually analyses the oxygen content of the exhaust gases directly from the richness of the burnt mixture).
The richness correction has a centre point of 128 with thresholds of 0 and 255 (experience has shown that under normal operating conditions # 35 is located close to 128 with only a small amount of variation).
- Value less than 128 : request for mixture to be made leaner.
- Value greater than 128 : request for mixture to be made richer.
Loop phase
Richness regulation begins after the timed starting period :
-
at 20C it is a maximum of :
17-20
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INJECTION
Richness regulation
17
Non-loop mode
When richness regulation is occurring, the operating phases when the computer ignores the voltage information from the oxygen sensor are:
- Full load: #35 = variable and greater than 128
- Sharp acceleration: #35 = variable and greater than 128
- Deceleration with no load information (injection cut) : #35 = 128
- Oxygen sensor fault: #35 = 128
DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT
If the voltage from the oxygen sensor is incorrect (# 05 varies only slightly or not at all) during richness regulation, the computer will only enter defect mode (# 35 = 128 ) if the fault has been present for 3 to 5 minutes.
The fault will be memorised in this case only.
If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system enters
the open loop mode directly (# 35 = 128 )
17-21
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INJECTION
Adaptive richness correction
17
PRINCIPLE
In the loop mode (see section 17 "Richness regulation"), richness regulation (# 35 ), corrects the injection timing to give fuel metering which is as close as possible to richness 1. The correction value is close to 128, with
limit values of 0 and 255.
Variations may affect the components of the injection system and the correction may drift towards 0 or 255,
to ensure richness 1 is obtained.
Adaptive correction allows the injection mapping to be adjusted to recentre the richness regulation to 128
and to ensure a constant authority of correction to make the mixture leaner or richer.
Adaptive correction to richness regulation has two parts:
- Adaptive correction for average and high engine loads (#30)
- Adaptive correction for idle speed and low engine loads (#31).
Adaptive corrections take 128 as the average value after initialisation (erasing the memory) and have the
following threshold values:
D7F
Engine
E7J
Engine
40 #30 192
40 #31 192
Adaptive correction only takes place when the engine is warm, in the loop phase (#35 variable) and for a
specified manifold pressure range.
The engine must have operated in the loop mode for several pressure zones in order that adaptive correction begins to change to compensate for the variations in engine operating richness.
Following reinitialisation of the computer (return to 128 for # 30 and # 31 ) a special road test must therefore
be carried out.
17-22
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INJECTION
Adaptive richness correction
17
ROAD TEST
Conditions :
-
For this test , it is advisable to start from a fairly low engine speed , in 3rd or 4th gear using progressive acceleration to stabilise the required pressure for 10 seconds in each zone (see table).
NOTE : for the D7F engine, for example, for zone n 1, attempt to maintain the average of 320 mbars for
at least 10 seconds.
Zone n 2
(mbars)
340
Zone n 3
(mbars)
470
Zone n 4
(mbars)
600
Zone n 5
(mbars)
730
870
E7J
Average 280
260
Average 405
385
Average 535
510
Average 665
635
Average 800
760
D7F
Average 320
Average 450
Average 570
Average 700
Average 865
17-23
http://vnx.su
970
INJECTION
Adaptive richness correction
17
If there is a lack of fuel (injectors dirty, fuel pressure and flow too low...), richness regulation # 35 increases to
obtain the richness as close as possible to richness 1 and adaptive correction # 30 and # 31 increases until the
richness correction returns to oscillate around 128.
If there is an excess of fuel, the situation is reversed : Richness regulation # 35 reduces and adaptive
correction # 30 and # 31 also reduces to recentre the richness correction (# 35) around 128.
NOTE : the analysis which may be made using # 31 remains difficult since this correction mainly operates for
idle speed and low loads and is also very sensitive.
Hasty conclusions should not therefore be drawn from this gate value, rather the position of # 30 should be
examined.
The information from these two gates gives an idea about the engine operation richness, and may be used as
a guide for fault finding. In order for these to be put to good use during fault finding, no conclusion may be
drawn from their value unless they are at the minimum or maximum correction limit, and if both gate values
were offset in the same direction.
IMPORTANT : # 30 and # 31 should only be examined and analysed after a customer complaint, an operating fault and if they are at the threshold with the value for # 35 also offset (# 35 varies above 175 or below 80).
17-24
http://vnx.su
COOLING
Specifications
19
Engine
D7F
E7J
F8Q
7.5
Grade
Special notes
GLACEOL RX (type D)
recommended coolant
only
Protection down to - 20 2C ,
warm, temperate and cold countries
Protection down to - 37 2C for
extreme cold countries
THERMOSTAT
Engine type
89
101
7.5
19-1
http://vnx.su
COOLING
Filling and bleeding
There is no heater matrix water control valve.
Water flow is continuous in the heater matrix,
which contributes to the cooling of the engine.
FILLING
19-2
http://vnx.su
19
COOLING
Testing
19
Engine
Colour of valve
D7F-E7J-F8Q
Brown
1.2
97871R
19-3
http://vnx.su
D7F Engine
COOLING
Diagram
19
10070-2R
1
2
3
4
5
Engine
Radiator
Hot bottle with permanent degassing
Heater matrix
3 mm diameter restriction
Water pump
Thermostat
Bleed screw
19-4
http://vnx.su
E7J Engine
COOLING
Diagram
19
13508R
1
2
3
4
5
6
Heater
Radiator
Hot bottle with permanent degassing
Heater matrix
Thermostat mounting
3 mm diameter restriction
Water pump
Thermostat
Bleed screw
Temperature switch
19-5
http://vnx.su
F8Q Engine
COOLING
Diagram
19
13504R
1
2
3
4
5
6
Water pump
Heater
Radiator
Hot bottle with permanent degassing
Heater matrix
Thermostat mounting
3 mm diameter restriction
Thermostat
Bleed screw
Temperature switch
19-6
http://vnx.su
COOLING
Water pump
D7F Engine
19
Mot.
Mot.
Mot.
Mot.
1054
1202
1273
1289-03
TDC pin
Mot. 1379
2 + 90
6.2
6.2
0.9
REMOVAL
Remove:
- the timing belt (see method described in
section 11 "Timing belt),
- the power assisted steering pump pulley (if fitted),
- the upper alternator mounting bolt and
slacken the lower bolt,
- the bolts for mounting the power assisted
steering pipe on the cylinder block,
- the bolts for mounting the power assisted
steering pump on its support (move the power assisted steering pump-pipe assembly to
one side),
- the power assisted steering pump support,
- the water pump hose,
- the tension wheel along with the water pump
itself.
19-7
http://vnx.su
COOLING
Water pump
D7F Engine
19
REFITTING
Special notes
Sealing of the water pump is carried out using
RHODORSEAL 5661, the bead (J) must be applied
following the illustration below.
Apply a bead of LOCTITE 518 on the sealing surface (L) between the inlet pipe elbow and the water pump.
10272R
19-8
http://vnx.su
COOLING
Water pump
E7J Engine
19
Mot.
Mot.
Mot.
Mot.
Mot.
591-02
591-04
1135-01
1202
1273
Index
Angle tightening wrench
Tool for tensioning the timing belt
Hose clip pliers
Tool for checking belt tension
EQUIPMENT REQUIRED
REFITTING
REMOVAL
92068R
CLEANING
19-9
http://vnx.su
COOLING
Water pump
F8Q Engine
19
Mot. 1202
1.6
2
2 + 115 15
REMOVAL
13090R
13086R1
19-10
http://vnx.su
COOLING
Water pump
F8Q Engine
19
13089S
CLEANING
19-11
http://vnx.su
EXHAUST
General
During operation, the catalytic converter reaches
high temperatures, and consequently, it is vital
not to park the vehicle in a place where combustible materials could come into contact with it, and,
as a result, ignite.
19
IMPORTANT:
- the seal, between the exhaust manifold gasket face and the catalytic converter (inclusive), must be in perfect condition,
_
it is imperative that every gasket removed be
REPLACED (especially at the catalytic converter
flange)
- during removal and refitting, the catalytic
converter must not undergo repeated mechanical shocks, as it will be damaged.
12847-1R
CUTTING
19-12
http://vnx.su
EXHAUST
General
19
99226-1R
P2
90 mm
DI1901
IMPORTANT: to cut the exhaust pipe, it is essential to use tool Mot. 1199-01; this tool allows
2mm thick pipes to be cut.
19-13
http://vnx.su
EXHAUST
General
19
95478R1
99227S
IMPORTANT:
- check that there is no point of contact between the exhaust pipe and the vehicle body,
- check for the presence and correct positioning
of all heat shields for the exhaust pipe,
- check that the two cutting marks are correctly
aligned.
IMPORTANT : the bolt and nut used for tightening the sleeve must be aligned vertically to
avoid any risks of touching the underside of the
body.
19-14
http://vnx.su
EXHAUST
Pipe assembly
19
E7J Engine
D7F Engine
13126R
1
2
3
ZC
13124R
Expansion box
Silencer
Catalytic converter
Pipe cutting area
19-15
http://vnx.su
EXHAUST
Pipe assembly
19
F8Q Engine
13125R
1
Catalytic converter
2
Silencer
ZC Pipe cutting area
19-16
http://vnx.su
FUEL TANK
Fuel tank
19
Mot. 1199-01
Mot. 1265
Mot. 1265-01
EQUIPMENT REQUIRED
NOTE : Alternatively, an INTAIRCO pneumatic siphoning pump may be used (see EQUIPMENT catalogue).
(Petrol version)
97163R2
19-17
http://vnx.su
FUEL TANK
Fuel tank
In the engine compartment, disconnect the fuel
pump relay at (K) , which is located in the engine
connection unit.
19
( Diesel
version)
Since Diesel versions are not fitted with an electrical fuel pump, a manual pump must be used to
drain the tank.
For example, the INTAIRCO pneumatic siphoning
pump is suitable for this operation (see
EQUIPMENT catalogue),
99641S
97163R2
19-18
http://vnx.su
TANK
Fuel Tank
REMOVAL OF THE TANK (petrol or
sions)
19
diesel ver-
12866R
97163R4
19-19
http://vnx.su
FUEL TANK
Fuel tank
19
99091R1
12873R
19-20
http://vnx.su
FUEL TANK
Fuel tank
19
13039R
19-21
http://vnx.su
FUEL TANK
Fuel tank
19
13037R
19-22
http://vnx.su
FUEL TANK
Fuel tank
19
13038R
19-23
http://vnx.su
FUEL TANK
Fuel tank
19
13036R
19-24
http://vnx.su
FUEL TANK
Fuel tank
19
Diesel version
13040R
19-25
http://vnx.su
FUEL TANK
Fuel tank
19
13035R
The tank breathes through the top opening of the fuel breather/sender unit assembly.
19-26
http://vnx.su
FUEL TANK
Fuel tank
Components
1
2
3
4
5
6
7
8
9
10
13
14
15
18
19
20
21
22
23
24
25
27
28
29
30
31
32
Tank
Bolt
Filler neck
Filler neck bowl
Rivet
Sleeve mounting clip
Fuel cap
Fuel supply pipe
Fuel return pipe
Clip
Cup
Canister pipe
Canister pipe
Canister
Bolt
Clip
Clip
Damper pad
Captive nut
Connection between filler neck outlet and
fuel passage pipe
Degassing - filling
Canister connection (fuel vapours)
Over-filling prevention valve
Excess pressure-under-pressure safety valve
Restriction valve
Leak prevention valve in case vehicle turns
over
Over-filling prevention valve and leak prevention valve in case vehicle turns over.
A
B
C
D
E
F
R
V
Quick-release union
Snap-fit union
Quick release union
Sleeve (not snap-fit)
Opening for air outlet during filling
Air volume allowing the fuel to expand
Fuel inlet for filling
Maximum fuel volume allowed.
19-27
http://vnx.su
19
FUEL TANK
Fuel tank
19
The filler neck for unleaded petrol has the following special features :
- a filling opening with a smaller diameter and
not compatible with a conventional filling
nozzle (the lead would have the effect of polluting the depollution system: oxygen sensor
and catalytic converter),
- a valve blocking the filing opening (30) (to
avoid fuel evaporating or the reverse passage
of fuel).
99212R2
19-28
http://vnx.su
FUEL TANK
Sender unit
In petrol versions, the pump and sender unit cannot be separated.
In diesel versions, there is no pump immersed in
the tank, and there is only a sender unit.
For the removal of the sender unit, please refer to
subsections "Tank", "Pump-sender unit".
Checking the sender unit
Indication
4/4
7 maximum
3/4
54.5 7
1/2
98 10
1/4
155 16
300 20
19-29
http://vnx.su
19
FUEL TANK
Pump- sender unit
19
Mot. 1264
Mot. 1264-01
Mot. 1265
Mot. 1265-01
IMPORTANT :
During all operations on the fuel tank or on the
fuel supply circuit , it is vital :
- to refrain from smoking and handling incandescent objects in the vicinity of the working
area,
- to avoid fuel projections, due to the residual
pressure present in the pipes during removal .
REMOVAL
96420R1
97163R5
19-30
http://vnx.su
FUEL TANK
Pump- sender unit
Remove the mounting nut at (5) using tool
Mot. 1264 or 1264-01 (release the nut, remove
the tool, hand slacken the nut, then remove it).
19
REFITTING
99367S
TRACK
ALLOCATION
A1
Earth
A2
B1
B2
Not used
C1
pump
C2
pump
19-31
http://vnx.su
D7F Engine
ENGINE MOUNTING
Suspended engine mountings
19
13359S
12924G
19-32
http://vnx.su
D7F Engine
ENGINE MOUNTING
Suspended engine mountings
19
13359R3
19-33
http://vnx.su
F8Q Engine
ENGINE MOUNTING
Suspended engine mountings
19
13086R2
19-34
http://vnx.su
Transmission
CLUTCH
MANUAL GEARBOX
DRIVESHAFTS
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRF2000
http://vnx.su
Transmission
Contents
Page
20 CLUTCH
Mechanism- Disc
Flywheel
20-1
20-4
ENSEMBLE
GEARBOX
MOTEUR ET BAS
21 MANUAL
Identification
Ratios
Capacities-Lubricants
Consumables
Parts to be systematically replaced
Gearbox (Removal-Refitting)
21-1
21-2
21-3
21-4
21-4
21-5
29 DRIVESHAFTS
General
Front driveshaft
http://vnx.su
29-1
29-2
CLUTCH
Mechanism - Disc
Vehicle
Type
Engine
Type
Mechanism
Disc
26 splines
D = 181.5 mm
E = 6.7 mm
F/K C0A
F/K C0C
20
GA : Grey Silver
VR : Violet Red
D7F
E7J
85873S
180 CP3300
90693R8
26 splines
D = 242 mm
E = 6.8 mm
F/K C0D
F/K C0E
76906R
RR : Red Ruby
GB : Grey Blue
F8Q
85873S
90693R9
20-1
http://vnx.su
76906R
CLUTCH
Mechanism - Disc
20
Mot. 582
or
Mot. 582-01
Locking tool
REFITTING
REMOVAL
95414S
Tighten progressively in a star pattern, then tightenthe mounting bolts to the correct torque.
99055R
20-2
http://vnx.su
CLUTCH
Mechanism - Disc
After refitting the gearbox, place the cable onto
the clutch fork, reset the notched sector and
check that the play compensation is in working order.
20
NOTE : in the case of any intervention not requiring the removal of the gearbox or after the fitting of the gearbox, DO NOT LIFT the fork, as it
would risk releasing itself from the slot (A) of the
clutch thrust bearing.
99054R
97758-1R
20-3
http://vnx.su
CLUTCH
Flywheel
REPLACEMENT
20
of the flywheel
Mot. 582
or
Mot. 582-01
Locking tool
Flywheel bolt
2 + 60
REMOVAL
Clean the threads of the mounting bolts of the flywheel on the crankshaft.
Remove the grease from the bearing face of the
flywheel on the crankshaft.
Refit the flywheel by immobilising it with tool
Mot. 582 or Mot. 582-01.
NOTE: the flywheel mounting bolts are to be systematically replaced.
20-4
http://vnx.su
MANUAL GEARBOX
Identification
All KANGOO vehicles are fitted with
21
JB type gearboxes.
The Workshop Repair Manual "B.V. JB. JC " deals with the complete repair of this component.
87227G
IDENTIFICATION PLATE
At A
At B
At C
At D
At E
At F
:
:
:
:
:
J B0 0 0 0
X X0 0 0 0 0
E
F
21-1
http://vnx.su
B
C
MANUAL GEARBOX
Ratios
21
JB1
Suffix
Vehicle
Differential
ratio
906
175
F/K C0D
16
55
171
172
F/K C0A
14
59
173
174
F/K C0E
16
57
Speedometer
gear
1st
2nd
3rd
4th
5th
Reverse
gear
39
31
11
41
21
19
21
43
28
39
34
35
39
32
11
39
26
37
33
JB3
Suffix
Vehicle
Differential
ratio
168
169
F/K C0C
14
59
Speedometer
gear
21
19
1st
2nd
3rd
4th
5th
Reverse
gear
11
14
21
43
28
39
34
35
39
32
11
39
21-2
http://vnx.su
26
MANUAL GEARBOX
Capacities - Lubricants
CAPACITY (in litres)
5 gear box
JB1
3.4
JB3
3.4
Viscosity grade
92081S
Filling is by overflow
21-3
http://vnx.su
21
MECHANICAL GEARBOX
Consumables
TYPE
PACKAGING
PART NUMBER
21
COMPONENT
Loctite 518
RHODORSEAL
5661
1 kg tin
77 01 421 145
24 ml syringe
77 01 421 162
100 g tube
77 01 404 452
24 cc bottle
77 01 394 071
Fork pivot
Thrust bearing guide
Fork pads
21-4
http://vnx.su
Clutch
MANUAL GEARBOX
Gearbox (removal - refitting)
SPECIAL
21
TOOLING REQUIRED
Set of punches
Engine sub-frame carrier
Ball joint extractor
B. Vi.
31-01
Mot. 1040-01
T. Av.
476
EQUIPMENT REQUIRED
4
2.5
5.5
18
6.5
4.5
4
9
4
REMOVAL
Remove :
- the engine cover,
- the battery.
13088R
21-5
http://vnx.su
MANUAL GEARBOX
Gearbox (Removal - Refitting)
Remove :
- the two mounting bolts (B),
13119R
91755-1R2
Remove :
- the upper bolts at the gearbox edge and on
the starter motor (slacken the bolt (D) as far
as possible)
- the earth strap bolts on the gearbox,
- the two bolts of the TDC sensor.
13097-2R
21
99070R1
21-6
http://vnx.su
MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Ensure that the rollers of the left driveshaft cannot be removed by hand. If they can, check if any
of the needles have fallen into the gearbox.
Disconnect and remove the starter motor.
Disconnect:
- the reversing light connector,
- the speedometer connector and remove the
gearbox sensor.
Remove :
- the exhaust downpipe,
- the entire gear control lever by removing the
bolt (E) and the three bolts of the heat shield
for access to the base of the gear lever
-
13120S
12993-1R2
13121S
21-7
http://vnx.su
MANUAL GEARBOX
Gearbox (Removal - Refitting)
21
Fit the sub-frame support (Mot. 1040-01) and lower the vehicle.
13122S
98755R1
12924R
21-8
http://vnx.su
MANUAL GEARBOX
Gearbox (Removal - Refitting)
REFITTING
Coat the walls of the guide tube and the fork pads
with MOLIKOTE BR2 grease.
86308R2
Refit:
- the engine sub-frame,
- the steering,
- the exhaust downpipe,
- the engine tie-bar.
SPECIAL NOTE FOR THE E7J ENGINE
21-9
http://vnx.su
21
DRIVESHAFTS
General
29
SPECIFICATION
Driveshaft seal
Vehicle type
Engines
FC0X
KC0X
Gearboxes
F8Q
JB1
D7F
JB1
E7J
JB1 / JB3
Left
Right
GE 86 + GI 69
GE 86 + RC 462
CONSUMABLES
Type
Quantity
Component concerned
RHODORSEAL 5661
Coat
MOBIL K 575 GS
180 g
GE 86
ELF GMPT89 or
MOBIL CVJ 825 BLACK STAR
110 cm3
RC 462
NOTE : the replacement of the NYLSTOP nut with the ENKO driveshaft nut means that the splines of the
stub axles must no longer be coated with Loctite SCELBLOC .
29-1
http://vnx.su
DRIVESHAFTS
Front driveshafts
29
B. Vi.
Rou.
T. Av.
T. Av.
31-01
604-01
476
1050-02
Driveshaft nut
Mounting bolt of gaiter on gearbox.
Wheel bolts
Shock absorber base nuts
Brake caliper mounting bolts
Track rod end nut
28
2.5
9
18
10
3.7
REMOVAL
99544R
REFITTING
Left side :
Left side :
Right side :
Right side :
On both sides :
Fit the driveshaft and check its positioning : angled pin B. Vi. 31-01.
Remove :
- The track rod end nut and extract the shaft :
tool T. Av. 476,
- the upper bolt of the shock absorber base.
Fit two new roll pins : B. Vi. 31-01. Seal the roll pin
holes using RHODORSEAL 5661 .
On both sides :
29-2
http://vnx.su
Lefthand
driveshaft
DRIVESHAFTS
Front driveshafts
29
T. Av. 1168
T. Av. 1256
T. Av. 1331
REFITTING
GI 69 JOINT
1
2
3
4
5
6
7
Spider
Rubber gaiter
Bearing guide
Retainer
Deflector
Circlip
Driveshaft
85884-1R1
DI2935R
NOTE : in order to avoid deformation of the bearing with a lip seal, and therefore any risk of leakage, do not press it on using a hammer, but using
a press, in order to apply progressive pressure.
REMOVAL
29-3
http://vnx.su
Lefthand
driveshaft
DRIVESHAFTS
Front driveshafts
GE 86 JOINT
1
2
3
4
5
6
7
8
9
10
29
DI2934R
REMOVAL
29-4
http://vnx.su
Lefthand
driveshaft
DRIVESHAFTS
Front driveshafts
REFITTING
Slightly lubricate the driveshaft in order to facilitate the fitting of the gaiter (position the smaller
diameter of the gaiter in the groove of the driveshaft).
RC 462 JOINT
1
2
3
4
5
29
Yoke sleeve
Spider
Locking spring ring
Gaiter
Clips
REMOVAL
90392R1
29-5
http://vnx.su
Righthand
driveshaft
DRIVESHAFTS
Front driveshafts
29
DI2934R
REMOVAL
29-6
http://vnx.su
Chassis
GENERAL
FRONT AXLE
REAR AXLE
STEERING ASSEMBLY
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRN3000
http://vnx.su
Chassis
Contents
Page
30 GENERAL
33 REAR AXLE
30-1
33-1
30-2
Brake drum
33-2
Brake cylinder
33-4
30-7
Brake linings (drum)
33-5
Bar specifications:
- front anti-roll bar
30-8
Bearing
33-7
30-8
Shock absorber
33-8
30-8
33-9
30-9
33-10
Brake fluid
30-9
Bushes, tubular rear axle
33-11
33-15
33-16
33-20
ENSEMBLE
AXLE
MOTEUR ET BAS
31 FRONT
Lower wishbone
31-1
31-2
31-3
Brake pads
31-4
31-5
Brake discs
31-6
31-7
31-9
Anti-roll bar
31-10
Engine sub-frame
31-12
http://vnx.su
Specifications
35-1
Wheel balancing
35-4
Contents
Page
36 STEERING ASSEMBLY
38 ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS
36-1
36-3
36-4
Gaiter
36-6
BOSCH ABS
38-1
Location of components
38-2
36-7
38-3
36-8
Wiring diagram
38-4
Steering column
36-12
38-5
31 track connector
38-6
Diagnostic socket
38-7
Hydraulic assembly
38-8
38-9
37-1
Brake servo
37-3
37-5
Vacuum pump
37-6
37-7
Handbrake control
37-8
Brake pipes
37-10
Braking compensator
37-11
37-22
37-23
37-24
http://vnx.su
GENERAL
General diagram of braking circuits
30
NOTE : the diagram below shows the general principle ; in no case should it be taken as reference for the
circuit connections and allocations. When replacing one of the components of the brake circuit on a vehicle,
always mark the pipes before removing them so that they can be connected back in their original positions.
91563S
30-1
http://vnx.su
FRONT
AXLE
GENERAL
Tightening torques (in daN.m)
30
DI3035R
30-2
http://vnx.su
FRONT
AXLE
GENERAL
Tightening torques (in daN.m)
30
DI3034R1
30-3
http://vnx.su
TUBULAR
REAR AXLE
GENERAL
Tightening torques (in daN.m)
30
88507-1R2
30-4
http://vnx.su
4 BAR
REAR AXLE
GENERAL
Tightening torques (in daN.m)
30
88507-2R2
30-5
http://vnx.su
GENERAL
Tightening torques (in daN.m)
30
DIMENSIONS
TIGHTENING TORQUES
0.6 to 0.8
M 10 100
1.7
M 10 100
1.7
M 10 100
or
M 12 100
1.7
M 10 100
or
M 12 100
1.7
Compensator inlet
M 10 100
or
M 12 100
1.7
Compensator outlets
M 10 100
or
M12 100
1.7
Bleed screw
30-6
http://vnx.su
GENERAL
Dimensions of the main braking components
30
FC0X
FC0X
KC0X
KC0X
CUS
CUA
54
54
Diameter of discs
238.2
238.2
Thickness of discs
20
20
17.7
17.7
17.8
17,8
5.5
5.5
0.07
0.07
22
22
Diameter of drums
203.2
228.3
204.45
229.5
Diameter of discs
Thickness of discs
Lining size
38
40
Secondary
22.2
22.2
Diameter
CUS :
CUA :
Standard payload
Increased payload
30-7
http://vnx.su
GENERAL
Front anti-roll bar specifications
30
VEHICLE TYPE
FC0X
KC0X
23
FC0X
KC0X
FC0X
KC0X
18
26.4
30
31
VEHICLE TYPE
DIAMETER (in mm)
FC0X
KC0X
FC0X
KC0X
22.1
25.5
30
30
31
31
VEHICLE TYPE
DIAMETER (in mm)
30-8
http://vnx.su
GENERAL
Brake unions and pipes
30
78491R
Brake fluid
Braking technology, in particular for disc brakes (hollow pistons which transmit little heat, low volume of
fluid in the cylinder, sliding calipers avoiding the need for a fluid reservoir in the least cooled area of the
wheel), has allowed us to avoid the risk of vapour lock as far as possible, even if the brakes are used
intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of
humidity and replacement of the fluid is therefore recommended (refer to vehicles Warranty and Servicing
Handbook).
Topping up the level:
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should
not be compensated for since the level will rise again when the pads are changed. The level should not
however be allowed to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to
deterioration of the cups. To avoid such risks, it is important to use only those brake fluids which have been
tested and approved by our Technical Department and which conform to standard SAE J 1703 dot 4.
30-9
http://vnx.su
FRONT AXLE
Lower wishbone
TIGHTENING TORQUES (in daN.m)
Wheel bolts
Lower wishbone nut on sub-frame
Key nut on stub-axle carrier
Anti-roll bar bearing nut
31
REFITTING
9
9
5.5
1.5
Refit:
REMOVAL
the wishbone,
Remove:
- the nut and key on the stub-axle carrier,
12992R
85875R2
31-1
http://vnx.su
FRONT AXLE
Lower wishbone rubber bushes
REPLACEMENT
90404R
31-2
http://vnx.su
31
FRONT AXLE
Lower wishbone ball joint
31
REMOVAL
85875R1
Remove:
-
REFITTING
31-3
http://vnx.su
FRONT AXLE
Brake pads
31
Fre. 823
REFITTING
Wheel bolts
Brake caliper guide bolt
9
4
REMOVAL
12994R
31-4
http://vnx.su
FRONT AXLE
Front brake calipers
REPAIR
Wheel bolts
Brake caliper guide bolt
Brake caliper mounting bolt
31
9
4
10
To do this:
REMOVAL
REFITTING
31-5
http://vnx.su
FRONT AXLE
Brake discs
31
Wheel bolts
Brake caliper mounting bolt
9
10
REMOVAL
Remove:
-
the disc.
REFITTING
31-6
http://vnx.su
FRONT AXLE
Stub axle carrier bearing
31
Rou.
15 -01
Shaft protector
Rou.
604 -01
T.Av.
476
T.Av. 1050-02
Driveshaft nut
Wheel bolts
Remove the lower bush from the hub using an extractor with jaws and tool Rou. 15-01.
28
9
18
10
3.7
5.5
REMOVAL
the wheel,
31-7
http://vnx.su
FRONT AXLE
Stub axle carrier bearing
31
79057S
REFITTING
Fit the bearing on the press, into the stub axle carrier using a tube of external diameter
70 mm and bore 66 mm, taking the weight on the
external bush.
85902S1
IMPORTANT : do not take the weight on the internal bush to avoid damaging the bearing as the
force required to push the bearing on is quite
considerable.
79058-1S
31-8
http://vnx.su
FRONT AXLE
Spring and shock absorber assembly
31
EQUIPMENT REQUIRED
Spring compressor
18
6
9
Remove:
-
the wheels,
31-9
http://vnx.su
FRONT AXLE
Anti-roll bar
31
Sus.
1413
Sus.
1414
3
1.5
REMOVAL
REFITTING
Refit:
12993-1R
12992R
31-10
http://vnx.su
FRONT AXLE
Anti-roll bar
-
31
12991R
31-11
http://vnx.su
FRONT AXLE
Engine sub-frame
31
Wheel bolts
Track rod end nut
Steering universal joint bolt
Sub-frame mounting bolt
9
3.7
2.5
front 10
6
rear 12
10.5
Sub-frame - side member tie rod nut
3
Key nut on stub axle carrier
5.5
Engine tie bar
6.5
Steering box mounting bolt
5
REMOVAL
12988R
Remove:
Remove:
-
12993-1R1
31-12
http://vnx.su
FRONT AXLE
Engine sub-frame
Lower the lift until the tool touches the ground.
Remove the sub-frame mounting bolts.
Carefully raise the lift.
REFITTING
Systematically renew the engine sub-frame mounting bolts and ensure they are tightened to the
correct torque.
Refitting is the reverse of removal.
31-13
http://vnx.su
31
REAR AXLE
Rear axle assembly
33
11
9
8.5
REMOVAL
REFITTING
Remove:
13132R
33-1
http://vnx.su
REAR AXLE
Brake drum
33
The two brake drums must be of the same diameter, if one is reground, the other must also be reground.
Never exceed the diameter marked on the drum.
Emb. 880
Rou. 943
Wheel bolts
Hub nut
9
17.5
REMOVAL
98991
98990G
Remove:
-
the drum.
33-2
http://vnx.su
REAR AXLE
Brake drum
REFITTING
Fit:
-
the drum,
the plug.
Adjust:
- the linings by repeatedly pressing the brake
pedal,
-
33-3
http://vnx.su
33
REAR AXLE
Brake cylinder
33
Wheel bolts
Hub nut
Bleed screw
Pipe bolt
9
17.5
0.5 to 0.8
1.7
REMOVAL
REFITTING
Remove:
Slacken:
33-4
http://vnx.su
REAR AXLE
Brake linings (drum)
33
Emb. 880
Rou. 943
REMOVAL
Wheel bolts
Hub nut
9
17.5
Remove:
- the brake drum (see corresponding paragraph),
- the lower spring (2) using brake shoe pliers.
Using adjustable pliers, remove the shoe side
retaining springs.
In turn, pass each brake shoe base over the fixed
point. Squeeze the bases of the shoes together to
separate the ends at the wheel cylinder end.
Separate the assembly (RAI and shoes) from the
brake backing plate then remove it, after
unclipping the handbrake cable.
98992-2R
A Leading shoe
B Trailing shoe
C Fixed point
P Base of brake shoe
F RAI wear take up system
1 Upper return spring
2 Lower return spring (for base)
3 Side retainer
4 Handbrake lever return spring
33-5
http://vnx.su
REAR AXLE
Brake linings (drum)
REFITTING
Ensure:
33
ADJUSTMENT
98992-3R
33-6
http://vnx.su
REAR AXLE
Bearing
33
Emb. 880
Rou. 943
Hub nut
Wheel bolts
17.5
9
CHECKING
REFITTING
REMOVAL
a new clip,
Remove:
-
33-7
http://vnx.su
REAR AXLE
Shock absorber
11.5
8.5
REMOVAL
the wheel,
33
REFITTING
Fit:
-
the wheel.
13133R
33-8
http://vnx.su
REAR AXLE
Anti-roll bar, tubular rear axle
5.5
REMOVAL
13132R
Mounting bolt
REFITTING
33-9
http://vnx.su
33
REAR AXLE
Half suspension arms, tubular rear axle
REFITTING
33
11
5.5
9
8.5
REMOVAL
86320R
13132R1
33-10
http://vnx.su
REAR AXLE
Bushes, tubular rear axle
33
This operation is carried out after removing the complete rear axle assembly and separating the two
suspension arms.
Grind the bearing races on the male suspension
arm (right hand side) using a straight grinding
wheel, taking care not to mark the tube.
T. Ar. 960-02
T. Ar. 960-05
REMOVAL
90864S
86182R
90863R
86180R
33-11
http://vnx.su
REAR AXLE
Bushes, tubular rear axle
33
REFITTING
90868R
90874R
Fit:
- the large needle bearing on mandrel (B),
Fit :
-
90865R
90866R
33-12
http://vnx.su
REAR AXLE
Bushes, tubular rear axle
-
33
90868-1R
90941R
Fit:
On the press, press on until mandrel (B) touches
the tube.
90868-2R
90867-5R
33-13
http://vnx.su
REAR AXLE
Bushes, tubular rear axle
Press on the assembly (D) and (C) until the sleeve
(C) reaches the edge (3) of the tube.
33
90867-2R
90867-4R
Fit :
IMPORTANT
90867-3R
33-14
http://vnx.su
REAR AXLE
Suspension bars, tubular rear axle
33
Emb. 880
Inertia extractor
X = 402 mm
11.5
8.5
REMOVAL
With the vehicle raised so its wheels hang free, remove the shock absorber on the side in question.
Remove the bar from the side, using tool
Emb. 880.
REFITTING
Nut, diameter 14 mm
Nut, diameter 12 mm
88637R2
Weld
the headlights.
75505R
33-15
http://vnx.su
REAR AXLE
Four bar rear axle
33
PRN3300
two arms connected by an "L" section. This assembly (1) cannot be dismantled. Any deformation would
mean its complete replacement.
The assembly is connected to the body by two bearings mounted on rubber bushes.
NOTE : Never take the weight of the vehicle using a jack on the "L" section (1) to lift the vehicle.
33-16
http://vnx.su
REAR AXLE
Four bar rear axle
33
Emb. 880
Inertia extractor
8.5
11.5
Wheel bolts
REMOVAL
REFITTING
Remove:
-
the wheels,
Fit:
-
13135R
33-17
http://vnx.su
REAR AXLE
Four bar rear axle
-
33
75505-1R1
13134S
Nut, diameter 14 mm
Nut, diameter 12 mm
88637R2
Refit:
Weld
the wheels.
Put the vehicle on its wheels and measure the underbody heights ( see section "values and settings" ).
33-18
http://vnx.su
REAR AXLE
Four bar rear axle
REMINDER
33-19
http://vnx.su
33
TUBULAR REAR
AXLE
REAR AXLE
Suspension arm bearings
33
75362S
REFITTING
DI3303
Alignment
Observe dimension "X" between the bearing
pressure face and the stub axle shaft:
X = 156 mm 3.5
DI3310
85909S
33-20
http://vnx.su
TUBULAR REAR
AXLE
REAR AXLE
Suspension arm bearings
33
Clearance
In this position, press on the bearing until the
dimension between the bearing centres is :
Y = 1164 mm 1
DI3311
33-21
http://vnx.su
REAR AXLE
Suspension arm bearings
33
DI3312
Clearance
In this position, press on the bearing until the
dimension between the bearing centres is :
Y = 1164 1 mm
90241G
REFITTING
The bearing is fitted in the arm, ensuring the correct alignment is observed and the clearance between the bearing and the arm is correct.
Alignment
Observe dimension "X" between the bearing
pressure face and the stub axle shaft
X = 124 3.5 mm
DI3313
33-22
http://vnx.su
35
WHEEL RIMS
TYPE
OF WHEEL
5 1/2 J 14
4 CH 36
WIDTH
(in inches)
5 1/2
NOMINAL DIAMETER
RIM
PROFILE
14
Number
of holes
4
Tyre bead
profile
CH
Offset
(in mm)
36
DI3501
35-1
http://vnx.su
35
TYRES
165
70
13
83
85920R2
165
70
Ratio h/l
height
width
Radial structure
13
83
Load index
Maximum speed
R
S
T
U
H
V
ZR over
Types of structure :
Diagonal
Radial
Bias belted
No marking
R
B
35-2
http://vnx.su
170
180
190
200
210
240
240
km/h
Type
Rim
Wheel bolt
torque
(daN.m)
5 B 13
FC0X
KC0X
5 B 13
Tyres
35
Inflation pressure
(bar) cold
Front
Rear
165/70 R 13 C 88/86
2.8
3.6
165/70 R 13 83 (1)
2.6
2.9
165/70 R 14
2.4
3.0
5,5 J 14
The tyre inflation pressures are values for a fully laden vehicle or motorway use.
The tyre inflation pressure must be checked when cold. The increase in temperature during driving increases
the pressure by 0.2 to 0.3 bar.
If the inflation pressures are checked when the tyres are warm, take this pressure increase into consideration.
Never deflate a warm tyre.
(1) Reinforced tyre.
Chains
For safety reasons, chains may NEVER be fitted to the rear axle.
"Snow" or "thermorubber" tyres: all four wheels must be fitted with these tyres to retain vehicle adhesion as
far as possible.
35-3
http://vnx.su
35
BALANCE WEIGHTS
A
B
88659R
35-4
http://vnx.su
STEERING ASSEMBLY
Axial ball joint
36
Dir. 1305-01
Dir. 1306
T.Av. 476
Wheel bolts
3.7
1.7
36-1
http://vnx.su
STEERING ASSEMBLY
Axial ball joint
REFITTING
83510-1R3
36-2
http://vnx.su
36
STEERING ASSEMBLY
Manual steering rack
36
T.Av. 476
REFITTING
Wheel bolts
Track rod end nut
Steering rack mounting bolts
Universal joint eccentric bolt
9
3.7
5.5
2.5
Remove:
-
36-3
http://vnx.su
STEERING ASSEMBLY
Power assisted steering rack
36
Mot. 453-01
T.Av. 476
Wheel bolts
Track rod end nut
Steering rack mounting bolt
3.7
2.5
6.5
the battery,
36-4
http://vnx.su
STEERING ASSEMBLY
Power assisted steering rack
Disconnect the high and low pressure pipes on the
steering rack (take precautions to catch the oil)
and the nut on the pipe retaining bracket.
36
REFITTING
12997R
NOTE :
- do not remove the pipes between the valve
and cylinder,
36-5
http://vnx.su
STEERING ASSEMBLY
Gaiter
The gaiter MUST be renewed with a new gaiter
whenever an axial ball joint is removed.
Fitting the gaiter
Use an ogive on the axial ball joint to prevent
damage to the gaiter during fitting.
Coat the gaiter bearing face on the axial ball joint
with grease to prevent the gaiter twisting.
Secure the gaiter with a new clip (supplied with
the gaiter).
NOTE : the steering MUST be at the centre point
to equalise the air.
36-6
http://vnx.su
36
STEERING ASSEMBLY
Steering pushrod
36
ADJUSTMENT
If the steering rack pinion is noisy, before considering replacing the steering rack, check that the pinion is
correctly adjusted.
1.
83920R
36-7
http://vnx.su
STEERING ASSEMBLY
Manual steering assistance pump
REPLACING THE PULLEY (D7F-F8Q engine without
AC)
36
REMOVAL
REMOVAL
Remove:
-
REFITTING
Dir. 1083
B.Vi. 22-01
+
12995R
REFITTING
B.Vi. 47
12996R
36-8
http://vnx.su
34.7 0.2
D7F engine
without AC
STEERING ASSEMBLY
Manual steering assistance pump
Mot. 453-01
T. Ar. 1094
Extractor
Remove:
-
the pulley.
REFITTING
36-9
http://vnx.su
36
STEERING ASSEMBLY
Manual steering assistance pump
F8Q engine
without AC
REFITTING
Mot. 453-01
36
REMOVAL
Remove:
-
the pulley.
36-10
http://vnx.su
STEERING ASSEMBLY
Manual steering assistance pump
E7J engine
without AC
REFITTING
Mot. 453-01
REMOVAL
Remove:
-
the alternator.
36
13296R
36-11
http://vnx.su
STEERING ASSEMBLY
Steering column
Disconnect the battery.
36
Remove:
4.5
2.5
2
REMOVAL
Remove:
- the steering wheel bolt (this MUST be renewed
on refitting),
- the steering wheel after noting its position.
12973S
REMOVAL
IMPORTANT: pyrotechnic systems (airbags and
pretensioners) must not be handled near to a heat
source or flame - they may be triggered.
36-12
http://vnx.su
STEERING ASSEMBLY
Steering column
If the switch is being replaced, the new part is
supplied ready-centred, held in place by an
adhesive label which tears off when the steering
wheel is moved for the first time (fit with the
wheels straight).
36
Remove:
-
12971R
12970S
12967-1R
36-13
http://vnx.su
STEERING ASSEMBLY
Steering column
36
Remove:
-
12968S
12970-1R1
12966R
12969-1R1
36-14
http://vnx.su
STEERING ASSEMBLY
Steering column
Remove the mounting bolts for the dashboard on
the steering column.
36
Release:
-
REFITTING
12964R2
13116S
12965-1R2
36-15
http://vnx.su
STEERING ASSEMBLY
Steering column
SPECIAL NOTES FOR VEHICLES FITTED WITH A
DRIVERS AIRBAG
36
IMPORTANT
36-16
http://vnx.su
37
1.7
1.8
REMOVAL
91101R
Remove:
REFITTING
DI3718
37-1
http://vnx.su
DI3719
37-2
http://vnx.su
37
1.8
2.3
REFITTING
37
dimension L = 104.8 mm ,
dimension X = 22.3 mm .
REMOVAL
91101R2
97860R
37-3
http://vnx.su
Petrol engine
37
Mot
453 -01
EQUIPMENT REQUIRED
Vacuum pump
CHECKING SEALING
When checking the sealing of the brake servo, ensure the seal between the brake servo and the master
cylinder is perfect. If there is a leak, replace the seal (A).
DI3701
37-4
http://vnx.su
37
REMOVAL
83 212
74883S
75 564
91101G
REFITTING
37-5
http://vnx.su
Diesel engine
13097-1S
REFITTING
CHECKING
37-6
http://vnx.su
37
37
Note the handbrake adjustment dimension,between the end of the nut (1) and the rod.
REMOVAL
98826-2R
12998S
REFITTING
37-7
http://vnx.su
Remove:
37
- prevents the correct operation of the automatic compensation system for the brake shoes ,
98992-1R3
98826-1R
37-8
http://vnx.su
98992-1R2
37-9
http://vnx.su
37
37
These vehicles have brake pipes without a copper seal. The seal is by contact "at the bottom of the cone" of
the shoulder (Y) on the pipe.
X = 1.5
Z= 1.3
96118R
For safety reasons and to ensure that the brake pipe is not twisted and is not liable to touch a suspension
component the following order of operations must be observed:
REMOVAL
REFITTING
85536R
37-10
http://vnx.su
37
CHECKING PRINCIPLE
85925S
37-11
http://vnx.su
37
NOTE
CHECKING
(in daN.m)
Hydraulic unions
1.7
1.8
REMOVAL
12865-1R
98828R
REFITTING
37-12
http://vnx.su
37
ADJUSTMENT
12865-1R
37-13
http://vnx.su
37
Tooling required:
37-14
http://vnx.su
37-15
http://vnx.su
37
37
Deflection ( mm )
PRN3700
37-16
http://vnx.su
37
Deflection ( mm )
PRN3704
37-17
http://vnx.su
37
Deflection ( mm )
PRN3700
37-18
http://vnx.su
37
Deflection ( mm )
PRN3700
37-19
http://vnx.su
37
PRN3702
37-20
http://vnx.su
37
PRN3703
37-21
http://vnx.su
37
REMOVAL
REFITTING
89204S
12986R
37-22
http://vnx.su
91830R1
37-23
http://vnx.su
37
37
1.5
2
3
3
REMOVAL
12988R
Remove:
- the lever - linkage mounting nut,
- the four nuts mounting the control unit.
12985R
12987R
37-24
http://vnx.su
PRG37.6R
REFITTING
37-25
http://vnx.su
37
37
B.Vi. 1133
ADJUSTMENT
93856-1S
92450-2R
92450-3S
37-26
http://vnx.su
37
93910S1
37-27
http://vnx.su
38
This vehicle is fitted with BOSCH ABS 5.3 of the four channel additional type; the conventional braking
equipment and the ABS equipment are separate.
SPECIAL NOTES
The system comprises four speed sensors. Each hydraulic braking channel is associated with a sensor at each
wheel. The front wheels are therefore regulated separately. The rear wheels however are regulated at the
same time and in the same way according to the select low principle (the first wheel which tends to lock
causes immediate regulation on the complete axle assembly). The compensator fulfils its normal function.
38-1
http://vnx.su
38
PRN3818
Hydraulic assembly
Master cylinder
Braking compensator
Brake servo
38-2
http://vnx.su
38
PRN3819
38-3
http://vnx.su
38
WIRING DIAGRAM
PRN3817
38-4
http://vnx.su
104
Ignition switch
118
ABS computer
150
151
152
153
160
Stop switch
225
Diagnostic socket
247
Instrument panel
260
Fuse box
777
R2
R36
ABS / Dashboard
38-5
http://vnx.su
38
38
PRN3813
Micro-spring connecting earth (terminal 19) to pins 20 and 21 (ABS and NIVOCODE warning lights) if the
connector is disconnected.
Description
Track
Description
15
16
17
Not connected
18
19
Electronic earth
20
Not connected
21
22
Not connected
10
Not connected
25
Not connected
11
Diagnostic line K
26
Not connected
12
Diagnostic line L
27
Not connected
13
Not connected
31
Not connected
14
38-6
http://vnx.su
PRN3807
Chassis earth
Electronic earth
Diagnostic line K
15
Diagnostic line L
16
+ battery
38-7
http://vnx.su
38
38
From below:
HYDRAULIC ASSEMBLY
Remove:
TIGHTENING TORQUES (in daN.m)
Pipe unions
M10 100
M12 100
REMOVAL
From above:
Disconnect the computer connector.
Remove the two earth bolts.
Disconnect the six pipes from the hydraulic assembly, marking their position for refitting.
13139R
REFITTING
38-8
http://vnx.su
38
This section describes the test to be carried out using the XR25, to check the mounting of the ABS system in
the vehicle and, in particular, the hydraulic circuit.
NOTE: for this test, two persons are required and the vehicle must be on a two post lift, if possible.
The pressure increases to master cylinder pressure for all four wheels.
The hydraulic test for the wheel in question is complete - begin the test for the three other wheels.
BLEEDING PROCEDURE
NOTE : the hydraulic assembly is pre-filled.
This bleeding procedure must be used when one of the following components has been removed:
-
the pipework (between the hydraulic assembly and the master cylinder).
38-9
http://vnx.su
38
a) Bleed the rear right brake by bleeding the hydraulic assembly secondary circuit using the XR25:
-
position the bleed container and the hose, open the brake bleed screw,
at the end of the bleed cycle on the XR25, continue to pump the brake pedal and close the brake
bleed screw.
b) Carry out the procedure described at a) for the rear left, front left and front right brakes.
c)
Check the pedal travel and if it is incorrect, restart the bleeding procedure.
a) Check the resistance of the sensor connections (from the computer connector to the 2 track speed sensor
connector).
b) Visually inspect the teeth ( 26 teeth) on the target and if they are faulty, replace the target.
c)
Check the air gap using a set of shims. Only the front sensors can be checked.
PRN3820
38-10
http://vnx.su
77 11 194 280
JULY 1997
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."
Edition Anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB4008
http://vnx.su
40 GENERAL
Dimensions
Engine and equipment
Identification
Means of lifting
Towing
Using symbols
Key to symbols
Description of Parts (exploded)
Opening clearances
Collision fault finding
Sub- frame dimensions
Repair bench
Special tooling
Part Number of special tooling
Page
A
B
C
D
E
F
G
H
I
J
Front wing
Headlight carrier panel
Cowl side panel (pillar lining)
part section
Upper reinforcement of cowl side
panel
Wheel arch, front section
Wheel arch
Plenum chamber
Windscreen aperture lower cross
member
Steering column mounting
Bulkhead
42-1
42-2
42-5
42-8
42-12
42-17
42-24
42-28
42-32
42-34
41- 1
41- 5
41-10
41-13
41-17
41-21
41-26
41-29
41-33
41-36
41-39
41-41
41-44
41-51
41-53
41-55
41-58
41-60
41-62
41-63
41-67
41-68
41-71
A
B
C
D
E
F
G
Front pillar
Windscreen pillar
Front pillar lining/Cowl side panel
Centre pillar / sill panel
Centre pillar lower reinforcement /
door pillar
Sill panel reinforcement
Left hand side sill panel
43-1
43-6
43-9
43-14
43-19
43-23
43-25
http://vnx.su
44-1
44-9
44-17
44-26
44-30
44-33
44-38
44-41
Contents
45 TOP OF BODY
A
B
C
D
Roof
Roof front cross member
Roof centre cross member
Roof rear cross member
45-1
45-7
45-8
45-9
Front door
Front door panel
Front door stiffener
Side door
Side door panel
Side door stiffener
47-1
47-2
47-6
47-8
47-11
47-14
Bonnet
Bonnet hinge
Rear opening doors
Tailgate
Roof flap
http://vnx.su
48-1
48-2
48-3
48-4
48-5
GENERAL
Dimensions
40
12333R
(1) Unladen
(2) Laden
Dimensions in metres.
40-1
http://vnx.su
GENERAL
Engine and equipment
40
Engine
Vehicle type
Clutch type
Gearbox type
manual and automatic
Type
Capacity
(cm 3)
FC0A
KC0A
D7F
1149
180 CP 3300
JB1
FC0C
KC0C
E7J
1390
180 CP 3300
JB3
FC0D
KC0D
FC0E
KC0E
F8Q
1870
JB1
40-2
http://vnx.su
GENERAL
Engine and equipment
40
Drivers airbag
Tailgate
Headlining
Boot carpet
40-3
http://vnx.su
GENERAL
Identification
POSITIONING OF VEHICLE IDENTIFICATION PLATE
13187R
40-4
http://vnx.su
40
GENERAL
Identification
40
6
7
8
RENAULT S.A.
9
e0-00/00-0000-000-000-00
1
VF000000000000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
11
12
13
000000000000000
Numbers given on the manufacturers plate and on the engine plate should be quoted in all letters or
orders.
1
2
3
4
5
6
7
8
9
10
11
12
13
10
40-5
http://vnx.su
GENERAL
Means of lifting
40
AXLE STANDS
12274-1R
85679-1G15
40-6
http://vnx.su
12333-2G
GENERAL
Means of lifting
40
SAFETY SYMBOL
FOG Company
FRONT
CHEMICO Company
98703S
REAR
98704S
40-7
http://vnx.su
GENERAL
Towing
40
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT
REAR
13189S
13366S
40-8
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GENERAL
Using symbols
40
e = 1 + 1
11644R1
Example :
place of operation and logical sequence
F - G - corresponding to the section (It is giH - I - J ven in one of the upper corners of
each drawing )
spot welding
weldable mastic
CAA11538R8
e = 1+1
40-9
http://vnx.su
GENERAL
Using symbols
40
SPECIFIC CASES
Under diagram I
1
1st operation
2
2
unpicking
with grinder
2nd operation
CAA11537-1R6
In this example, there is no direct access for removing part 1. The spot welds should be unpicked
through part 2, which should be kept.
10354R
E
CAQ11697-1R5
2
This arrow indicates that it is necessary
to cut the part it crosses before accessing the joint.
1
2
10349R
unpicking
welding
40-10
http://vnx.su
GENERAL
Key to Symbols
40
Plug welding.
Under MAG gas protection.
Chiselling
Safety symbol.
This means that the welding operation
in question concerns one or more of the
vehicles vital safety components.
Unpicking
Spray on sealer
spray gun.
two pot anti-gravel and anticorrosion mastic.
Spot weld
40-11
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GENERAL
Description of parts (exploded view)
40
SUB-FRAME
PRB4002
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
40-12
http://vnx.su
GENERAL
Description of parts (exploded view)
40
UPPER STRUCTURE
PRB4003
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
40-13
http://vnx.su
GENERAL
Description of parts (exploded view)
40
REMOVABLE COMPONENTS
PRB4004
61
62
63
64
65
66
67
68
69
70
40-14
http://vnx.su
GENERAL
Opening clearances
40
12333R1
12333-2R
40-15
http://vnx.su
GENERAL
Opening clearances
40
12333-3R
12333R2
40-16
http://vnx.su
GENERAL
Opening clearances
40
1
3
12848R
12850R
12849R
12853R
40-17
http://vnx.su
GENERAL
Opening clearances
40
12854R
12852R
12851R
12906R
40-18
http://vnx.su
GENERAL
Opening clearances
12
12905R
10
12856R
13
12861R
11
12858R
12855R
40-19
http://vnx.su
40
GENERAL
Opening clearances
14
40
16
12857R
12860R
17
15
12864R
12859R
40-20
http://vnx.su
GENERAL
Opening clearances
40
18
12863R
19
12862R
40-21
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GENERAL
Collision fault finding
40
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is necessary to carry
out a series of tests :
VISUAL INSPECTION
This inspection involves the examination of the sub-frame of the vehicle where mechanical components
are mounted and in the crumple zones or vulnerable areas in order to detect folds where materials have
been deformed.
12664-1R
40-22
http://vnx.su
GENERAL
Collision fault finding
GAUGE POINTS
Point G :
Point G1 :
40
12842R
12670R
Points C and C1 :
Sub-frame front mounting and front end of side
member.
12843R
40-23
http://vnx.su
GENERAL
Collision fault finding
Point B :
40
Left hand side
12846R
12844R
Point J :
Rear end of rear side member.
Right hand side
12847R
40-24
http://vnx.su
GENERAL
Sub-frame dimensions
DESCRIPTION
40
205
402.5
DIAMETER
SLOPE %
71
18.5
1 999.3
657
71.3
2020
X : 820
- 418
447
130
1010
(squared)
- 418
465
130
1010
(squared)
2 333.13
545.75
184
12.5
18.5
545.50
657
48
G1
600
- 375
2020
(squared)
600
351.6
2020
(squared)
2 918
497.5
151
12.216.2
575
315
280
14.25
X : 302
Y : 1
3 121
- 497.5
151
M8
- 247
483.5
514
M10
- 113
483.5
514
M10
40-25
http://vnx.su
X : 3
X : 430
Z : 5
GENERAL
Sub-frame dimensions
40
12664R
40-26
http://vnx.su
GENERAL
Repair Bench
40
NOTE :
12666R
12893R
40-27
http://vnx.su
GENERAL
Repair Bench
40
12845R
40-28
http://vnx.su
GENERAL
Repair Bench
40
12669R
12844R1
40-29
http://vnx.su
GENERAL
Repair Bench
II - ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
12666R1
40-30
http://vnx.su
40
GENERAL
Repair Bench
40
12668R
12843R1
40-31
http://vnx.su
GENERAL
Repair Bench
40
E-
F-
12665R
12841S
40-32
http://vnx.su
GENERAL
Repair Bench
40
12841S
12667R
40-33
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GENERAL
Repair Bench
40
12668R1
12667R1
It is used for replacing the front end cross member, with or without mechanical units.
NOTE : The operation for replacing the front end
cross member can be carried out without the removal of the engine and transmission assembly,
but requires the removal of the radiator.
2 - Front mechanical units in place
The bracket helps with fault finding on the front
cross member.
40-34
http://vnx.su
GENERAL
Repair Bench
40
PRB4005
40-35
http://vnx.su
GENERAL
Repair Bench
40
PRB4006
PRB4007
40-36
http://vnx.su
GENERAL
Repair Bench
40
IV - SPECIAL TOOLING
BLACKHAWK
CELETTE
Photo
Photo
40-37
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GENERAL
Special tooling
40
13470R
Points (A) and (B) are the references for the positioning of the jig on the
vehicle.
Before fitting, when fault finding is carried out, the user must ensure that
these points are correct.
Points (E), (F) and (G) and their symmetry help with the mounting and positioning of the replaced components.
When points (A) or (B) can no longer be used as a reference (detected during a fault finding inspection), the points on the opposite side of the impact fulfil the function of positioning reference.
Drawing
Manual Part
Number
Car. 1439
Parts Department
Number
00 00 143 900
Description
40-38
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LOWER STRUCTURE
Front end lower cross member
INTRODUCTION
JOINTS WITH:
41 A
1
2
3
4
5
6
7
8
PRB4121
41-1
http://vnx.su
1.5
1.5
1.5
1
0.8
1.5
1.2
2.5
LOWER STRUCTURE
Front end lower cross member
41 A
CAR11700-1R3
12899R
C
1
CAS13025-1R1
CAQ11697R7
41-2
http://vnx.su
LOWER STRUCTURE
Front end lower cross member
41 A
D
3
CAI11550-3R1
12900R
E
1
6
1
CAA11538-1R4
CAR11700-1R1
41-3
http://vnx.su
LOWER STRUCTURE
Front end lower cross member
12902R
F
8
CAS13025-1R5
41-4
http://vnx.su
41 A
LOWER STRUCTURE
Front side member, front section
41
INTRODUCTION
PRB4122
or
The replacement of this part also requires the replacement of the side member closure panel
which will have to be ordered separately.
JOINTS WITH:
1 -Side member
Part assembled with:
- engine mounting height adjuster (only on the
right hand side),
- sub-frame front mounting.
1
2
3
4
5
6
7
41-5
http://vnx.su
1.5
2.5
0.8
0.8
1.2
1.8
1.5
LOWER STRUCTURE
Front side member, front section
41
C
4
1
5
CAS13028-6R1
12903R
1
5
CAA11537-3R2
CAS13028-6R1
E
5
6
4
1
5
1
CAS13028-6R1
CAE11546-4R7
41-6
http://vnx.su
LOWER STRUCTURE
Front side member, front section
13005R
F
2
1
CAB11539R8
41-7
http://vnx.su
41
LOWER STRUCTURE
Front side member, front section
41
H
1
CAA11538R3
12896R
2
CAG11548-6R1
CAA11536R3
41-8
http://vnx.su
LOWER STRUCTURE
Front side member, front section
12894R
13010R
41
3
2
1
1
5
CAN11689R3
CAS13028-6R2
41-9
http://vnx.su
LOWER STRUCTURE
Front side member closure panel
INTRODUCTION
JOINTS WITH:
41
1
2
3
4
PRB4123
41-10
http://vnx.su
1.5
1.2
1.2
1
LOWER STRUCTURE
Front side member closure panel
41
B
3
1
CAB11539-1R7
12903R3
C
3
4
2
4
1
CAT13323R3
CAT13322R7
41-11
http://vnx.su
LOWER STRUCTURE
Front side member closure panel
41
D
4
CAB11539-1R1
12902R1
or
F
3
CAS13033R2
CAS13033R2
41-12
http://vnx.su
LOWER STRUCTURE
Front half unit
41 D
INTRODUCTION
or
2
3
JOINTS WITH:
Plenum chamber
Injection unit mounting and impact sensor (left
hand side)
Front side member, rear section
Shock absorber cup height adjuster
1 Plenum chamber
2 Injection unit mounting and impact
sensor (left hand side)
3 Front side member, front section
4 Front side member, rear section
5 Shock absorber cup height adjuster
6 Shock absorber cup
7 Cowl side panel (pillar lining)
41-13
http://vnx.su
1
2
1.5
1.8
1
2
1.5
LOWER STRUCTURE
Front half unit
13007R1
41 D
13000R2
B
6
5
1
5
1
CAA11536R8
CAS13024-3R3
41-14
http://vnx.su
LOWER STRUCTURE
Front half unit
13010R4
12894R1
41 D
1
3
CAA11538R8
CAN11689R3
41-15
http://vnx.su
LOWER STRUCTURE
Front half unit
41 D
CAA11536-4R2
13005R4
G
5
4
4
3
3
CAB11539R3
CAS13029-4R1
41-16
http://vnx.su
LOWER STRUCTURE
Front side cross member
INTRODUCTION
JOINTS WITH:
Bulkhead
Floor
Windscreen wiper motor mounting
Rear side member, front section
Rear side member, rear section
Sill panel closure panel
Sill panel reinforcement
Sill panel
Front sub-frame rear mounting
41
1
2
3
4
5
6
7
8
9
10
PRB4125
41-17
http://vnx.su
1
1
1
1.5
1.8
2.5
1.2
0.7
1
2.5
LOWER STRUCTURE
Front side cross member
41
B
5
3
1
CAG11548-2R8
12893R2
3
1
CAT13321-2R3
CAF11547-2R1
41-18
http://vnx.su
LOWER STRUCTURE
Front side cross member
41
F
6
10
CAM11557-5R6
12904R
9
8
7
1
CAT13329-1R8
CAA11538R5
H
8
6
7
1
CAS13024-1R5
CAE11546-2R8
41-19
http://vnx.su
LOWER STRUCTURE
Front side cross member
41
J
1
2
1
7
CAA11538-2AR8
1
13020R
CAA11538R5
41-20
http://vnx.su
LOWER STRUCTURE
Front side member, rear section
41
INTRODUCTION
JOINTS WITH:
Bulkhead
Floor
Sill panel closure panel
Bulkhead
Floor
Front side member, rear section
Sill panel closure panel
Sill panel reinforcement
Sill panel
Side member closure panel
reinforcement
8 Front side cross member
1
2
3
4
5
6
7
PRB4126
41-21
http://vnx.su
1
1
1.8
1.2
0.7
1
2.5
1
LOWER STRUCTURE
Front side member, rear section
41
B
2
CAT13324R1
12898R1
1
2
CAD11545R3
CAA11538R5
41-22
http://vnx.su
LOWER STRUCTURE
Front side member, rear section
41
CAA11538R5
12893R3
8
CAT13321R4
CAF11547-2R2
41-23
http://vnx.su
LOWER STRUCTURE
Front side member, rear section
12904R1
41
13020R
6
5
4
8
CAT13329-1R8
CAA11538R5
J
6
4
8
8
4
CAE11546-2R8
CAA11538-2aR8
41-24
http://vnx.su
LOWER STRUCTURE
Front side member, rear section
41
CAA11538R5
12897R
CAF11547-2R23
41-25
http://vnx.su
LOWER STRUCTURE
Front mounting of sub-frame
INTRODUCTION
JOINTS WITH:
41 G
PRB4127
41-26
http://vnx.su
1.5
1.2
1.2
1
1.5
LOWER STRUCTURE
Front mounting of sub-frame
41 G
C
1
CAA11538R6
1
12901R
A
5
D
3
2
CAR11700R4
4
CAT13322-1R4
B
2
CAA11536R5
41-27
http://vnx.su
LOWER STRUCTURE
Front mounting of sub-frame
41 G
F
4
CAB11539R1
12903R4
E
3
4
CAU13323-3R3
41-28
http://vnx.su
LOWER STRUCTURE
Sill panel closure panel
INTRODUCTION
JOINTS WITH:
41 H
1
2
3
4
5
6
7
PRB4128
or
41-29
http://vnx.su
1.2
1
0.8
1
1.5
1
0.8
LOWER STRUCTURE
Sill panel closure panel
12898R
41 H
13015R1
B
6
CAT13326R2
CAA11537-1R3
41-30
http://vnx.su
LOWER STRUCTURE
Sill panel closure panel
41 H
D
1
4
CAA11538-1R3
13011R
C
1
3
CAA11538-1R3
41-31
http://vnx.su
LOWER STRUCTURE
Sill panel closure panel
13018R1
13232R
41 H
CAA11536-1R7
CAN11690-4R1
F
1
CAA11536-1R7
41-32
http://vnx.su
LOWER STRUCTURE
Cross member under front seat
41
INTRODUCTION
JOINTS WITH:
The replacement of this part is an operation following a side impact, complementary to the replacement of the sill panel closure panel .
Side floor
Front side member, rear section
Sill panel closure panel
1
2
3
4
5
PRB4129
41-33
http://vnx.su
1
1
1.8
1.2
1.2
LOWER STRUCTURE
Cross member under front seat
41
B
1
3
CAF11547-2R5
13017R
A
1
2
CAA11538R2
41-34
http://vnx.su
LOWER STRUCTURE
Cross member under front seat
41
4
CAF11547-2R1
13011R1
C
1
CAA11538R3
41-35
http://vnx.su
LOWER STRUCTURE
Side floor
41
INTRODUCTION
JOINTS WITH:
Tunnel
Rear floor
1 Tunnel
2 Side floor
3 Rear floor
PRB4130
41-36
http://vnx.su
1.2
0.8
1
LOWER STRUCTURE
Side floor
41
B
2
CAA11538R3
13019R
2
1
CAA11538-1R5
41-37
http://vnx.su
LOWER STRUCTURE
Side floor
41
D
3
CAB11540R1
13016R
C
3
CAT13325R1
41-38
http://vnx.su
LOWER STRUCTURE
Tunnel
INTRODUCTION
JOINTS WITH:
Rear floor
Side floor
Bulkhead
41
1
2
3
4
Rear floor
Side floor
Tunnel
Bulkhead
PRB4131
41-39
http://vnx.su
1
0.8
1.2
0.7
LOWER STRUCTURE
Tunnel
41
13016R1
13019R1
C
4
1
2
3
3
CAT13325-1R1
CAA11536-2R8
B
1
CAB11540R1
41-40
http://vnx.su
LOWER STRUCTURE
Rear floor, front section
41
INTRODUCTION
JOINTS WITH:
1
2
3
4
5
6
PRB4132
41-41
http://vnx.su
0.8
1
1.2
0.8
1.2
1.5
LOWER STRUCTURE
Rear floor, front section
41
B
1
CAA11538R2
1
13347R
CAA11538R2
CAN11690R5
41-42
http://vnx.su
LOWER STRUCTURE
Rear floor, front section
41
E
5
CAA11538R7
13348R
D
6
1
1
CAR11700R5
CAF11547-2R8
CAR11700R5
41-43
http://vnx.su
LOWER STRUCTURE
Rear floor, rear section (part section)
41
INTRODUCTION
JOINTS WITH:
Side floor
Upper shock absorber gusset
Sill panel closure panel
Rear axle assembly mounting unit
Shock absorber mounting upper reinforcement
Sill panel closure panel, rear section
Rear floor front cross member, front section
Rear side member
Wheel arch
Spring bumper mounting
Rear floor stiffener
Centre cross member
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PRB4133
or
41-44
http://vnx.su
1
0.8
1.5
1.2
1.2
1.2
1.5
0.8
1.5
1
1.5
1.5
1
1.5
0.8
LOWER STRUCTURE
Rear floor, rear section (part section)
41
1 - ALONG CUT A
CAA11538R4
C
13018R2
6
1
or
CAN11690R6
D
CAS13028R4
10
1
CAN11690R6
41-45
http://vnx.su
LOWER STRUCTURE
Rear floor, rear section (part section)
1
9
CAA11538-1R5
CAH11549R1
41-46
http://vnx.su
41
LOWER STRUCTURE
Rear floor, rear section (part section)
41
11
CAH11549R1
13001R
G
12
10
9
11
CAF11547-2R4
CAH11549R1
J
1
10
CAA11538R3
41-47
http://vnx.su
LOWER STRUCTURE
Rear floor, rear section (part section)
41
2 - ALONG CUT B
13001R1
13018R3
K
1
CAS13033R1
CAA11536-2R2
or
41-48
http://vnx.su
LOWER STRUCTURE
Rear floor, rear section (part section)
1
13
CAA11538-1R6
1
14
CAA11538-1R6
41-49
http://vnx.su
41
LOWER STRUCTURE
Rear floor, rear section (part section)
INTRODUCTION
Below you will find special details for vehicles fitted with a rear floor, front section .
13348R1
1
1
1
8
CAT13329R1
1
2
41-50
http://vnx.su
41
LOWER STRUCTURE
Rear floor front cross member, front section
41 N
INTRODUCTION
JOINTS WITH:
Rear floor
Sill panel closure panel, front section
Sill panel closure panel, rear section
Part only.
PRB4134
or
41-51
http://vnx.su
0.8
1
1.2
1.5
LOWER STRUCTURE
Rear floor front cross member, front section
41 N
B
2
CAA11538R7
13232R1
or
A
4
2
1
CAS13033R1
1
CAA11538-2aR3
1
2
41-52
http://vnx.su
LOWER STRUCTURE
Rear floor stiffener
41 O
INTRODUCTION
Part only.
PRB4135
JOINTS WITH:
Rear floor
Rear side member
1
0.8
1.5
41-53
http://vnx.su
LOWER STRUCTURE
Rear floor stiffener
41 O
CAF11547-2R2
13221R
C
3
1
2
2
1
CAA11538-2aR4
CAA11538R5
1
2
41-54
http://vnx.su
LOWER STRUCTURE
Rear end cross member
INTRODUCTION
JOINTS WITH:
41
1
2
3
4
5
6
7
8
PRB4136
41-55
http://vnx.su
1.2
1
1.5
1.5
1.5
0.7
0.8
1.5
LOWER STRUCTURE
Rear end cross member
41
C
6
CAA11536-1R3
13225R
D
6
1
2
CAB11539R7
CAT13327R3
2
6
1
CAB11539R7
41-56
http://vnx.su
LOWER STRUCTURE
Rear end cross member
41
CAT13328R1
13221R1
2
1
7
1
4
CAA11538R5
CAT13327R5
CAH11549-1R1
41-57
http://vnx.su
LOWER STRUCTURE
Rear shock absorber reinforcement
INTRODUCTION
Part only.
PRB4137
JOINTS WITH:
1
2
3
4
41-58
http://vnx.su
1
1.2
1.5
1.5
41 Q
LOWER STRUCTURE
Rear shock absorber reinforcement
13351R1
41 Q
13352R
1
CAT13327R5
CAT13327R6
41-59
http://vnx.su
LOWER STRUCTURE
Rear side member extension
INTRODUCTION
PRB4138
JOINTS WITH:
41-60
http://vnx.su
1.5
1.5
1.5
41
LOWER STRUCTURE
Rear side member extension
41
13221R2
13225R1
2
CAA11536R7
CAA11536R7
CAA11538R5
41-61
http://vnx.su
LOWER STRUCTURE
Rear side member, part section
41
INTRODUCTION
or
CAS13033R1
PRB4139
or
1.5
41-62
http://vnx.su
LOWER STRUCTURE
Complete rear side member
41
INTRODUCTION
JOINTS WITH:
PRB4140
41-63
http://vnx.su
1.5
1
1.5
1.2
1.5
1
1.5
LOWER STRUCTURE
Complete rear side member
13012R
41
13232R2
B
4
4
CAA11536R6
CAO11694R1
41-64
http://vnx.su
LOWER STRUCTURE
Complete rear side member
41
D
1
6
CAA11538-1R8
13237R
C
1
3
CAA11538-1R8
41-65
http://vnx.su
LOWER STRUCTURE
Complete rear side member
41
CAS13024-2R5
13235R
E
1
3
CAA11538-1R1
41-66
http://vnx.su
LOWER STRUCTURE
Centre cross member of rear floor
41 U
INTRODUCTION
13237R1
A
1
CAA11538R4
PRB4141
JOINTS WITH:
1.5
1.5
1
CAS13024-1R5
41-67
http://vnx.su
LOWER STRUCTURE
Seat anchoring reinforcement
41
INTRODUCTION
JOINTS WITH:
Rear floor
Rear floor front cross member, front section
Rear floor centre cross member
PRB4142
41-68
http://vnx.su
1.2
1.5
0.8
1
1.5
LOWER STRUCTURE
Seat anchoring reinforcement
41
B
3
CAA11538R7
13222R
C
3
1
CAA11538R5
CAF11547-2R2
D
4
2
1
CAN11690-3R4
41-69
http://vnx.su
LOWER STRUCTURE
Seat anchoring reinforcement
41
F
2
CAR11700R1
13237R2
CAA11538R6
41-70
http://vnx.su
LOWER STRUCTURE
Rear floor unit
INTRODUCTION
JOINTS WITH:
Side floor
Tunnel
Sill panel closure panel
Side panel lining
Rear wheel arch
41
1
2
3
4
5
6
7
8
9
10
11
12
PRB4143
41-71
http://vnx.su
Side floor
Tunnel
Rear floor, rear section
Sill panel closure panel
Side panel lining
Wheel arch
Sill panel closure panel, rear section
Rear floor front cross member
Side panel
Spring bumper mounting
reinforcement
Spring bumper mounting
Shock absorber mounting upper
reinforcement
0.8
1.2
1
1.2
0.7
1
1.5
0.8
0.8
1.5
1.5
1.2
LOWER STRUCTURE
Rear floor unit
13012R1
13232R3
41
5
3
CAB11540-1R1
CAN11690-3R1
F
4
3
CAB11540-1R1
CAA11536R6
41-72
http://vnx.su
LOWER STRUCTURE
Rear floor unit
41
12
6
CAA11536R8
13018R4
7
5
CAA11536R7
41-73
http://vnx.su
LOWER STRUCTURE
Rear floor unit
41
H
6
10
11
CAF11547-2R7
13001R2
I
10
CAF11547-2R4
CAA11538R4
41-74
http://vnx.su
42 A
INTRODUCTION
13330R
Remove :
- the plastic cover at (A) on the wing side (see section 55),
- the wheel arch plastic mudguards (see section 55),
- the bumper and its mounting blade (see section 55),
- the indicator repeater,
the front wing : 8 hexagonal-head bolts 6 mm and a torx bolt 6 mm.
42-1
http://vnx.su
PRB4209
JOINTS WITH:
1
2
3
4
5
6
7
42-2
http://vnx.su
1
1.5
1.5
1
1
1.5
1.5
42
42
B
5
CAG11548R6
13002R
C
5
1
4
CAC11541-1R6
CAA11538-1R2
42-3
http://vnx.su
42
F
5
4
1
3
7
CAN11690-2R8
CAA11536R7
G
4
1
CAA11538-1R1
CAP11696R6
42-4
http://vnx.su
42
INTRODUCTION
PRB4210
or
JOINTS WITH :
1
2
3
4
5
42-5
http://vnx.su
1.5
2
2
1
1
42
5
1
CAA11538-1R4
12895R
A
1
2
CAA11538-1R3
42-6
http://vnx.su
42
D
1
CAG11548-7R3
12999R
or
C
1
CAA11536-1R3
CAS13033R2
42-7
http://vnx.su
42 D
1
1
1
2
2
1
1
1.5
Parts only :
1 - Cowl side panel upper reinforcement, front
section.
2 - Cowl side panel upper reinforcement, rear
section.
12892R
PRB4211
JOINTS WITH :
2 / 3
CAA11538R4
42-8
http://vnx.su
42 D
C
2
CAS13026R7
12903R1
B
2
1
2
CAF11547-2R8
CAA11536R4
42-9
http://vnx.su
42 D
G
1
CAA11538R7
12891R
CAF11547-2R8
CAF11547-2R8
I
8
3
5
CAN11690R2
CAR11700R1
42-10
http://vnx.su
42 D
K
3
7
8
CAF11547-2R3
12890R
L
3
1
2
1
7
CAS13022R1
CAN11690R5
42-11
http://vnx.su
42
INTRODUCTION
JOINTS WITH :
1
2
3
4
5
6
7
Engine mounting
Shock absorber cup height adjuster
Side member closure panel
Side member, front section
Front wheel arch
Front end lower cross member
Cowl side panel (pillar lining)
PRB4212
or
42-12
http://vnx.su
2
2
1
1.5
1
1.5
1.5
42
B
5
CAQ11697R5
13009R
CAR11700R5
CAI11550-2R5
42-13
http://vnx.su
42
E
5
4
CAS13028R1
12903R2
or
D
1
5
CAS13028R8
42-14
http://vnx.su
42
G
7
CAC11541R7
13010R1
H
5
4
2
CAB11540R1
CAS13028R2
42-15
http://vnx.su
13005R3
2
5
CAP11696-1R4
42-16
http://vnx.su
42
42
INTRODUCTION
JOINTS WITH :
Plenum chamber
Side member closure panel
Front side member
Front end lower cross member
1
2
3
4
5
6
7
8
9
10
11
42-17
http://vnx.su
1
1.5
1.5
2
1
1
1.5
2.5
1
1.5
2
42
B
9
CAQ11697R5
13009R
10
9
CAR11700R5
CAI11550-2R5
42-18
http://vnx.su
42
E
1
7
CAA11538-1R3
12895R1
F
1
3
7
CAA11536-1R3
CAS13029R1
42-19
http://vnx.su
42
CAA11536R2
13005R1
H1
G1
1
1
8
CAA11537-2R5
CAA11536-4R2
CAA11537-1R5
42-20
http://vnx.su
42
J
1
6
7
CAE11546R7
13005R2
K
9
7
I
1
6
7
CAS13028R1
CAB11539-1R8
L
2
CAA11538R7
42-21
http://vnx.su
13007R
42
13000R
N
4
1
5
1
5
CAA11536R8
CAS13024-1R3
42-22
http://vnx.su
42
P
9
7
CAS13028R2
13010R2
O
5
11
CAA11538R8
42-23
http://vnx.su
42 G
INTRODUCTION
JOINTS WITH :
Wheel arch
Injection unit and impact sensor mounting (left
hand side)
Bulkhead
Pillar lining (cowl side panel)
Windscreen aperture lower cross member
1
2
3
4
In the following operation there are only descriptions of the joints specific to the part concerned.
Information concerning other parts is dealt with
in the respective section.
5
6
7
8
Plenum chamber
Part assembled with :
- bonnet lock mounting,
- windscreen wiper motor mounting.
Plenum chamber
Shock absorber cup height adjuster
Shock absorber cup
Injection unit and impact sensor
mounting (left hand side)
Bulkhead
Cowl side panel (pillar lining)
Windscreen wiper mounting
Windscreen aperture lower cross
member
PRB4214
or
42-24
http://vnx.su
1
1
2
2
1
1.5
1.5
1.2
13007-1R
42 G
13000R1
C
1
2
3
2
1
CAA11536R8
CAS13024R3
CAB11540R6
42-25
http://vnx.su
42 G
13003-1R
13013R
D
6
E
1
CAA11538R7
CAS13033R2
F
5
CAA11538R7
42-26
http://vnx.su
13010R3
G
1
CAA11538R8
42-27
http://vnx.su
42 G
42 H
INTRODUCTION
or
JOINTS WITH :
Bulkhead
Windscreen aperture lower cross member
Windscreen aperture lower cross member
reinforcement
Steering column mounting height adjuster
Steering column mounting
Cowl side panel (pillar lining)
Windscreen wiper mounting
Steering mounting
Part only.
1 Bulkhead
2 Windscreen aperture lower cross
member
3 Windscreen aperture lower cross
member reinforcement
4 Steering column mounting height
adjuster
5 Steering column mounting
6 Cowl side panel (pillar lining)
7 Windscreen wiper mounting
42-28
http://vnx.su
1
1.2
1.2
1.5
2
1.5
1.5
42 H
2
6
CAB11539R3
13014R1
C
7
2
1
6
CAB11539-1R5
CAF11547-2R7
or
42-29
http://vnx.su
42 H
D
6
CAA11538R8
13224R
E
F
3
2
4
CAS13030R6
CAF11547-4R1
42-30
http://vnx.su
42 H
G
1
CAA11536-3R1
13014R2
or
2
1
2
CAS13025R3
CAB11539-1R5
42-31
http://vnx.su
42
INTRODUCTION
JOINTS WITH :
In the following operation there are only descriptions of the joints specific to the part concerned.
Steering mounting:
Part only.
PRB4216
42-32
http://vnx.su
2
1.5
1
42
1
2
CAA11536R7
13224R1
C
3
CAA11538-1R8
CAA11536-3R1
42-33
http://vnx.su
JOINTS WITH :
Floor
Windscreen wiper mounting
Windscreen wiper motor mounting
Windscreen pillar
Windscreen pillar lining
Front side cross member
42
1
2
3
4
5
6
7
8
Bulkhead
Floor
Windscreen wiper motor mounting
Windscreen pillar
Windscreen pillar lining
Rear side member, front section
Front side cross member
Front pillar
PRB4217
or
42-34
http://vnx.su
0.7
0.8
1.5
1
1
2.5
1
0.8
42
B
1
CAA11536-1R8
12893R1
C
1
1
7
6
2
2
CAG11548-1R8
CAS13031R7
42-35
http://vnx.su
42
E
1
CAD11545-3R2
13003R
or
D
1
CAA11536-2R1
2
or
CAA11536-2R4
42-36
http://vnx.su
42
CAS13033R2
12890R1
or
CAB11540-1R6
42-37
http://vnx.su
13008R1
I
4
5
CAS13028-1R7
1
2
42-38
http://vnx.su
42
43 A
INTRODUCTION
JOINTS WITH:
Inner reinforcement
Windscreen pillar lining
Windscreen aperture lower cross member
Pillar lining
Sill panel closure panel
Upper reinforcement of cowl side panel
1
2
3
4
5
6
7
8
Front pillar
Inner reinforcement
Windscreen pillar lining
Windscreen aperture lower cross
member
Pillar lining
Sill panel closure panel
Upper reinforcement of cowl side panel
Sill panel reinforcement
PRB4311
43-1
http://vnx.su
1
1.2
1
1.2
1.2
1.2
1.2
1.2
43 A
CAV13465R1
13234R
C
1
5
2
CAV13466R7
CAE11546-5R1
43-2
http://vnx.su
43 A
E
5
2
1
CAN11690-3R4
13233R
or
1
X = 220 mm
D
1
5
CAS13033R8
CAO11694R4
43-3
http://vnx.su
43 A
2
5
CAI11550-3R4
13231R
X = 400 mm
1
4
5
2
1
CAC11541-2R1
CAN11690-3R4
43-4
http://vnx.su
43 A
CAE11546-5R3
CAE11546-5R3
N
1
1
CAE11546-5R8
CAS13033R5
or
L
1
CAE11546-5R8
43-5
http://vnx.su
JOINTS WITH:
43
1
2
3
4
5
6
7
PRB4312
43-6
http://vnx.su
1
0.8
0.7
1
0.7
1.2
0.7
13214R
A
6
1
CAS13028R8
43-7
http://vnx.su
43
43
C
3
4
1
CAI11550-2R4
13213R
1
CAV13469R5
CAQ11697R1
CAA11537R6
43-8
http://vnx.su
43
INTRODUCTION
JOINTS WITH:
1
2
3
4
5
PRB4313
or
43-9
http://vnx.su
43
3
1
CAA11538-1R4
13014R
A
1
CAA11536-1R8
43-10
http://vnx.su
43
D
1
CAA11537R3
13015R
3
1
CAA11538-1R4
43-11
http://vnx.su
43
CAS13033R1
12999-2R
E
5
1
CAS13028R7
43-12
http://vnx.su
43
CAS13024R6
13008R
CAA11536-1R6
43-13
http://vnx.su
JOINTS WITH:
43 D
1
2
3
4
5
Centre pillar
Centre pillar reinforcement
Sill panel closure panel
Sill panel reinforcement
Body side lining
PRB4314
or
43-14
http://vnx.su
1
1.2
1.2
1.2
0.8
43 D
B
1
4
CAI11550R1
13231R1
or
X = 400 mm
A
3
4
1
CAI11550R6
43-15
http://vnx.su
43 D
D
1
CAS13033R8
13226R
or
C
5
2
1
CAI11550R7
CAI11550R8
43-16
http://vnx.su
43 D
G
3
5
1
CAI11550R6
13230R
CAI11550R1
CAI11550R6
I
1
2
CAI11550R1
43-17
http://vnx.su
13229R
or
J
1
CAS13033R8
43-18
http://vnx.su
43 D
43
INTRODUCTION
CAA11538-1R4
CAB11539R6
PRB4315
43-19
http://vnx.su
1
2
3
4
43-20
http://vnx.su
1.2
1.2
0.8
1.2
43
43
B
3
CAI11550R8
13355R1
2
1
CAA11538-1R4
43-21
http://vnx.su
43
D
1
3
5
CAE11546R7
13353R
1
4
CAF11547R4
CAA11537R2
F
3
CAA11536R6
43-22
http://vnx.su
Part only.
PRB4316
LIST OF JOINTS :
43-23
http://vnx.su
1.2
1.2
1.2
43
43
B
2
CAB11539-1R3
13353R1
C
1
1
2
CAA11537-1R2
CAB11539-1R8
43-24
http://vnx.su
43 G
INTRODUCTION
LIST OF JOINTS :
1
2
3
4
Part only.
PRB4317
or
43-25
http://vnx.su
0.8
0.7
1.2
1.2
43 G
B
2
1
2
CAV13468R3
or
13219R
2
or
C
1
2
1
1
CAA11537-1R4
CAS13033R5
or
or
43-26
http://vnx.su
43 G
CAN11691R7
13609R
F
or
3
2
1
D
1
CAE11546-2R8
CAS13033R7
4
or
2
1
CAE11546-2R8
43-27
http://vnx.su
44 A
INTRODUCTION
JOINTS WITH :
1
2
3
4
5
6
7
8
9
10
11
12
13
PRB4413
44-1
http://vnx.su
0.8
0.7
1.2
1
1.2
1
0.7
0.7
1.2
1.2
1.5
1.2
0.7
44 A
B - C
2
CAI11550-2R1
13226R1
or
CAS13033R1
44-2
http://vnx.su
44 A
E
2
CAQ11697R3
13227R
F
2
2
12
1
CAI11550-2R1
CAI11550-2R4
44-3
http://vnx.su
44 A
H
11
2
1
CAE11546-2R7
13229R1
or
G
1
2
11
CAE11546-2R4
CAS13033R1
44-4
http://vnx.su
44 A
13216R
13212R1
or
CAB11540-1R1
CAV13468R1
K
5
CAB11540-1R7
44-5
http://vnx.su
13356R
2
1
2
44-6
http://vnx.su
CAN11691R7
44 A
GLAZED
VERSION
13218R1
44 A
13217R1
or
A
1
A
1
CAS13033R8
CAS13033R8
44-7
http://vnx.su
VERSION WITH
ROOF FLAP
44 A
INTRODUCTION
CAC11541-1R6
13475R
13
CAC11541-1R6
44-8
http://vnx.su
44
INTRODUCTION
JOINTS WITH :
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
At the end of the section there are also special details for the glazed version and the version with a
roof flap.
PRB4414
44-9
http://vnx.su
0.8
0.7
1.2
1
1.2
1
0.7
0.7
1.2
1.2
1.5
0.7
1.2
0.7
0.7
44
B - C
CAI11550-2R1
13218R2
or
CAS13033R1
44-10
http://vnx.su
44
E
11
2
1
CAE11546-2R7
13219R1
or
1
13
11
CAE11546-2R4
7
1
CAI11550-2R3
CAS13033R1
44-11
http://vnx.su
44
H
11
10
1
CAE11546-2R7
13216R
J
1
10
11
CAE11546-2R4
CAB11540-1R1
K
5
CAB11540-1R7
44-12
http://vnx.su
13212R1
44
12665R1
or
2
1
2
CAV13468R1
1
2
44-13
http://vnx.su
CAN11691R7
13018R
13210R
44 B
15
1
14
CAA11538-1R8
CAV13463R7
44-14
http://vnx.su
GLAZED
VERSION
44
13218R1
or
13217R1
or
A
1
A
1
1
1
CAS13033R7
CAS13033R7
44-15
http://vnx.su
VERSION WITH
ROOF FLAP
44
INTRODUCTION
CAC11541-1R6
13475R
CAC11541-1R6
44-16
http://vnx.su
44
INTRODUCTION
JOINTS WITH :
1
2
3
4
5
1 - complete
2 - partial by cut A-A
3 - partial by cut B.B for glazed version
6
7
8
9
10
11
12
13
PRB4415
44-17
http://vnx.su
44
COMPLETE
2
1
CAA11538-1R1
C
13220R
A
2
CAO11694-1R1a
CAA11537R8
44-18
http://vnx.su
44
CAA11538R6
13211R
D
5
1
CAN11690R3
44-19
http://vnx.su
44
H
8
CAO11694R1
13355R
F
1
1
8
9
CAJ11551-4R7
CAO11694-1R7
J
8
2
1
9
CAN11690-2R8
CAQ11697R8
44-20
http://vnx.su
44
L
1
6
CAA11538-1R8
13353R2
1
7
6
CAF11547-3R3
CAA11538-1R8
44-21
http://vnx.su
44
O
12
1
11
CAK11552-4R2
13354R
P
10
11
11
CAW13601-3R1
CAQ11697R6
44-22
http://vnx.su
44
11
CAQ11697R2
13351R
Q
1
13
CAA11536-2R4
44-23
http://vnx.su
44
13354R1
13215R
or
1
CAB11540R1
or
CAS13033R1
44-24
http://vnx.su
44
13210R1
13354R2
or
or
CAS13033R1
CAS13033R1
44-25
http://vnx.su
44 D
INTRODUCTION
JOINTS WITH:
PRB4416
44-26
http://vnx.su
0.7
1
1.2
0.8
1.2
1.2
1.2
0.7
44 D
B
1
6
CAA11538-1R8
13214R1
CAA11537-1R5
44-27
http://vnx.su
44 D
CAP11696-2R6
13211R2
C
1
5
4
1
CAJ11551-1R3
CAA11537R5
F
7
CAO11694-1R3
44-28
http://vnx.su
VERSION WITH
ROOF FLAP
44 D
7
CAO11694R6
13475R1
1
CAO11694R6
44-29
http://vnx.su
44
INTRODUCTION
PRB4417
JOINTS WITH:
Rear floor
Rear side member
44-30
http://vnx.su
1
1.5
1.5
1.5
1.5
0.8
44
3
1
2
CAE11546-3R7
13471R
2
1
7
CAF11547-3R4
CAA11538-1R3
D
1
CAN11690-2R6
44-31
http://vnx.su
E
1
CAA11537-1R7
F
1
5
4
CAP11696-2R7
44-32
http://vnx.su
44
JOINTS WITH:
44
1
2
3
4
5
6
7
8
9
10
PRB4418
or
44-33
http://vnx.su
1.5
1.2
0.7
0.8
1.02
0.7
0.7
1
1
1
44
1 - COMPLETE REPLACEMENT
CAO11694R4
13211R1
CAW13605-1R2
44-34
http://vnx.su
44
D
1
CAA11536-3R2
13212R
E
1
CAA11536-3R2
CAA11536-5R2
44-35
http://vnx.su
44
G
3
CAU13326R1
13223R
H
4
1
10
CAQ11697R4
CAL11554-2R1
44-36
http://vnx.su
13223R1
13351S
or
I
10
10
CAV13467R3
44-37
http://vnx.su
44
44 G
INTRODUCTION
JOINTS WITH:
The replacement of this part is carried out partially following a rear side impact and is complementary to the rear wing panel (see diagram and method below).
1
2
3
4
Part only.
PRB4419
44-38
http://vnx.su
1
0.7
0.7
1.2
44 G
CAN11689R5
13223R2
or
2
A
1
CAA11536-1R3
CAA11536-3R2a
or
2
4
CAA11538R7
44-39
http://vnx.su
3
1
CAA11538-1R4
44-40
http://vnx.su
44 G
JOINTS WITH:
44 H
1
2
3
4
5
Part only.
PRB4420
or
44-41
http://vnx.su
1
1.2
1.5
0.8
1
44 H
B
1
3
2
CAE11546R8
13223R3
C
or
1
3
2
1
CAB11539-1R7
CAS13030-1R2
CAA11538R5
44-42
http://vnx.su
44 H
3
1
CAA11536-4R8
13223R4
or
E
1
4
5
CAS13033R1
CAE11546-8R2
44-43
http://vnx.su
TOP OF BODY
Roof
45 A
INTRODUCTION
JOINTS WITH :
1
2
3
4
5
PRB4503
45-1
http://vnx.su
Roof
Roof front cross member
Roof centre cross member
Roof rear cross member
Roof rear cross member
reinforcement
Side panel
Upper reinforcement of side
panel rain channel
Centre pillar door pillar
reinforcement
Windscreen pillar lining
Stretcher lining
Roof flap rain channel
0.8
0.8
1
0.8
1.2
0 .8
1.2
1.2
1
0.7
0.7
TOP OF BODY
Roof
45 A
B
1
CAA11536-4R2
1
13228R
A
1
2
CAG11548-2R5
CAQ11697R7
D
1
CAQ11697R7
45-2
http://vnx.su
TOP OF BODY
Roof
45 A
13213R1
13214R2
F
1
CAC11544-1R1
CAC11544-1R1
45-3
http://vnx.su
TOP OF BODY
Roof
45 A
13211R3
13212R2
H
1
1
5
4
CAC11544-1R2
CAE11546-6R1
45-4
http://vnx.su
TOP OF BODY
Roof
45 A
K
1
6
CAS13025-4R2
J
1
1
CAG11548-2R5
10
CAS13025-4R2
1
2
45-5
http://vnx.su
TOP OF BODY
Roof
VERSION WITH
ROOF FLAP
45 A
INTRODUCTION
CAA11536-4R1
1
2
13475R1
A
11
CAA11536-4R1
11
1
CAJ11551-1R5
45-6
http://vnx.su
TOP OF BODY
Roof front cross member
45
INTRODUCTION
Part only.
13213R2
PRB4504
CAA11537-1R6
JOINTS WITH :
0.8
1
45-7
http://vnx.su
TOP OF BODY
Roof centre cross member
45
INTRODUCTION
PRB4505
CAA11537-1R6
JOINTS WITH :
0.8
1.2
45-8
http://vnx.su
TOP OF BODY
Roof rear cross member
INTRODUCTION
JOINTS WITH :
45 D
1
2
3
4
PRB4506
45-9
http://vnx.su
0.8
1.2
0.7
0.7
TOP OF BODY
Roof rear cross member
45 D
B
2
3
1
CAJ11551R3
13211R4
CAA11537-1R5
45-10
http://vnx.su
VERSION WITH
ROOF FLAP
TOP OF BODY
Roof rear cross member
INTRODUCTION
13473R
CAA11537-1R5
45-11
http://vnx.su
45 D
47 A
PRB4706
REMOVAL
13021R1
13021R
REFITTING
47-1
http://vnx.su
JOINTS WITH:
47
This operation also requires the stiffener to be replaced and this must be ordered separately.
PARTS CONCERNED (thickness in mm):
1
2
3
4
PRB4707
or
47-2
http://vnx.su
0.8
1.2
0.8
1.2
47
B
1
CAQ11697R4
13343R
or
1
3
CAT13318R1
1
CAS13033R3
47-3
http://vnx.su
47
E
3
2
1
CAT13318R2
1
13343-1R
2
or
D
3
CAS13033R3
47-4
http://vnx.su
47
G
3
2
1
CAT13318R2
1
13344R
F
2
CAN11689R1
CAV13463R1
47-5
http://vnx.su
Part only.
PRB4710
JOINTS WITH:
47-6
http://vnx.su
0.8
1.2
1.2
47
47
13472-1R
13472R
B
1
CAA11538R7
CAA11538R3
47-7
http://vnx.su
47 D
PRB4709
13105R
12978R
pin.
Remove :
- the rear stop,
47-8
http://vnx.su
47 D
12979R
12976R
12977R
47-9
http://vnx.su
47 D
REFITTING
12975R
13106R
47-10
http://vnx.su
JOINTS WITH:
47
1
2
3
4
PRB4708
or
be replaced.
47-11
http://vnx.su
0.8
1.2
0.8
1.2
47
B
3
2
1
CAT13318R2
1
13346R
A
2
CAN11689R1
CAV13463R1
47-12
http://vnx.su
47
D
3
CAQ11697R5
13345R
E-G
or
1
3
CAT13318R1
1
CAS13033R3
47-13
http://vnx.su
Part only.
PRB4710
JOINTS WITH:
47-14
http://vnx.su
0.8
1.2
1.2
47
47
B
3
CAB11539-1R1
13608R
A
1
CAA11538R7
47-15
http://vnx.su
48 A
REFITTING
PRB4808
REMOVAL
13238R
48-1
http://vnx.su
48
REFITTING
PRB4809
REMOVAL
13238R
Remove:
- the bonnet nuts at (A) (operation must be carried out by two people),
- the bonnet,
- the strut mounting bolts (B) on the headlight
carrier panel.
48-2
http://vnx.su
48
REFITTING
PRB4810
REMOVAL
13101R
48-3
http://vnx.su
48 D
REFITTING
PRB4811
REMOVAL
13474R
After removal of trim and wiring, remove the balancers then the mounting bolts (A) from the roof
rear cross member (this operation should be carried out with two people).
48-4
http://vnx.su
48
REFITTING
PRB4812
REMOVAL
13247R
48-5
http://vnx.su
77 11 292 482
JANUARY 2000
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
EDITION ANGLAISE
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.
RENAULT 2000
http://vnx.su
EXPLODED VIEW
http://vnx.su
40 GENERAL INFORMATION
Dimensions
Engine and equipment
Towing
Key to symbols
Fitting the extension elements
Description of parts
Sub-frame dimensions
Repair bench
Tools and specific products
40-1
40-2
40-3
40-4
40-5
40-6
40-8
40-9
40-12
41 LOWER STRUCTURE
P
X
41-1
41-8
44-1
44-3
44-12
44-14
44-24
44-28
44-30
44-33
45 TOP OF BODY
Aa Grand volume added roof
E
Roof inner panel extender
http://vnx.su
45-1
45-5
GENERAL 140
INFORMATION
Dimensions
(1) Empty
(2) Laden
Dimensions in metres.
40-1
http://vnx.su
40
GENERAL INFORMATION
Engine and equipment
40
Engine
Vehicle type
Type
Capacity
Clutch type
Gearbox type
manual and automatic
(cm3 )
FC0HHF
E7J
1390
180 CP 3300
JB3
FC0EHF
F8Q
1870
JB1
EXTENDED
PASSENGER
COMPARTMENT
BODY
Petrol
Diesel
Petrol
Diesel
550
600
580
580
1175
1220
1195
1240
610
660
610
655
565
560
585
585
1227
1270
1246
1291
40-2
http://vnx.su
GENERAL INFORMATION
Towing
40
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
SPECIAL FEATURES OF THE KANGOO GRAND VOLUME
This vehicle does not have a rear towing eye.
REAR
FRONT
40-3
http://vnx.su
GENERAL INFORMATION
Key to Symbols
40
Chiselling
Safety symbol.
This means that the welding operation in
question concerns one or more of the
vehicle's vital safety components.
Unpicking
Unsoldering.
Plug welding.
Under MAG gas protection.
40-4
http://vnx.su
GENERAL INFORMATION
Fitting extension elements
1
2
3
4
5
Roof
Rear ring
Side panel
Wing panel
Basic body
40-5
http://vnx.su
40
GENERAL INFORMATION
Description of parts
40
UPPER STRUCTURE
PRF4011
1
2
3
4
5
6
7
8
9
Roof added
Roof rear cross member
Rear wing panel (panel and glazed version)
Side panel rain channel support
Side panel added (panel and glazed version)
Side panel extender
Side inner panel extender
Upper rear corner stiffener
Roof inner panel extender
40-6
http://vnx.su
GENERAL INFORMATION
Description of parts
40
SUB-FRAME
PRF4012
40-7
http://vnx.su
GENERAL INFORMATION
Sub-frame dimensions
40
DESCRIPTION
DIAMETER
SLOPE %
3 446
- 497.5
151
M8
40-8
http://vnx.su
GENERAL INFORMATION
Repair Bench
40-9
http://vnx.su
40
GENERAL INFORMATION
Repair Bench
BLACKHAWK BODY JIG BENCH
PRF4013
40-10
http://vnx.su
40
GENERAL INFORMATION
Repair Bench
SPECIAL TOOLING PART NUMBER
BLACKHAWK
CELETTE
Order at:
Order at:
BLACKHAWK S.A.
Centre Eurofret
Rue de Rheinfeld
67100 STRASBOURG
CELETTE S.A.
B.P. 9
38026 VIENNA
40-11
http://vnx.su
40
GENERAL INFORMATION
Tools and specific products
40
MATERIAL
40-12
http://vnx.su
GENERAL INFORMATION
Tools and specific products
3M ADHESIVE FINISHING SEAL
(Part number 77 11 212 385)
16595R4
40-13
http://vnx.su
40
LOWER STRUCTURE
141
Semi-rear end cross member
41
INTRODUCTION
This part is changed in addition to changing the rear
end panel. It may be performed in two ways:
Cut 1
Cut 2
41-1
http://vnx.su
1.5
1
1
1.2
1
1
0.8
1
1
LOWER STRUCTURE
Semi-rear end cross member
SPECIAL FEATURE OF THE FOLLOWING
REPLACEMENT CUT 1
41-2
http://vnx.su
41
LOWER STRUCTURE
Semi-rear end cross member
41-3
http://vnx.su
41
LOWER STRUCTURE
Semi-rear end cross member
41-4
http://vnx.su
41
LOWER STRUCTURE
Semi-rear end cross member
41-5
http://vnx.su
41
LOWER STRUCTURE
Semi-rear end cross member
SPECIAL FEATURES OF THE FOLLOWING
REPLACEMENT CUT 2
761P4-16604-1
41-6
http://vnx.su
41
LOWER STRUCTURE
Semi-rear end cross member
41-7
http://vnx.su
41
LOWER STRUCTURE
Rear floor extender
41
INTRODUCTION
1
2
3
4
5
6
7
8
9
41-8
http://vnx.su
X
0.8
1
1.2
1
1.5
0.8
1
1
1
LOWER STRUCTURE
Rear floor extender
41-9
http://vnx.su
41
LOWER STRUCTURE
Rear floor extender
CAA11536-1R5A
CAA11538-1R5
41-10
http://vnx.su
41
TOE14621-5R7
44-1
http://vnx.su
0.8
44
44
CAS13033R7
764A1-16607
or
SPECIAL FEATURE
Only operations related to the partial cut are dealt with
in this method. Other operations are described in
Repair Manual 326.
CAS13033R7
44-2
http://vnx.su
PRF4417
44-3
http://vnx.su
44
Aa
44
Aa
16619S
16619-1S
Moulding 7 mm
Moulding 5 mm
44-4
http://vnx.su
0.8
0.8
0.8
1.5
1
1
44
Aa
16586-1R1
16619R1
16595R1
16584-1R1
44-5
http://vnx.su
16589R1
44
Aa
16691R
A
B
16596R1
16593R1
44-6
http://vnx.su
44
Aa
16592R1
16588R1
16590R1
16587R1
44-7
http://vnx.su
44
Aa
REFITTING
We recommend that you follow the order given below:
position the panel on the body,
bond the panel,
fit and adjust it,
strap the part (refer to section 44Bb),
solder.
NOTE: the panel should be stuck and fitted to the body
as quickly as possible.
The adhesive moulding diameters change depending
on the glue course (see below).
16584-1R1
Adhesive moulding 5 mm
between sheets (1) and (2)
16619-1R1
16586-1R1
Adhesive moulding 5 mm
between sheets (1) and (6)
44-8
http://vnx.su
44
16595R1
Aa
16596R1
A adhesive moulding 7 mm
between sheets (1) and (3)
B adhesive moulding 5 mm
between sheets (1) and (3)
Adhesive moulding 7 mm
between sheets (1) and (3)
16589R1
Adhesive moulding 7 mm
between sheets (1) and (3)
44-9
http://vnx.su
44
Aa
SPECIAL FEATURE
Wide masking tape should be applied to the basic
body wing panel at the adhesive moulding position
(section 6), which will prevent the mounting body wing
panel being damaged when the part is removed once
more.
16593R1
Adhesive moulding 5 mm
between sheets (1) and (3)
16691R
A
B
16592R1
Adhesive moulding 7 mm
between sheets (1) and (3)
44-10
http://vnx.su
16590R1
44
Aa
16587R1
16588R1
44-11
http://vnx.su
44
INTRODUCTION
The basic body side panel of the Kangoo Grand
Volume may be partially replaced by following the
method given below.
This is made possible by masking the connection
when the Grand Volume added panel is in place.
IMPORTANT: this method cannot be used on a series
Kangoo.
44-12
http://vnx.su
0.8
44
CAS13033R7
764B1-16606
or
SPECIAL FEATURE
Only operations related to the partial cut are dealt with
in this method. Other operations are described in
Repair Manual 326.
CAS13033R7
CAA11536-2R7
44-13
http://vnx.su
44-14
http://vnx.su
44
Bb
44
Bb
Moulding 7 mm
Moulding 5 mm
44-15
http://vnx.su
0.8
0.8
0.8
1,5
1
1
44-16
http://vnx.su
44
Bb
A
B
44-17
http://vnx.su
44
Bb
44
Bb
16587R3
44-18
http://vnx.su
44
Bb
REFITTING
We recommend that you follow the order given below:
bond the panel,
adjust and strap the part (refer to section 44Bb),
solder.
ATTENTION: The adhesive moulding diameters
change depending on the glue course (see below).
A
B
Adhesive moulding 5 mm
between sheets (1) and (3)
Adhesive moulding 7 mm
between sheets (1) and (3)
16620-1R
16584-1R3
Adhesive moulding 5 mm
between sheets (1) and (2)
44-19
http://vnx.su
Adhesive moulding 5 mm
between sheets (1) and (6)
44
Bb
SPECIAL FEATURE
Wide masking tape should be applied to the basic
body wing panel at the adhesive moulding position
(section 6), which will prevent the mounting body side
panel being damaged when the part is removed once
more.
16595R3
A
B
Adhesive moulding 5 mm
between sheets (1) and (3)
Adhesive moulding 7 mm
between sheets (1) and (3)
16691R
A
B
44-20
http://vnx.su
44
Bb
16591R1
Adhesive moulding 7 mm
between sheets (1) and (3)
16593R3
16592R3
Adhesive moulding 5 mm
between sheets (1) and (3)
16590R3
44-21
http://vnx.su
44
Bb
16588R3
16587R3
16631S
44-22
http://vnx.su
16632S
44-23
http://vnx.su
44
Bb
44
INTRODUCTION
1
2
3
4
5
44-24
http://vnx.su
G
1
1
1
1,2
1
44
1 - COMPLETE REPLACEMENT
TOA14581R7
764G1-16608
TOH14634R7
TOA14581R7
TOB14593R6
44-25
http://vnx.su
Moulding 5 mm
44-26
http://vnx.su
44
764G2-16646
CAA11536-2R7
44-27
http://vnx.su
44
44
INTRODUCTION
Replacing this part is an additional operation to the
rain channel lights support after a rear impact.
This operation may be carried out partially.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts will be dealt with in their
respective sections (refer to contents).
or
PRF4413
CAS13033R7
0.8
1.5
0.8
0.7
44-28
http://vnx.su
44
CAB11539-1R1
CAA11536-2R6
Moulding 5 mm
CAA11536-2R3
44-29
http://vnx.su
44
INTRODUCTION
This part is changed in addition to changing roof with
cross member and inner panel.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts will be dealt with in their
respective sections (refer to contents).
764J1-16628
1
2
3
4
5
6
7
8
1
0.8
0.8
1.5
0.8
0.8
0.8
0.8
44-30
http://vnx.su
44
CAA11536-2R5
CAA11536-2R2
Moulding 5 mm
CAW13605-4R1
CAA11536-2R2
Moulding 5 mm
44-31
http://vnx.su
44
CAA11538-1R4A
764J2-16643-1
CAA11536-2R5
44-32
http://vnx.su
44
INTRODUCTION
This part is changed in addition to changing the
rearend panel. It is carried out partially.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts to which this is additional, will be
dealt with in their respective sections (refer to
contents).
16715S
44-33
http://vnx.su
1.5
16627R
1
2
CAS13033R5
44-34
http://vnx.su
44
TOP OF BODY
145
Grand volume added roof
45
INTRODUCTION
The replacement of this part is a basic operation for a
side impact.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on additional parts will be dealt with in their
respective sections (refer to the contents).
Added roof
Added side panel
Basic body roof
Roof rear cross member
Luggage grid spacer extractor
Upper rear corner stiffener
45-1
http://vnx.su
0.7
0.8
0.8
0.8
15
1
Aa
TOP OF BODY
Grand volume added roof
45
Aa
REMOVAL - REFITTING
16584R
765A2-16625
Moulding 5 mm
Moulding 5 mm
16582R
Moulding 5 mm
45-2
http://vnx.su
TOP OF BODY
Grand volume added roof
45
765A1-16626
Aa
16583R
Moulding 5 mm
16586R
Moulding 5 mm
Moulding 5 mm
45-3
http://vnx.su
TOP OF BODY
Grand volume added roof
45
Aa
16829R
16633S
45-4
http://vnx.su
TOP OF BODY
Roof inner panel extender
45 E
REMOVAL
INTRODUCTION
This part is changed in addition to changing roof with
cross member.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.
Information on parts to which this is additional, will be
dealt with in their respective sections (refer to
contents).
765E1-16643
F = bolt of 8 mm
1
0.8
1.5
0.8
0.7
CAA11538R8
45-5
http://vnx.su
TOP OF BODY
Roof inner panel extender
45 E
CAA11536-2R5
CAA11536-2R5
CAB11539-1R1
Moulding 5 mm
45-6
http://vnx.su
77 11 194 289
JULY 1997
The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
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.
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB5000
http://vnx.su
Mechanisms and
accessories
Contents
Pages
50 GENERAL
Safety
Tooling
Pages
54 WINDOWS
50-1
50-2
54-4
54-5
54-6
54-7
MECHANISMS
Window winder handle on front
door
Door opening handle - interior,
front door
Door opening handle - exterior,
front door
Front door lock
Front door window riser
Door barrels
Interior handle for opening the
sliding door
Exterior handle for sliding door
Locking warning light and sliding
door lock
Sliding door runners
Adjusting the sliding door
51-1
55 EXTERIOR PROTECTION
51-2
51-3
51-4
51-5
51-6
51-7
51-8
56 EXTERIOR ACCESSORIES
51-9
51-10
51-12
54 WINDOWS
Windscreen
Front door window
56-1
56-2
56-3
56-4
MECHANISMS
Exterior handle for rear door
Rear screen wiper motor
Rear door lock
Rear door latches
Exterior handle for tailgate
Hinged rear roof flap cross member
55-1
55-3
55-4
55-5
Dashboard
57-1
58-1
http://vnx.su
59-1
59-2
GENERAL
Safety
50 A
96310-1S
98718R1
Each time the steering wheel is removed, the steering wheel bolt MUST be renewed. Refer to sections 88 and 57A.
IMPORTANT : Whenever the steering wheel is removed, the air bag connector (B) MUST be disconnected.
The air bag has a connector which short circuits
when it is disconnected to prevent incorrect triggering.
HEAT SHIELDS
TIGHTENING TORQUES
PRODUCTS
Read the precautions for use with care and observe the safety instructions by using the appropriate protection (gloves, mask, etc.).
50-1
http://vnx.su
GENERAL
Tooling
50 A
Door window winder handles may also be removed. (First affix a small piece of masking tape to
the door panel to avoid damaging it during removal.)
The pliers have one flat and one bent nose, giving
easy access to remove clips without damaging
them. The heads of the clips are not deformed,
enabling them to be re-used when refitting.
99331S
12776S
50-2
http://vnx.su
GENERAL
Tooling
50 A
13411S
13412S
50-3
http://vnx.su
92221R
51-1
http://vnx.su
51
PRB5101
REMOVING
13114R1
51-2
http://vnx.su
51
PRB5102
REMOVING
First remove the trim (see section 72) and the antitamper shield. Then remove the handle mounting
bolt.
12980S
12981R
51-3
http://vnx.su
51
51
PRB5104
REMOVING
12983R
12982R
51-4
http://vnx.su
51
PRB5105
REMOVING
12984S
12983R2
51-5
http://vnx.su
PRB5106
REMOVING
12974R
51-6
http://vnx.su
51
PRB5103
REMOVING
51-7
http://vnx.su
51
PRB5103
REMOVING
First remove the trim (see section 72) and then unclip:
- the linkage for the door locking warning light
(1),
13159R
51-8
http://vnx.su
51
51
13158R
Release the mounting clips (1), linkage (2) and control cable (3).
REMOVING THE LOCK
51-9
http://vnx.su
51
12979R
12978R
12977R
51-10
http://vnx.su
51
12976R
13106R
12975R
51-11
http://vnx.su
51
12333-3R1
Opening clearances:
A = 4.5 mm
B = 4 mm
C = 4 mm
D = 6 mm
51-12
http://vnx.su
51
13156R
13157R
13155S
51-13
http://vnx.su
PRB5201
REMOVING
13070R1
52-1
http://vnx.su
52
PRB5205
REMOVING
Swing-out doors
Tailgate
13070R
13071R
52-2
http://vnx.su
52
52
PRB5206
13113R
REMOVING
13104R
52-3
http://vnx.su
PRB5202
REMOVING
First remove trim for lock (see section 72) and then
unclip cables (see section 52).
13256R
52-4
http://vnx.su
52
PRB5203
REMOVING
13071-1R
52-5
http://vnx.su
52
52
PRB5204
REMOVING
13247R
52-6
http://vnx.su
WINDOWS
Windscreen
54
PRB5401
REMOVING
96826R
54-1
http://vnx.su
WINDOWS
Windscreen
54
Remove:
- the lower embellisher strip (4),
- the positioning spacers (5),
- the lower seal (can be reused),
- the exterior embellisher surround (cannot be
reused) for the traditional "wire" cutting
operation.
The exterior embellisher does not have to be
removed when the "EASY CUT" tool is used (see
Technical Note 414A).
REFITTING
13069-1R
54-2
http://vnx.su
WINDOWS
Front door window
54
PRB5402
REMOVING
12983R1
54-3
http://vnx.su
WINDOWS
Tilting or fixed windows in sliding door
54
TILTING WINDOW
FIXED WINDOW
PRB5403
REMOVING
FIXED WINDOW
REFITTING
54-4
http://vnx.su
WINDOWS
Fixed or moving side window
54
PRB5404
REMOVING
FIXED WINDOW
54-5
http://vnx.su
WINDOWS
Window in rear door and window in tailgate
54
PRB5405
REMOVING
Remove:
- window (window in rear door),
- exterior embellisher surround for tailgate
window (bonded window).
See Technical Note 371A for information on
preparation and bonding.
13256S
54-6
http://vnx.su
WINDOWS
Moving window/latch
54
PRB5406
REMOVING WINDOW
13333R
13332R
Unclip embellisher.
Remove screws (A) holding window in position.
54-7
http://vnx.su
WINDOWS
Moving window/latch
REMOVING THE LATCH
13253R
Remove cover.
13252R
Unclip latch.
54-8
http://vnx.su
54
EXTERIOR PROTECTION
Roof protection strip
55
PRB5501
REMOVING
REFITTING
13115R
13245R
55-1
http://vnx.su
EXTERIOR PROTECTION
Roof protection strip
13246R
PRB5502
55-2
http://vnx.su
55
EXTERIOR PROTECTION
Bumpers
55
FRONT
PRB5503
PRB5504
55-3
http://vnx.su
EXTERIOR PROTECTION
Side protection strips
55
PRB5505
13258S
13259S
55-4
http://vnx.su
EXTERIOR PROTECTION
Protective panel at rear
55
PRB5506
REMOVING
13112S
13111S
Remove clips.
Remove bolt or bolts (A) on inner surface.
55-5
http://vnx.su
EXTERIOR PROTECTION
Protective panel at rear
REFITTING
13255S
55-6
http://vnx.su
55
EXTERIOR ACCESSORIES
Exterior rear view mirror
56
PRB5601
REMOVING
13108R
- mounting nuts.
13109S
Remove:
- inner cover,
56-1
http://vnx.su
EXTERIOR ACCESSORIES
Rear view mirror
PRB5602
REMOVING
13107S
56-2
http://vnx.su
56
EXTERIOR ACCESSORIES
Rear screen washer jet
PRB5605
REMOVING
13110R
56-3
http://vnx.su
56
EXTERIOR ACCESSORIES
Number plate light
PRB5604
REMOVING
13111-1R
56-4
http://vnx.su
56
57
PRB5702
REMOVING
Remove:
- the air bag,
- the steering wheel bolt (when refitting, use a
new bolt with adhesive applied and tightened
to a torque of 4.5 daN.m),
- the steering wheel (with the wheels in the
straight ahead position).
12973S
57-1
http://vnx.su
12971R
57
12969-1R
Remove :
- the half cowling (three bolts),
12968S
12970-1R
57-2
http://vnx.su
12967-1R
57
12966R
Remove:
- lower protector (four screws).
12971-1R
57-3
http://vnx.su
12965-1R
57
12963R
Disconnect connectors.
12965-1R1
12963R1
Remove :
- fittings securing steering column (two nuts,
two bolts),
Remove :
- heating control panel (two screws).
57-4
http://vnx.su
57
CONSOLE
12964R
PRB5701
Disconnect connectors.
Disconnect:
- connectors for headlight height adjustment
and hazard warning lights,
- remaining connectors (e.g. decoder).
Remove dashboard.
57-5
http://vnx.su
PRB5801
REMOVING
13249R1
58-1
http://vnx.su
58
59
PRB5903
59-1
http://vnx.su
37
25
59
PRB5904
59-2
http://vnx.su
37
AIR CONDITIONING
77 11 198 230
FEBRUARY 1998
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
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.
Renault 1998
http://vnx.su
EXPLODED VIEW
PRO60.5
http://vnx.su
Heating and
Ventilation
Contents
Pages
61 HEATING
Control panel
Control cables
Particle filter
Fan assembly (GMV)
Radiator
Air distribution unit
61-1
61-2
61-3
61-4
61-5
61-6
62 AIR CONDITIONING
General
Fault finding - Introduction
Fault finding - XR25 fiche
Fault finding - Interpretation
of XR25 bargraphs
Fault finding - Customer complaints
Fault finding charts
Fault finding - Associated checks
Wiring diagram
Evaporator
Air blower unit
Compressor
Condenser
Pressure relief valve
Dehydration canister
Connecting pipes
Electrical control
Computer
http://vnx.su
62-1
62-3
62-4
62-6
62-18
62-19
62-43
62-44
62-48
62-50
62-51
62-54
62-55
62-56
62-57
62-60
62-61
HEATING
Control panel
61
Disconnect :
- control panel connector,
- the control cables for the rotator arms.
REMOVAL
92224S
REFITTING
12963R
12963R1
61-1
http://vnx.su
HEATING
Control cables
61
REMOVAL
REFITTING
Remove :
- the ashtray,
- the control unit.
92224R1
61-2
http://vnx.su
HEATING
Particle filter
REPLACEMENT
REMOVAL
PRO61.1
REFITTING
61-3
http://vnx.su
61
HEATING
Fan assembly (GMV)
61
REMOVAL
PRO61.2
REFITTING
61-4
http://vnx.su
HEATING
Radiator
61
REMOVAL
Unclip the four securing clips (E) and take out the
radiator.
13084S
98816R
13085S
61-5
http://vnx.su
HEATING
Air distribution unit
61
REMOVAL
12969-1R
Remove :
- the ashtray,
- the two screws securing the heater control panel,
- the fuse holder plate securing screws (five
screws),
- the dashboard mounting nuts.
12971R
12965-1R
61-6
http://vnx.su
HEATING
Air distribution unit
61
Remove :
- the flange bolt from the heater pipes,
- the windscreen wiper arms using tool
El. 1294-01,
- the upper seal for the plenum chamber as well
as the external air intake grille,
- the blown air unit,
- the air distribution unit mounting bolt.
13084S
13069R3
13085S
61-7
http://vnx.su
HEATING
Air distribution unit
61
REFITTING
Remove :
- the air distribution unit,
- the heater unit radiator.
Check :
- that the wiring is correctly routed behind the
dashboard,
- that the air ducts are correctly secured to prevent noises developing.
Change the steering wheel bolt (pre-bonded bolt,
tightening torque : 4.5 daN.m).
IMPORTANT : Before reconnecting the AIR BAG
cushion it is necessary to apply the air bag system
operational check procedure :
PRO61.3
61-8
http://vnx.su
AIR CONDITIONING
General
62
91096-3R1
62-1
http://vnx.su
AIR CONDITIONING
General
A
B
C
D
E
F
Passenger compartment
Engine compartment
Exterior air
To air mixing unit
Scuttle panel grille
Exterior or recirculated air
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Consumables:
-
Compressor oil
Coolant
R134a: 650 g 35
Compressor
SANDEN SD 7V 16
62-2
http://vnx.su
62
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Introduction
62
ISO selector on S8
Enter D17
n.61
PRECAUTION :
When carrying out checks using a multimeter, avoid using a contact tip on the connectors the size of which
could damage the clips and result in poor contact.
After repairing the air conditioning system, enter G0** on the XR25 keypad to erase the fault stored.
c11010.0
62-3
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - XR25 fiche
62
FI21761
c11010.0
62-4
http://vnx.su
AIR CONDITIONING
Fault finding - XR25 fiche
KANGOO
ALL TYPES
62
REPRESENTATION OF BARGRAPHS
If illuminated, this indicates a fault on the component in question, the associated text defines
the fault.
either
or
Engine running
Extinguished when the function or condition described on the fiche is no longer carried out.
Illuminated when the function or condition described on the fiche is carried out.
c11010.0
62-5
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Interpretation of XR25 bargraphs
Left-hand bargraph 1 illuminated
62
Fiche n 61
COMPUTER FAULT
NOTES
None.
AFTER
REPAIR
62-6
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
62
Fiche n 61
NOTES
None.
Before establishing communication between the XR25 and the control unit, check that you have switched
on the ignition.
Ensure that the XR25 is not the cause of the fault by trying to communicate with a computer on another
vehicle.
Check that the ISO interface is in position S8 and that you are using the latest version of the XR25 cassette
and the correct access code (D 17).
Check the battery voltage (U > 10.5 volts). Recharge the battery if necessary.
Check that the control unit connectors are engaged correctly.
Check that the air conditioning control unit is supplied correctly:
- earth on track 4 of the red 15-way connector
-+ after ignition on track 1 of the blue 30-way connector
-+ after ignition on track 6 of the red 15-way connector
-+ fuse board on track 5 of the red 15-way connector
Check that the diagnostic socket is supplied correctly:
track K
track L
track 6
track 3
If there is still no dialogue between the XR25 and the control unit, change the air conditioning control
unit.
AFTER
REPAIR
62-7
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Interpretation of XR25 bargraphs
Left-hand bargraph 2 illuminated
62
Fiche n 61
COOLANT SENSOR
XR 25 assistance:
NOTES
*02
None.
Low level
YES
NO
AFTER
REPAIR
62-8
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Interpretation of XR25 bargraphs
62
CONT
High level
YES
NO
AFTER
REPAIR
62-9
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
62
Fiche n 61
COMPRESSOR CONTROL
XR25 assistance :
NOTES
C.O.
C.C.1
open circuit
short circuit to 12 volts
Before any removal, enter G0** on the XR25 and reinitialise the system.
YES
NO
NO
AFTER
REPAIR
62-10
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Interpretation of XR25 bargraphs
62
CONT 1
YES
NO
NO
Check the continuity and absence of short circuits of the electrical wiring
between track 1 of the clutch and tracks 2 and 17 of the air conditioning control
unit 30-way connector.
Repair the electrical wiring if necessary.
For petrol vehicles:
Use the XR25 fiche which corresponds to the vehicle.
With the engine running, operate the AC then check on the XR25 fiche whether
the "Compression authorised or prohibited" status bargraph is illuminated.
Is the bargraph illuminated?
AFTER
REPAIR
YES
NO
62-11
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Interpretation of XR25 bargraphs
62
CONT 2
YES
NO
Check the continuity and absence of short circuits of the electrical wiring.
Repair if necessary.
Check that 12 volts is present on tracks 2 and 17 of the air conditioning control
unit 30-way connector.
Is 12 volts present?
YES
NO
AFTER
REPAIR
62-12
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Interpretation of XR25 bargraphs
62
Fiche n 61
NOTES
A2
Repair if necessary.
Check the continuity and insulation from earth and from 12 volts of the electrical wiring between tracks:
air recirculation
motor connector
B2
B3
27
26
AFTER
REPAIR
62-13
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
62
Fiche n 61
NOTES
C.O.
C.C.1
open circuit
short circuit to 12 volts
Check the condition of the earth of fan assembly (2) (the relay is controlled by 0 volt).
Repair the fan assembly earth if necessary.
Connect the XR25 and enter # 16. Check that the coolant pressure is approximately 20 bars.
If it is not, top up the coolant (operation of the cooling fan assembly is dependent on the coolant
pressure).
Check the condition of the wiring between the relay of fan assembly (2) and track 10 of the injection
computer.
Repair it if necessary.
Check the operating status of the relay by entering G23* on the XR25.
The fan assembly should be heard to knock.
Is the fan assembly heard to knock?
YES
Check the continuity and insulation from 12 volts of the electrical wiring
between track F2 and track 23 of the air conditioning control unit 30-way
connector.
Repair the faulty electrical wiring.
NO
AFTER
REPAIR
62-14
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
62
Fiche n 61
NOTES
C.O.
C.C.1
open circuit
short circuit to 12 volts
Check the continuity and insulation from 12 volts of the electrical wiring
between track M2 and track 22 of the air conditioning control unit 30-way
connector.
Repair the faulty electrical wiring.
NO
AFTER
REPAIR
62-15
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
62
Fiche n 61
+ 12 accessories
NOTES
AFTER
REPAIR
62-16
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
62
13
Fiche n 61
NOTES
First check that the air conditioning has been selected (selection on the control panel).
Check the continuity of the electrical wiring between track 5 of the injection computer and track 13 of
the air conditioning control unit 30-way connector (P.A. information).
Repair it if necessary.
Check the continuity of the electrical wiring between:
- track 51 of the injection computer and track 18 of the AC computer 30-way connector for D7F and E7J
engines,
- track 19 of the injection computer and track 18 of the AC computer 30-way connector for F8Q engines.
Repair it if necessary.
If the problem persists, check the injection fault finding procedure, as it is a problem related to the
injection.
AFTER
REPAIR
62-17
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Customer complaints
62
CHART 1
CHART 2
CHART 3
No heat
CHART 4
Too hot
CHART 5
CHART 6
CHART 7
CHART 8
CHART 9
CHART 10
Controls stiff
CHART 11
No cold air
CHART 12
Too cold
CHART 13
Performance poor
CHART 14
CHART 15
c11010.0
62-18
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 1
62
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
yes
yes
no
no
no
yes
A
AFTER
REPAIR
62-19
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 1
CONT
no
Repair if possible,
otherwise change the distribution unit or the
control panel.
yes
AFTER
REPAIR
62-20
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 2
62
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
no
See CHART 9.
no
no
yes
See CHART 1.
yes
Check the air intake circuit, scuttle panel
grille, particle filter, rain shield.
Are they correct?
yes
Check that the air extraction circuit
is not blocked.
Repair if necessary.
Does the fault persist?
yes
Is it a passenger compartment
air distribution problem?
no
Remove the heater radiator.
It must be blocked, clean or change it
(only valid for vehicles which have been
driven without the particle filter).
AFTER
REPAIR
62-21
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 3
62
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
yes
no
See CHART 1.
no
no
no
Visually check that
the action of the control moves
the mixing flap.
Does the flap move?
yes
Visually check
whether the flap travel is complete.
Is it complete?
yes
Check the cooling circuit
(correct filling and bleeding),
the condition of the circuit (pipes,
connections, conformity
of the circuit...).
Repair if necessary.
Does the fault persist?
yes
AFTER
REPAIR
62-22
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AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 3
CONT
no
no
no
yes
Check that there is no unwanted intake of
cold air into the passenger compartment
(seals, grommets, cables ...).
Repair if necessary
Does the fault persist?
yes
Check the air inlets (particle filter)
and outlets.
Partially blocked air inlets or outlets
reduce the flow of heated air
into the
passenger compartment.
Repair if necessary.
Does the fault persist?
yes
The heater radiator must be blocked. Remove
the radiator and clean or change it
(only valid for vehicles which have been
driven without the particle filter).
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-23
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 4
62
NO HEAT
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
yes
See CHART 2.
no
no
See CHART 1.
no
no
Check the level of coolant in the cooling
circuit.
NOTE: if the coolant level is too low, the circuit may become unprimed when driving at
low load and at idle.
Repair if necessary.
Does the fault persist?
yes
Visually check that moving the control
moves the mixing flap.
Does it move?
yes
Check the coolant circuit.
NOTE: fitting an oil, water or air cooler which
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-24
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 5
62
TOO HOT
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
no
See CHART 1.
no
yes
Check that the flap travel
is complete.
Is the travel complete?
yes
Check the operation
of the recirculation flap.
Is it jammed in the recirculation position?
yes
no
Check the operation
of the engine coolant thermostat.
Change the thermostat if necessary.
AFTER
REPAIR
62-25
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 6
62
None.
NOTES
no
yes
Remove the centre console and check
that the connection and sealing between the
air distribution unit and the heating duct to
the rear seats is correct.
Repair if necessary.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-26
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 7
62
NOTES
no
no
yes
See CHART 1.
yes
See CHART 2.
yes
See CHART 3.
yes
Ensure that there are no water leaks into the
passenger compartment which would
significantly increase the humidity level and
reduce the effectiveness of the demisting.
Locate the leak and repair it.
Does the fault persist?
yes
Is it an air distribution problem?
no
Is it an air flow problem?
no
Is it a heater performance problem?
no
Check that the recirculation flap is not
jammed in the recirculated air position
(see CHART 11).
Repair if necessary.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-27
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 8
62
None.
NOTES
yes
See CHART 2.
yes
See CHART 1.
yes
no
Is it an air distribution problem?
no
Check that the mixing flap
travel is complete.
Is is correct?
no
Readjust the cable.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-28
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 9
62
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
no
no
no
no
yes
Check the connections between the fuses
and the instrument panel connector.
Repair if necessary.
Does the fault persist?
yes
With the ignition on and the air conditioning
selected, position the ventilation at the
various speeds and check that 12 V
is present on the tracks of the
control panel connector:
- B5 in position 1,
- B4 in position 2,
- B2 in position 3,
- B3 in position 4.
Is 12 V present?
yes
Check the condition of the wiring between:
B2
A2
control
B3
A1
resistance
panel
B4
C4
unit
B5
C1
Is the wiring in good condition?
yes
A
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-29
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 9
CONT
A
Supply the fan with 0 and 12 V.
Does the fan operate?
no
no
yes
Check the condition of the electrical wiring
between the the fan and tracks A1 and A2 of
the resistor unit connector at the fan end.
Is the wiring in good condition?
yes
Change the resistor unit.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-30
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CONTROLS STIFF
(passenger compartment inconvenience)
CHART 10
None.
NOTES
no
no
yes
Unclip the cable from the side
of the unit and check the stiffness of
movement of each component, control
button and flap control
on the air distribution unit.
Is it correct?
yes
Change the flap control cable.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-31
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
CHART 11
62
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
no
no
no
yes
With the ignition on and air recirculation
selected, check that 12 V is present on track
A2 of the control panel.
Is 12 V present?
yes
Check the insulation and continuity of the
electrical wiring between:
computer
26
B3
resistance
blue 30-way
unit
connector
27
B2
connector
Is the wiring in good condition?
yes
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-32
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 11
CONT
no
no
yes
Check that the recirculation flap control
sprockets are in good condition and that the
flap is not jammed.
Repair if necessary.
Does the fault persist?
yes
Change the recirculation motor.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-33
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 12
NOTES
no
no
no
no
yes
Check the connections between track A1 of
the control panel and track 2
of the air conditioning computer.
Is the wiring in good condition?
yes
Check the electrical wiring between:
air
2
1
conditioning
compressor
computer
17
1
Is the wiring on good condition?
yes
Using the XR25, enter G21*
(compressor clutch control).
Does the compressor cut in?
yes
Change the
air conditioning computer.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-34
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 12A
NOTES
yes
no
no
no
Using the XR25, measure the pressures of the
coolant circuit by entering #16 or use
pressure gauges.
The pressures should be:
- high pressure
< 28 bars,
- low pressure
> 2 bars.
Is this correct?
yes
Check the connections between:
air
9
A
fluid
conditioning
pressure
computer
10
B
sensor
Is the wiring in good condition?
yes
Change the pressure sensor.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-35
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 13
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
yes
no
no
See CHART 1.
no
no
Check that the recirculation flap does not
remain in the recirculated air position.
Operate the control button
and check that the flap moves.
Does it move?
yes
Check that the action of the
heater control
moves the flap.
Does it move?
yes
Visually check that
the flap travel is complete.
Is it correct?
yes
Change the fan assembly.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-36
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 14
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
no
no
no
no
yes
yes
Check the tension of the compressor belt, the
clutch air gap and its condition.
Retension the belt or change
the compressor clutch.
Does the fault persist?
yes
Ensure that the recirculation flap is in the
recirculation position in air conditioning
recirculation mode.
Is it in this position?
yes
Check that the flap travel is complete,
readjust the cable if necessary.
Does the fault persist?
yes
Is it an air flow problem?
no
A
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-37
http://vnx.su
CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 14
CONT
no
no
yes
Check the cleanness of the
condenser wiring harness.
Clean or change the condenser.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-38
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 14A
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
yes
no
no
Connect the XR25 and enter G21*
(direct compressor control).
Does the compressor operate?
yes
If the fault persists,
change the compressor.
Check the pressure of the coolant circuit.
The compressor should cut in for:
- low pressure
2 bars,
- high pressure
28 bars.
Is this correct?
no
no
yes
Check the electrical wiring:
air
9
1
pressure
conditioning
10
4
sensor
computer
11
3
connector
and between the connector and the sensor.
Is the wiring in good condition?
yes
Change the pressure sensor.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-39
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 14B
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
no
yes
no
no
yes
Check the electrical wiring between:
air
9
1
pressure
conditioning
10
4
sensor
computer
11
5
connector
and between the connector and the sensor.
Is the electrical wiring in good condition?
yes
Change the pressure sensor.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-40
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 15
NOTES
no
no
no
Repair.
yes
Check that 12 volts is present on track 5 of the
low speed and high speed relays.
Is this correct?
yes
Check that the fan assembly is correctly
supplied with 12 volts and 0 volt.
Is this correct?
yes
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-41
http://vnx.su
AIR CONDITIONING
Fault finding charts
KANGOO
ALL TYPES
62
CHART 15
CONT
no
no
yes
Check the electrical wiring between:
heating and
9
1
interventilation
10
4
mediate
computer
11
3
connector
and between:
inter1
A
pressure
mediate
4
C
sensor
connector
3
B
Is the wiring in good condition?
yes
Change the pressure sensor.
If the fault persists,
change the fan.
AFTER
REPAIR
Check that the components which were removed are connected correctly.
Check that the system operates correctly.
c11010.0
62-42
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Associated checks
62
To use this function, enter G on the XR25 keypad, then the number of the command selected followed by
an asterisk.
G21* : compressor clutch control
G22* : fan low speed control
G23* : fan high speed control
G24* : recirculation motor control
G13* : end of fault finding
COMMAND MODE #
c11010.0
62-43
http://vnx.su
D7F ENGINE
AIR CONDITIONING
Wiring diagram
62
PRO13781
62-44
http://vnx.su
F8Q ENGINE
AIR CONDITIONING
Wiring diagram
62
PRO13948
62-45
http://vnx.su
E7J ENGINE
AIR CONDITIONING
Wiring diagram
62
PRO14441
62-46
http://vnx.su
AIR CONDITIONING
Wiring diagram
120
Injection computer
171
206
225
Diagnostic socket
234
236
248
260
Fuse box
319
320
419
466
Shunt box
597
700
62-47
http://vnx.su
62
AIR CONDITIONING
Evaporator
Remove:
- the windscreen wiper arms,
- the air inlet grille,
- the six plenum chamber closure panel (2) retaining bolts (A) and remove the plenum chamber,
- the evaporator protector in the plenum chamber.
62
0.6
0.8
0.8
1.2
0.8
2.1
2.1
0.8
REMOVAL
13826R
13831R
62-48
http://vnx.su
AIR CONDITIONING
Evaporator
Move aside the dashboard by removing:
- the six steering column mounting bolts,
- the four dashboard side retaining nuts and the
two bolts behind the ashtray assembly.
NOTE: take care to protect the sections of the
REFITTING
IMPORTANT
62-49
http://vnx.su
62
AIR CONDITIONING
Air blower unit
REMOVAL
REFITTING
IMPORTANT
Ensure that all of the seals are positioned correctly. Lubricate them with P.A.G. SP 10 oil.
62-50
http://vnx.su
62
D7F ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL
REFITTING
Remove:
- the compressor drive belt,
- the two connecting pipes (A),
- the retaining strut bolt (B),
- the three compressor retaining bolts (C).
and on the compressor to prevent the entry of humidity into the circuit.
IMPORTANT
13829R1
62-51
http://vnx.su
F8Q ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL
REFITTING
IMPORTANT
13947R
62-52
http://vnx.su
E7J ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL
REFITTING
Create a vacuum, then fill the R134a coolant circuit using the filling equipment.
NOTE: when refitting the connecting pipes on the
IMPORTANT
14229R
62-53
http://vnx.su
AIR CONDITIONING
Condenser
62
REMOVAL
Remove:
- the plastic air deflector on the upper crossmember,
- the seal (1),
- the upper crossmember (2),
- the retaining bolt (3),
- the two R134a coolant pipes (4) (fit plugs to
prevent the entry of humidity),
- the two radiator upper retaining bolts.
13828R
REFITTING
13830R
IMPORTANT
62-54
http://vnx.su
AIR CONDITIONING
Pressure relief valve
REPLACEMENT
13826R1
62-55
http://vnx.su
62
AIR CONDITIONING
Dehydration canister
REMOVAL
REFITTING
62
Check that the seals are in good condition and lubricate them with P.A.G. SP 10 oil.
Remove:
- the two radiator upper mounting bolts,
- the two mounting bolts which secure the pipes
to the dehydration canister.
Create a vacuum, then fill the R134a coolant circuit using the filling equipment.
Through the bumper, remove the two dehydration canister to condenser retaining bolts (1).
13828R1
62-56
http://vnx.su
AIR CONDITIONING
Connecting pipes
62
REFITTING
REMOVAL
Create a vacuum, then fill the R134a coolant circuit using the filling equipment.
NOTE:
- Pipes to compressor
retaining bolt:
- Pipes to pressure relief valve
retaining nut:
- Pipes to condenser
retaining bolt:
PRO62.4
62-57
http://vnx.su
2.1 daN.m
0.8 daN.m
0.8 daN.m
AIR CONDITIONING
Connecting pipes
62
REFITTING
REMOVAL
NOTE:
PRO62.5
version fitted with the E7J engine, in order to remove the cut off (1) retaining bolt.
62-58
http://vnx.su
AIR CONDITIONING
Connecting pipes
62
REFITTING
Create a vacuum, then fill the R134a coolant circuit using the filling equipment.
PRO62.6
62-59
http://vnx.su
0.8 daN.m
0.8 daN.m
AIR CONDITIONING
Electrical control
62
PRESSURE SENSOR
bly)
The pressure sensor (1) is located next to the
condenser on the pressure relief valvedehydration canister high pressure pipe.
REMOVAL
REFITTING
13827R
RECIRCULATION MOTOR
It is only possible to gain access to the recirculation motor following removal of the air blower
unit (refer to the relevant section) and therefore
the evaporator assembly.
62-60
http://vnx.su
AIR CONDITIONING
Computer
62
13825R
Description
Not used
AC operating information
Recirculation on/off
AC computer earth
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
62-61
http://vnx.su
AIR CONDITIONING
Computer
30-way connector (B)
Track
Description
Compressor control
L diagnostic information
Not used
K diagnostic information
Not used
TDC information
10
11
12
13
14
Not used
15
Not used
16
17
Compressor control
18
19
Not used
20
21
Not used
22
23
24
Not used
25
Not used
26
AC recirculation motor
27
AC recirculation motor
28
Not used
29
30
Not used
62-62
http://vnx.su
62
BODY SEALING
77 11 194 289
JULY 1997
The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
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.
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB6000
http://vnx.su
Sealing and
Soundproofing
Contents
Pages
64 BODY SEALING
Seals for side opening elements
Luggage compartment seal
Interior finishing seal for sliding
door and side opening
http://vnx.su
64-1
64-2
64-3
BODY SEALING
Seals for side opening elements
PRB6402
64-1
http://vnx.su
64
BODY SEALING
Luggage compartment seal
PRB6403
+ 20
-0
64-2
http://vnx.su
64
BODY SEALING
Interior finishing seal for sliding door and side opening
PRB6401
64-3
http://vnx.su
64
JULY 1997
The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB7000
http://vnx.su
Trim and
upholstery
Contents
Pages
FRONT SEAT FRAMES AND
75 RUNNERS
Pages
71-1
71-1
71-2
71-3
71-5
71-7
75-1
76 RUNNERS
76-1
72-1
72-2
73
Seatback trim
Folding seatback trim
Seat squab trim
77-1
77-3
77-4
73-1
78-1
78-4
74-1
79 SEAT ACCESSORIES
Locking cable - 3rd seat belt
retractor
http://vnx.su
79-1
PRB7101
REMOVING
B-pillar lining
PRB7102
REMOVING
71-1
http://vnx.su
71
PRB7103
REMOVING
13100S
71-2
http://vnx.su
71
71
PRB7104
REMOVING
13072R1
13073S
71-3
http://vnx.su
13248R
13249R
71-4
http://vnx.su
71
71
PRB7105
REMOVING
PRB7104
PRB7106
71-5
http://vnx.su
71
REFITTING
13250S
First protect the seats and then apply adhesive to the section(s) of
head lining as shown below:
- 6 beads, 4 mm dia.
- 2 beads, 4 mm dia.
At least two persons are required to carry out this operation.
NOTE: For bonding the headlining use a single-pot PU adhesive
(windscreen adhesive type).
71-6
http://vnx.su
71
PRB7107
Remove the centre console to fit the carpet at the front and take out the seats to fit it at the back.
Unclip the retaining pins.
71-7
http://vnx.su
72
PRB7201
REMOVING
13114R
Remove:
- the window winder handle,
- the pull handle for closing the door,
- the inside opening handle,
- the door storage compartment.
72-1
http://vnx.su
PRB7202
REMOVING
13102R
72-2
http://vnx.su
72
PRB7301
REMOVING
13103R
73-1
http://vnx.su
73
PRB7401
74-1
http://vnx.su
74
75
PRB7501
Runners
REMOVING
13178
13160R
75-1
http://vnx.su
PRB7601
REMOVING
13251R
76-1
http://vnx.su
76
77
PRB7701
REMOVING
13178-1
94121S
Remove :
- the seat,
- the head restraint and the upper parts of the
head restraint guide,
77-1
http://vnx.su
13177
77
13175
13176
77-2
http://vnx.su
77
REMOVING
13173
13174
77-3
http://vnx.su
77
PRB7702
REMOVING
13176-1
13172
77-4
http://vnx.su
78
PRB7801
REMOVING
13170
13171
78-1
http://vnx.su
13169
78
13167
Unclip :
- the cover for the third belt and the seatback,
and the upper parts of the head restraint
guide.
13168
13166
78-2
http://vnx.su
13165
13164
78-3
http://vnx.su
78
78
PRB7802
REMOVING
13162
13163
78-4
http://vnx.su
SEAT ACCESSORIES
Locking cable - 3rd seat belt retractor
13161
79-1
http://vnx.su
79
Electrical equipment
BATTERY - HEADLIGHTS
REAR AND INTERIOR LIGHTING
IMMOBILISER
INSTRUMENT PANEL
CONTROLS - SIGNALS
WIPERS
ELECTRICAL ASSISTANCE EQUIPMENT
WIRING
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition Anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRO80.1
http://vnx.su
Electrical
Equipment
Contents
Page
BATTERIE -PROJECTEURS
HEADLIGHTS
80 BATTERY
Page
84 CONTROLS - SIGNALS
Battery
Special notes
80-1
Headlights
Lens units and indicators
Remote adjustment
80-3
80-4
84-1
84-2
84-3
84-4
84-6
85 WIPERS
ECLAIRAGE
AND INTERIOR
ARRIERE LIGHTS
81 REAR
Courtesy light
Fuses
82
81-1
81-2
87
IMMOBILISER
Coded key immobiliser system
82-1
83 INSTRUMENT PANEL
Dashboard
Instrument panel
Fuel level sensor
Oil level sensor
Coolant temperature sensor
85-1
85-3
85-4
Relay plate
87-1
88 WIRING
83-1
83-6
83-10
83-12
83-13
http://vnx.su
88-1
88-3
88-8
BATTERY
Special notes
To remove the battery, slacken mounting (A).
80
It is vital :
to ensure that there is no sulphation on the
terminals,
to clean and grease the terminals if necessary,
to check that the nuts are correctly tightened
on the terminals. Incorrect contact could cause
starting faults or charging faults which could
cause sparks, making the battery liable to
explode,
to check the electrolyte level.
12422R
A - CHECKING
80-1
http://vnx.su
BATTERY
Special notes
80
B - PRECAUTIONS
2)
1)
DANGER = ACID
80-2
http://vnx.su
HEADLIGHTS
Lens units and indicators
NOTE : The lens unit and indicators cannot be separated.
80
ADJUSTMENT
REMOVAL - REFITTING
Disconnect:
- the battery,
- the connectors for the bulbs in the lens unit
and the indicator and for the remote
adjustment unit.
Remove the upper bolt (A).
Remove:
- the two bolts (D) from the bumper and the
three mounting bolts for the mudguard to allow the bumper to be partially removed,
- mounting bolt (C) and bolt (B) to remove the
lens unit.
13057R
13055R
80-3
http://vnx.su
HEADLIGHTS
Remote adjustment
REMOVING - REFITTING OF THE CONTROL
80
13056S
Remove the coin tray or the switch mounting depending on version and, passing your hand inside
the dashboard, unclip the control and push it outwards.
13057R1
80-4
http://vnx.su
81
After removing the bulb, remove bolt (C) and unclip the mounting (D).
13074R
13072R
Release the assembly towards the front and disconnect the connector.
81-1
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Symbol
Rating
Description
10
15
30
Consumer cut-out
30
Towing connection
30
20
15
15
Rear screen wash - wipe/ Reversing lights / Heated rear screen / Immobiliser
/ Lights on reminder buzzer
15
15
10
25
25
20
Heated seats
15
Air conditioning
15
25
Heating
81-2
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81
81
Symbol
Rating
Description
10
10
10
10
7.5
Left hand side light/ Instrument panel / Controls lighting / Radio / Heating Control Panel
7.5
7.5
15
Horn
10
Flasher unit
10
NOTE : To determine the exact position of the fuses, refer to the vehicle fuse box label or the Technical Note
"Wiring Diagrams".
81-3
http://vnx.su
81
12840S
Rating
D7F
F8Q
E7J
30A
Injection (238-279)
Injection (236)
30A
Fan assembly
(234)
Fan assembly
(234)
Injection (238)
Injection (120)
15A
5A
15A
Engine functions
(238-250-450-927)
15A
Injection / ignition
(236-250-663-664)
70A
Preheating unit
50A
Engine functions
(234-450-700)
60A
Dashboard (209-713)
Dashboard (209-713)
Dashboard (209-713)
60A
Dashboard (104-209)
Dashboard (104-209)
Dashboard (104-209)
10
60A
Electric windows
11
60A
ABS
ABS
ABS
81-4
http://vnx.su
IMMOBILISER
Coded key immobiliser system
82
GENERAL
NOTES
If the decoder unit recognises the code, the vehicle will be permitted to be started.
The immobiliser is activated a few seconds after
the key is withdrawn from the ignition and this is
shown by the flashing of the red immobiliser warning light on the instrument panel.
82-1
http://vnx.su
IMMOBILISER
Coded key immobiliser system
82
DESCRIPTION
With this system the engine immobiliser is activated 10 seconds after switching off the ignition
(shown by the flashing of the red engine immobiliser warning light).
Place the key head on a table with the metal insert facing downwards.
Use a small screwdriver as a lever as shown below,
ensuring that the end of the screwdriver is placed
on the lower section (E) of the key head. This allows the upper section to slide off the lower section.
13078R
- a coded chip (A) for controlling the immobiliser and the electronic unit for the remote control (B) allowing the opening
elements to be locked or unlocked (depending on equipment).
13077R
13076R
NOTE : To remove the metal insert, move the retaining tab aside before removing it. When refitting, check the insert is correctly clipped into position.
82-2
http://vnx.su
IMMOBILISER
Coded key immobiliser system
An antenna ring (C) around the ignition
switch, with an electronic unit which transmits
the key code to the decoder unit (D).
82
12967R1
13067R
Removal - Refitting
Remove the half cowlings from under the steering
wheel, release the antenna ring from the ignition
switch and disconnect its connector.
82-3
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IMMOBILISER
Coded key immobiliser system
82
Removal - Refitting
The dashboard must be partially removed to remove the decoder unit.
Remove:
- the steering wheel with the wheels straight,
- the half cowlings under the steering wheel,
- the knee protector under the steering column,
- the lights and wiper controls,
- the instrument panel surround,
- the instrument panel,
- the ashtray, its mounting and the two dashboard mounting bolts on the heating unit,
- the trim at the bottom of the dashboard on the
drivers side,
- the two speaker grilles on the dashboard,
- the dashboard mountings.
13065R1
Move the dashboard as far back as possible, disconnect the decoder unit and remove the two
mounting bolts (B) using a small ratchet fitted
with a Torx 20 socket.
82-4
http://vnx.su
IMMOBILISER
Coded key immobiliser system
-
OPERATION
When the immobiliser system is activated (approximately 10 seconds after cutting + after ignition feed), the red immobiliser warning light
flashes (slow flashing; 1 flash / second).
After switching the ignition on, the antenna ring
analyses the code from the key and transmits it to
the decoder unit.
If the code is not recognised by the decoder unit,
the injection warning light (petrol) illuminates for
a few seconds and extinguishes while the red immobiliser warning light flashes (rapid flashing).
If the code is recognised by the decoder unit, it
sends a code to the injection computer (petrol) or
coded solenoid valve (diesel) via the coded line
and extinguishes the red immobiliser warning
light (after approximately 3 seconds).
At this precise moment, one of several situations
may arise:
- The injection computer (petrol) or coded solenoid valve (diesel) has no reference code in its
memory :
the code sent to it is stored in its memory.
82
82-5
http://vnx.su
IMMOBILISER
Coded key immobiliser system
82
SPECIAL NOTES
Diesel vehicles
On these vehicles, the decoder unit is identical to
the decoder unit of a petrol immobiliser system.
When replacing it the new "diesel" part must be
configured by means of the XR25 test kit.
This configuration will enable the decoder unit to
check that the coded solenoid valve is operating
correctly (indicated by the immobiliser warning
light) (see diesel configuration).
82-6
http://vnx.su
IMMOBILISER
Coded key immobiliser system
82
PROGRAMMING PROCEDURE
D
5
6
Enter code
(fiche n 56),
bargraphs 19 RH and 19 LH must be illuminated (programming not carried out). If both of
these bargraphs are not illuminated, replace
the decoder unit (this unit has already been
used).
G
0
4
*
Enter
on
the XR25, ignition still off (bargraph 9 LH illuminates).
Switch the ignition on, the red immobiliser
warning light should flash more quickly and
the vehicle should be impossible to start.
Diesel configuration
On diesel vehicles the decoder unit must be configured in "diesel" using the XR25.
4. Switch the ignition on for a few seconds (without starting the engine) to send the code to
the injection computer or the coded solenoid
valve.
82-7
http://vnx.su
IMMOBILISER
Coded key immobiliser system
5.
REPLACING A KIT
(decoder unit plus two key heads)
Enter code
7.
8.
9.
10.
3.
6.
The code in the injection computer or coded solenoid valve cannot be erased with the security code
(using the number for the old kit) unless the decoder unit fitted to the vehicle has been programmed with a different code (which is the case in the
following procedure).
2.
1.
82
Enter command
82-8
http://vnx.su
IMMOBILISER
Coded key immobiliser system
NOTE: On petrol vehicles use the XR25 to check
that the injection computer has been correctly decoded (in injection fault finding).
Connect the XR25 to the diagnostic socket , position the ISO selector and enter the injection code :
bargraph 2 RH side (immobiliser) should be illuminated.
After entering
82
For diesel :
Ignition off, configure the decoder unit to
"diesel" (see diesel configuration using command
)
G
2
2
*
2
*
the message
NOTE
- petrol vehicles: Using the XR25, check the injection computer has been programmed with
the code. Bargraph 2 RH (immobiliser) should
be extinguished.
After entering
(*22),
If the display shows
82-9
http://vnx.su
IMMOBILISER
Coded key immobiliser system
12.
- Switch the ignition on and check the vehicle cannot be started and that the red warning light flashes (rapid flashing).
13.
82
After replacing the kit carry out a resynchronisation operation (see simple resynchronisation procedure, section 88).
82-10
http://vnx.su
IMMOBILISER
Coded key immobiliser system
82
If the decoder unit is supplied, switching the ignition on causes a coded signal to be sent from the
decoder unit to the injection computer or coded
solenoid valve (and the code is then programmed).
After entering
the message
the message
82-11
http://vnx.su
IMMOBILISER
Coded key immobiliser system
82
Enter the vehicle security code (number corresponding to the original key number).
After entering
the message
Diesel vehicle
Petrol vehicle
on the XR25 to allow the engine immobiliser system to operate again.
Enter code
on the XR25 or by disconnecting the battery (approximately 30 seconds) to allow the engine immobiliser system to operate again.
82-12
http://vnx.su
IMMOBILISER
Coded key immobiliser system
4. Enter mode
82
G
is displayed.
After determining the security code number (request from the local assistance network, example
DELTA Assistance for France, NVSR for the UK by
fax only) , carry out the following operations:
Bargraph 10 LH extinguishes.
The engine may be started.
The vehicle is protected once more :
approximately 10 minutes after switching
the ignition off (automatically),
after disconnecting the battery.
1. Ignition off, the red engine immobiliser warning light should flash (slow flashing).
is displayed.
82-13
http://vnx.su
IMMOBILISER
Coded key immobiliser system
DECODER UNIT CONNECTIONS (fullest version)
13063R
Track
Allocation
A1
A2
A3
A4
A5
A6
A7
+ after ignition
A8
Earth
A9
+ before ignition
B1
Infrared input*
B2
B3
Not used
B4
Door switch*
B5
B6
Not used
B7
Not used
B8
Door open*
B9
Door lock*
82-14
http://vnx.su
82
IMMOBILISER
Coded key immobiliser system
82
PRO12827
82-15
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IMMOBILISER
Coded key immobiliser system
KEY
104
120
123
138
140
141
142
154
178
180
181
213
225
247
249
260
503
711
82
FAULT FINDING
Ignition switch
Injection computer
Door locking button
Rear right door locking motor
Drivers door locking motor
Passengers door locking motor
Luggage compartment door locking motor
Luggage compartment door switch
Rear right door switch
Drivers door switch
Passengers door switch
Courtesy light
Diagnostic socket
Injection warning light and red immobiliser
warning light on instrument panel
Remote control receiver
Passenger compartment fuse box
Decoder unit
Coded solenoid valve
92656S2
82-16
http://vnx.su
INSTRUMENT PANEL
Dashboard
83
PRB5702
REMOVAL
12973S
83-1
http://vnx.su
INSTRUMENT PANEL
Dashboard
Remove:
- the half cowlings (three bolts),
83
12969-1R
12971R
12968S
12970-1R
83-2
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INSTRUMENT PANEL
Dashboard
83
Remove:
- the lower protector (four bolts),
12966R
12967-1R
12971-1R
83-3
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INSTRUMENT PANEL
Dashboard
- the fuse boards (five bolts).
12965-1R
83
12963R
Remove:
- the steering column mountings (two bolts, two
nuts),
Remove:
- the heating control unit (two bolts),
12965-1R1
12963R1
83-4
http://vnx.su
INSTRUMENT PANEL
Dashboard
- the loud speaker grilles,
- the dashboard mountings.
83
REFITTING
When refitting, it is important to ensure the various wires are correctly routed and have sufficient space so that the dashboard can be correctly
centred.
Renew the steering wheel bolt each time it is removed (pre-bonded bolt) for a steering wheel
with airbag.
Observe the correct tightening torque (4.5
daN.m).
IMPORTANT
Before reconnecting the drivers airbag cushion,
check to see if the system is operating correctly as
follows:
12964R
83-5
http://vnx.su
INSTRUMENT PANEL
Instrument panel
83
REMOVAL - REFITTING
REPAIR
Remove:
- the two bolts (A) and remove the upper half
cowling,
- the four bolts (B) and the two bolts (C).
12971R1
Remove the four bolts (D) and remove the instrument panel.
12969R
83-6
http://vnx.su
INSTRUMENT PANEL
Instrument panel
83
DESCRIPTION
electronic speedometer,
display : mileometer/trip recorder and clock
coolant temperature gauge,
fuel gauge,
warning light functions.
13054S
NOTE :
Under normal operating conditions, the oil level is only measured if the ignition has been switched off for
over one minute; otherwise the old oil level value is re-displayed.
If a fault is detected, however, an oil level measurement is made each time the ignition is switched on to
check if the fault is persisting.
It is normal to find that the oil level is not always the same:
- parking on a slope,
- too short a wait after running the engine for a short moment (especially when the oil is cold), ...
83-7
http://vnx.su
INSTRUMENT PANEL
Instrument panel
CONNECTION
(fullest
83
version)
13066S
Connector C (clear)
Track
Connector M (brown)
Allocation
Track
Allocation
Fuel gauge
+ before ignition
Not used
Not used
+ lighting
AT warning light
Not used
10
Not used
10
+ after ignition
83-8
http://vnx.su
INSTRUMENT PANEL
Instrument panel
Connector N (black)
Track
Allocation
Not used
Not used
Not used
Speed signal
10
Connector G (grey)
Track
Allocation
Earth
Not used
Not used
10
83-9
http://vnx.su
83
INSTRUMENT PANEL
Fuel level sensor
83
Mot. 1264
Mot. 1264-01
Mot. 1265
Mot. 1265-01
IMPORTANT :
- Do not smoke.
ASSEMBLY
97163R6
96420R2
83-10
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INSTRUMENT PANEL
Fuel level sensor
Disconnect the connector and the pipes on the
sender unit side.
83
CONNECTION
Special notes
Check that the seal is in good condition and replace it if necessary.
97162S
Fit the seal on the fuel tank first before fitting the
assembly.
Refit the pump and sender unit assembly in the
fuel tank by aligning it so that the indexing arrow
(F) is positioned in line with the longitudinal axis
of the vehicle, pointing towards the rear of the
vehicle.
DI8307
Track
Allocation
A1
Earth
A2
B1
B2
Not used
C1
+ pump
C2
- pump
Checking
97163R7
Indication
Value between
terminals
A1 and B1 (in )
4/4
7 maximum
3/4
54.5 7
1/2
98 10
1/4
155 16
Low fuel
300 20
83-11
http://vnx.su
INSTRUMENT PANEL
Oil level sensor
83
OPERATION
CHECKING
The sensor is deemed to be in open circuit for a value higher than 22 ohms.
The sensor is deemed to be in short circuit for a value lower than 4 ohms.
LOCATION
Example : F engine
When the ignition is switched on, the central display shows the oil level in a series of "blocks" for
approximately 30 seconds, before returning to
displaying the trip mileometer and total mileometer functions (or "odometer" function).
NOTE : Turning the trip mileometer reset button
before the end of the timed period will display
the "odometer" function.
98898R1
83-12
http://vnx.su
INSTRUMENT PANEL
Coolant temperature sensor
83
F engine
OPERATION
CHECKING
LOCATION
D engine
12535R1
E engine
11634R3
98711R4
83-13
http://vnx.su
CONTROLS - SIGNALS
Windscreen wiper stalk
REMOVAL -
REFITTING
84
CONNECTION
13061R
Track
12970R
Allocation
A1
Front timer
A2
A3
A4
A5
Not used
A6
A7
B1
B2
Rear timer
B3
Not used
B4
B5
Earth
B6
Not used
B7
Not used
84-1
http://vnx.su
CONTROLS - SIGNALS
Lights stalk
REMOVAL -
REFITTING
84
CONNECTION
13062R
Track
12970R1
Allocation
A1
A2
Not used
A3
A4
Horn
A5
A6
A7
B1
Side lights
B2
B3
B4
Not used
B5
Dipped headlights
B6
B7
84-2
http://vnx.su
CONTROLS - SIGNALS
Stalk mounting
84
REMOVAL - REFITTING
Remove the steering wheel and the two half cowlings (for vehicles with an airbag, refer to the removal of the rotary switch on the following page
or section 88 for special notes on removing the
steering wheel).
For vehicles with an airbag, observe the recommendations in the section " Special notes for
the rotary switch under the steering wheel" on
the following page or section 88 (drivers airbag).
12970R2
84-3
http://vnx.su
CONTROLS - SIGNALS
Rotary switch under steering wheel
This makes the electrical connection between the
steering column and the steering wheel.
84
REMOVAL - REFITTING
If it is being replaced, the new part is supplied ready centred by an adhesive label which will tear off
as soon as the steering wheel is turned for the first
time (fit with the wheels straight).
12970R3
12973R
84-4
http://vnx.su
CONTROLS - SIGNALS
Rotary switch under steering wheel
Special notes for refitting
Ensure the wheels are still straight.
Ensure the rotary switch under the steering wheel
is still immobilised before refitting.
If there is any doubt follow the method for centring described in section 88 "drivers airbag".
Renew the steering wheel bolt each time it is removed (pre-bonded bolt).
Observe the correct tightening torque (4.5
daN.m).
IMPORTANT
Before reconnecting the drivers airbag cushion,
check to see if the system is operating correctly as
follows:
IMPORTANT: if these instructions are not observed, the systems may not operate normally and
may be incorrectly triggered.
84-5
http://vnx.su
84
CONTROLS - SIGNALS
Ignition switch
84
REMOVAL - REFITTING
Position the ignition key in position 3 and tilt retaining lugs (H) while releasing the switch.
DI8404
13068R
84-6
http://vnx.su
WIPERS
Front windscreen wiper
85
El. 1294-01
Check that the motor is in the park position before refitting the wiper arms.
Remove:
- the wiper arms using tool El. 1294-01,
- the scuttle panel grille seal,
- the scuttle panel grille after removing the two
side covers and the two bolts and disconnecting
the washer pipe.
13069R
85-1
http://vnx.su
WIPERS
Front windscreen wiper
85
Check that the motor is in the park position before refitting the wiper arms.
13069R1
Remove:
- the motor shaft nut (B) and release the linkage
after noting its position,
- the three motor mountings.
Release the motor after disconnecting it.
85-2
http://vnx.su
WIPERS
Rear screen wiper
Tailgate version
13070R
85-3
http://vnx.su
85
WIPERS
Electric washer pump
This vehicle is fitted with a bidirectional electric
pump (E) which feeds fluid from the same reservoir to both the front and rear screen washers according to the electrical feed to the two track
connector (D).
REMOVAL - REFITTING
Feed
+ 12 Volts
Earth
85
The pipes are fed via the white end piece (1)
whilst the front windscreen washer is in operation.
Track
Feed
Earth
+ 12 Volts
The pipes are fed via the black end piece (2) whilst
the rear screen washer is in operation.
13069R2
85-4
http://vnx.su
12965R
1
2
3
4
5
6
7
87-1
http://vnx.su
87
8
4
87
L
1
5
2
95182R4
95182R2
CONNECTION
Track
CONNECTION
Allocation
Track
Allocation
+ timer
Door switch
Earth
+ side lights
Wiper control
Wiper park
+ washer pump
87-2
http://vnx.su
87
R
+
8
4
C
1
5
2
95182R5
95182R2
CONNECTION
Track
CONNECTION
Allocation
Track
Allocation
+ indicators
+ timer
+ central control
Earth
Earth
+ rear wiper
Not used
Earth
+ washer pump
87-3
http://vnx.su
87
86
87a
87
87
85
86
87a
30
85
30
95182R6
95182R6
CONNECTION
Track
CONNECTION
Allocation
Track
Allocation
86
+ relay control
86
+ accessories feed
85
Earth
85
Earth
30
30
87a
Not used
87a
Not used
87
Rear screen
87
87-4
http://vnx.su
13058R
CONNECTION
Track
Allocation
85
+ relay control
86
Earth
30
87a
Not used
87
87-5
http://vnx.su
87
WIRING
Heated rear screen
The heated grid applied to the inner face of the
window may be accidentally cut, making the part
of the grid affected inefficient.
DETECTION
88
BETWEEN LINES C AND A
Connect the - wire of the voltmeter to the - terminal of the rear screen.
Move the + wire towards line A (arrow); the voltage drops progressively.
If the voltage drops quickly, the filament must be
cut at this point (carry out this operation for each
filament).
DI8815
DI8814
88-1
http://vnx.su
WIRING
Heated rear screen
88
REPAIR
Using a small brush proceed to carry out the repair, applying a sufficiently thick coat. Where successive coats are applied allow drying time between each coat. Do not repeat the operation
more than three times.
However, if there is a run it will be possible to eliminate it using the point of a knife or razor blade
once the product is sufficiently hardened (after several hours).
The adhesive tape acting as a guide must not be
removed for one hour after application. The tape
must be torn off perpendicularly to the resistance
in the direction of the arrow. The varnish, applied
at an ambient temperature of 20oC, is completely
dry in three hours. At a lower temperature the
drying time should be slightly increased.
77324S
88-2
http://vnx.su
WIRING
Remote control for door locking
. GENERAL
2.
NOTE: The 10 seconds are shown by the illumination of the red immobiliser warning light
and bargraph 17 LH on the XR25 (code D56,
fiche n 56).
3.
Replacing or adding a remote control with immobiliser function without replacing the decoder
unit.
- If both remote controls (if fitted) are desynchronised, two resynchronisation procedures will have to be carried out (one for
each remote control).
1.
88
4.
88-3
http://vnx.su
WIRING
Remote control for door locking
Replacing or adding a remote control without immobiliser function without replacing the decoder
unit.
3.
- If both remote controls (if fitted) are desynchronised, two resynchronisation procedures will have to be carried out (one for
each remote control).
2.
If the vehicle does not have an immobiliser, the remote control does not have a special number. A
key head without a number may therefore be ordered.
1.
88
NOTE: The 10 seconds are shown by the illumination of bargraph 17 LH on the XR25 (code
D56, fiche n 56).
88-4
http://vnx.su
WIRING
Remote control for door locking
Ignition off:
1.
88
NOTE: The 10 seconds are shown by the illumination of the red immobiliser warning light
(if fitted) and bargraph 17 LH on the XR25
(code D56, fiche n 56).
2.
3.
12967R
Removal - Refitting
88-5
http://vnx.su
WIRING
Remote control for door locking
Move the dashboard as far back as possible, disconnect the decoder unit and remove the two
mounting bolts (B) using a small ratchet fitted
with a Torx 20 socket.
88
Removal - Refitting
Remove:
- the light diffuser, lifting it with a small screwdriver at points (A),
13065R
Replacement
For vehicles fitted with an immobiliser, refer to
section 82 (programming procedure). The decoder
unit is common to the immobiliser.
For vehicles without an immobiliser, carry out a
resynchronisation operation.
NOTE : Fault finding for the remote control system may be carried out using the XR25 (fault finding fiche n 56).
13073R
88-6
http://vnx.su
WIRING
Remote control for door locking
- the two courtesy light console mounting bolts
(B).
88
Remove the receiver and its printed circuit by separating tabs (F) (example: infrared receiver).
13072R
13075R
After removing the bulb, remove bolt (C) and unclip mounting (D).
13074R1
13074R2
88-7
http://vnx.su
WIRING
Airbags and seat belt pretensioners
88
GENERAL
96310-1S
MAB11197S
98124S
88-8
http://vnx.su
WIRING
Airbags and seat belt pretensioners
88
1) Function
In the event of an accident, the airbag prevents the head striking the steering wheel or dashboard.
It also reduces the maximum acceleration of the head, by absorption.
2) Trigger threshold
Generally speaking, there are four different basic situations.
OBSTACLE
DI8816
A
B
OBSTACLE
DI8817
Direction of travel
Centre of gravity
88-9
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Airbags and seat belt pretensioners
88
Here the airbag trigger speed depends on the angle of impact and the flexibility of the vehicle hit
in the direction of travel.
DI8818
A
B
C
DI8819
Direction of travel
Centre of gravity
Immobilised vehicle
- The airbag only reacts to deceleration in the direction of driving. A side impact or the vehicle rolling over
cannot trigger the airbag.
- The vehicles projectile energy is transformed into deformation energy of the front part of the vehicle.
Deceleration is greater when the deformation of the vehicle hit is less, meaning that the airbag will trigger
much earlier.
- The minimum speed at which the airbag is triggered is greater when the angle of impact is large (see
above).
- If, in a frontal impact, there is no deformation at the front pillars, or engine - gearbox - sub-frame impact,
the fact that the airbag was not triggered cannot be considered as a fault since the trigger speed may not
have been reached.
- The pretensioners always trigger at a lower speed than the airbag.
- Experience has shown that the impact speeds given by customers are often not correct. Their reactions are
generally reduced by shock: there is almost always confusion between the cruising speed before the impact and the actual speed of the impact which is thankfully much lower in most cases.
88-10
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Airbags and seat belt pretensioners
Various vehicle configurations are possible:
SPECIAL TOOLING
PRESENTATION
88
- pretensioners only,
XR25
NOTE :
92656S
88-11
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Airbags and seat belt pretensioners
XRBAG TEST UNIT (El. 1288)
88
96833G
PRD99498
IMPORTANT: It is not permitted to carry out measurements on these systems with an ohmmeter or
any other electrical measuring instrument: there
is a risk of triggering due to the operating current
of the instrument.
88-12
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Airbags and seat belt pretensioners
88
DESTRUCTION UNIT
96832R
88-13
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Airbags and seat belt pretensioners
88
When refitting the computer, it MUST be mounted on the vehicle before its connectors are reconnected.
COMPUTER
IMPORTANT
88-14
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Airbags and seat belt pretensioners
LOCATION OF THE COMPUTER
88
98716S
13059S
IMPORTANT :
The computer must be replaced after the pretensioners and airbags have been triggered.
Certain components will lose their nominal characteristics after the trigger energy has passed
through them.
98715S
88-15
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Airbags and seat belt pretensioners
IMPORTANT :
CONNECTION
When carrying out an operation under the vehicle (exhaust, bodywork, etc.), do not use a
hammer or transmit impacts to the floor without having removed the pretensioner fuse
and waited 5 minutes for the reserve capacity
to discharge (see section "Fuse allocation", in
the "Wiring diagram" technical note) or for vehicles with the airbag function, wait for 2 seconds for the unit to discharge automatically.
2 track connector
(located under the front seats)
88
Pretensioner triggering.
NOTE: The pretensioner trigger line connectors
short circuit (tab holder side) when they are disconnected, which prevents incorrect triggering of
the systems (aerial effect for example).
Track
NOTE : The computer and ignition modules are
normally fed from the vehicle battery.
A reserve capacity is however included in the
computer in case the battery is disconnected at
the start of the impact.
Allocation
+ Drivers pretensioner
- Drivers pretensioner
+ Passengers pretensioner
- Passengers pretensioner
+ After ignition
Warning light
Earth
10
+ Drivers airbag
11
- Drivers airbag
12
13
14
15
16
17
Shunt
18
19
Shunt
20
Not used
21
22
Shunt
23
Not used
24
Not used
25
26
Shunt
27
Not used
28
29
Shunt
30
Not used
88-16
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Airbags and seat belt pretensioners
88
This computer is then on standby and notes decelerations of the vehicle using the signal measured
by the integral decelerometer.
When a frontal impact of sufficient strength occurs it triggers the simultaneous ignition of the
pyrotechnic generators of the two seat belt pretensioners after receiving confirmation of detection of an impact by the electromechanical safety
sensor.
Under the action of the gases generated by the
system, a piston is displaced in its cylinder,
carrying with it a cable connected to the
corresponding central catch, thus enabling the
seat belt to be retracted (see pretensioner
section).
If the frontal impact is greater than this, the decelerometer triggers the ignition of the pyrotechnic
gas generators which inflate the driver and passenger airbags once the impact has been validated by the electromechanical safety sensor.
88-17
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Airbags and seat belt pretensioners
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DESCRIPTION
DI8802
96438S
A pretensioner includes:
- a special seat belt catch (A),
- a pyrotechnic gas generator and ignition
module (B).
DI8801R
88-18
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Airbags and seat belt pretensioners
88
SEAT BELTS
REFITTING
REMOVAL
IMPORTANT: The pyrotechnic systems (pretensioners) must not be handled near a heat source or
flame; there is a risk of triggering.
REMINDER: if the pretensioners have been triggered their computer MUST be replaced.
Remove:
- the pretensioner connector under the front
seat,
- the pretensioner assembly, after removing its
protective trim.
88-19
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Airbags and seat belt pretensioners
88
Warning light
on the instrument panel
shows the correct operation of the drivers airbag,
the passengers airbag and the pretensioners (depending on equipment).
DRIVERS AIRBAG
DESCRIPTION
It comprises:
- an inflatable cushion,
- a pyrotechnic gas generator and ignition
module.
These components cannot be separated.
96310-1S
88-20
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Airbags and seat belt pretensioners
88
Remove:
- the airbag cushion by its two Torx bolts (tightening torque: 0.5 daN.m) located behind the
steering wheel and disconnect connector (D),
12973R
88-21
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Airbags and seat belt pretensioners
SPECIAL NOTES FOR THE ROTARY SWITCH
UNDERNEATH THE STEERING WHEEL
88
REFITTING
REMOVAL
by ensuring that the wheels are straight on removal so that the track may be positioned in
the centre,
by immobilising the rotary switch rotor using
adhesive tape.
PRD99529
12970R4
If it is being replaced, the new part is supplied ready centred by an adhesive label which will tear off
as soon as the steering wheel is turned for the first
time (fit with the wheels straight).
88-22
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Airbags and seat belt pretensioners
88
SPECIAL CASES
PRD99530
IMPORTANT :
Refit the steering wheel and replace the prebonded bolt, ensuring its correct tightening torque (4.5 daN.m).
IMPORTANT:
If these procedures are not correctly observed the
systems may not operate correctly or may be
accidentally triggered.
88-23
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Airbags and seat belt pretensioners
88
LOCATION
98124S
Warning light
on the instrument panel
shows the correct operation of the airbags and
the pretensioners.
NOTE : this system is operational after the ignition
has been turned on. A vehicle fitted with a passengers airbag will be identified by a label in the
bottom corner of the windscreen on the passengers side, and by the word "Airbag" on the dashboard on the same side. Two additional labels on
the front window and the side of the dashboard
indicate that a child seat cannot be fitted to the
front seat. The passenger must not set his feet on
the dashboard or stick or pin objects to the dashboard (refer to the Drivers Handbook).
13060S
Each time the windscreen (or passenger door window) is replaced, remember to fit the labels showing that the vehicle is fitted with airbags.These
labels are available in a kit Part Number : 77 01
205 442.
REMINDER : The computer must be replaced after
the airbag has been triggered. Certain components will lose their nominal characteristics after
the trigger energy has passed through them.
88-24
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Airbags and seat belt pretensioners
Accessibility of passenger airbag ignition modules for fault finding
88
REMOVAL
The dashboard must be removed to reach the passenger airbag ignition modules.
IMPORTANT : The ignition module must be
checked using the XRBAG as indicated in the
"Fault finding" section.
13064S
88-25
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Airbags and seat belt pretensioners
88
REFITTING
IMPORTANT : The following safety advice MUST
be followed when refitting or replacing a passenger airbag module. If these instructions are not
followed the system may not operate normally
and could even cause a risk for the vehicle occupants.
IMPORTANT :
IMPORTANT :
88-26
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Airbags and seat belt pretensioners
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DESTRUCTION PROCEDURE
In order to avoid any risk of an accident, the pyrotechnic gas generators must be triggered before
the vehicle is scrapped or the part is scrapped.
96832R
PRETENSIONERS
IMPORTANT: Do not trigger pretensioners which
must be returned under warranty for a stalk problem. This makes analysis by the supplier impossible.
Return the part in the packaging of the new part.
96438R
88-27
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Airbags and seat belt pretensioners
88
96835S
96834S
88-28
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