N.T. 3218A DA03 - EA03: Follow The Instructions Regarding Cleanliness When Working On This Vehicle

N.T.
3218A
DA03 - EA03
SPECIAL FEATURES OF THE

F5R 740 ENGINE
(including related assemblies)
Follow the instructions regarding cleanliness

when working on this vehicle.
For all parts not dealt with in this Technical Note refer to Workshop Repair Manual
MR 312.
77 11 205 759 JULY 1999 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes by the manufacturer in the reference numbering system is forbidden without the prior written authority of
production of the various component units and accessories from which his vehicles Renault.
are constructed".
C RENAULT 1999
Contents
Pages Pages
07 VALUES AND SETTINGS 13 FUEL SUPPLY
Capacities - Grades 07-1 Specifications 13-1

Accessories belt tensioning 07-3 Supply pump 13-2
Timing belt tensioning procedure 07-4 Supply pressure / Pump output 13-3
Cylinder head tightening 07-21 High pressure pump 13-4
Tyres - wheels 07-22 Injection rail / Injectors 13-6
Brakes 07-23 Pressure sensor 13-11
Brake compensator 07-24 Anti-percolation system 13-13
Underbody height 07-25
Front axle angle checking values 07-27
Rear axle angle checking values 07-29
14 ANTI-POLLUTION
Oil vapours rebreathing 14-1
ENGINE AND PERIPHERALS Exhaust gas recirculation E.G.R. 14-2
10
ASSEMBLY Fuel vapours rebreathing 14-4
Identification 10-1
Oil pressure 10-2
Engine and transmission assembly 10-3
Sump 10-8 16 STARTING - CHARGING
Multi-function support 10-11
Alternator 16-1
Starter 16-4
11 TOP AND FRONT OF ENGINE

Timing belt 11-1
Cylinder head gasket 11-8
12 FUEL MIXTURE
Specifications 12-1
Inlet manifold 12-4
Exhaust manifold 12-6
Contents
Pages Pages
17 IGNITION - INJECTION 21 MANUAL GEARBOX
Static ignition 17-1 Identification 21-1

General 17-2 Gears 21-1
Installation 17-3 Capacities - Lubricants 21-2
Special features of direct injection 17-5 Consumables 21-3
Cleanliness / Safety 17-6 Parts which must always be repla-
Operation 17-9 ced 21-3
Injection fault warning light 17-10 Special features 21-4
Engine immobiliser function 17-11
Injection / AC strategy 17-12
Idle speed correction 17-13
Fuel pressure regulation 17-15 33 REAR BEARING ELEMENTS
Mixture regulation 17-16
Adaptive mixture correction 17-17 Brake hub / disc 33-1
Centralised coolant temperature Hub / disc bearing 33-2
management 17-18
Computer 17-19
Wiring diagram 17-22
36 STEERING ASSEMBLY
Mechanical power steering pump 36-1
19 COOLING Power steering unit 36-3
Filling - bleeding 19-1

Diagram 19-2
Coolant pump 19-3
Catalytic converter 19-4 MECHANICAL COMPONENT
37 CONTROLS
Master cylinder 37-1

20 CLUTCH Brake servo 37-3
Cover - Disc 20-1

Flywheel 20-4
62 AIR CONDITIONING
General 62-1
Compressor 62-2
Condenser 62-3
Connecting pipes 62-5
VALUES AND SETTINGS
Capacities - Grades 07
Capacity
Units in litres Grade
(approx.) *
Petrol engine When European Union countries and Turkey

(oil) draining
PETROL
- 15 °C
- 30 °C - 20 °C - 10 °C 0 °C + 10 °C + 20 °C + 30 °C
ACEA A2/A3 15W40-15W50
ACEA A1*/A2/A3 10W30-10W40-10W50
ACEA A1*/A2/A3 0W30-5W30
ACEA A1*/A2/A3 0W40-5W40-5W50
ACEA A1-98 standard

* Oil for fuel economy
5.1
F5R
5.4 (1)
Other Countries
If the lubricants specified for the European Union countries are not
available, the following specifications must be taken into account:
PETROL
- 15 °C
- 30 °C - 20 °C - 10 °C 0 °C + 10 °C + 20 °C + 30 °C
API SH/SJ 15W40-15W50
API SH/SJ 10W40-10W50
API SH/SJ 10W30
API SH/SJ 5W30
API SH/SJ 5W40-5W50
Oil for fuel economy:

API SJ-IL SAC GF2 standard
* Adjust using a dipstick

(1) Following replacement of the oil filter
07-1
VALUES AND SETTINGS
Capacities - Grades 07
Capacity
Units Grade Special features
in litres
JC5 All countries: TRANSELF TRX 75 W 80 W

3.1
gearbox (API GL5 or MIL-L 2105 G or D standards)
Protection to - 20 °C ± 2 °C for hot, temperate and

F5R
Glacéol RX cold climates.
cooling 7
(type D) Protection to - 37 °C ± 2 °C for very cold climates.
circuit
07-2
VALUES AND SETTINGS
Accessories belt tensioning 07
To remove the belt, turn the belt’s automatic ten- ALTERNATOR, POWER STEERING AND AIR
sioner in the direction indicated below using a 13 CONDITIONING
mm offset ring ended spanner. Clamp the tensio-
ner using a 6 mm hexagonal wrench (1).
15304R
A Crankshaft
15579-1R1 B Air conditioning compressor
C Alternator
WARNING: the accessories belt rests on the ridged D Power steering pump
part on the pulley (F). E Coolant pump
F Pulley
T Automatic tensioner
When refitting the belt, it is essential to ensure

that the tooth (X) inside the pulleys (timing side)
remains "free".
15110R
07-3
VALUES AND SETTINGS
Timing belt tensioning procedure 07
ESSENTIAL SPECIAL TOOLS
Mot. 799-01 Tool for immobilising pinions for

toothed timing belt
Mot. 1054 Top Dead Centre pin
Mot. 1368 Tool for tightening camshaft
pulleys
Mot. 1383 Pipe wrench for removing HP
pipes
Mot. 1448 Clip pliers for spring clips
Mot. 1453 Engine support tool
Mot. 1488 Tool for refitting camshaft
covers
Mot. 1512 Tool for fitting the camshaft
seals
Mot. 1526 Tool for setting the camshafts
Mot. 1535 Tool for immobilising the
camshaft pulleys
ESSENTIAL EQUIPMENT
Angular tightening wrench
There are two very distinct procedures for setting

the timing.
1st PROCEDURE
The first procedure is applied in the event of re-

placement of any components in the timing face
which do not require slackening of the camshaft
pulley(s).
Follow the instructions regarding cleanliness and

safety when working on the fuel circuit.
07-4
VALUES AND SETTINGS
Setting the timing
WARNING: it is essential to de-

grease the end of the cranks-
haft, the crankshaft pinion
bore and the crankshaft pulley
contact surfaces to prevent sli-
ding between the timing and
the crankshaft which could
destroy the engine.
Position the camshaft grooves

using Mot. 799-01 as indicated
in the diagram opposite.
It is essential that the grooves

are horizontal and offset
downwards.
15614S
Fit tool Mot. 1526 which is secured at the end of

the camshafts.
16077R
07-5
VALUES AND SETTINGS
Check that the crankshaft is at Top Dead Centre
and not in the balancing hole.
Correct position
15163-1S
Incorrect position
15163S
07-6
VALUES AND SETTINGS
The crankshaft groove (5) should be between the two marks on the en-
gine block.
15577R
The exhaust camshaft pinion mark should be opposite the cylinder posi-
tion sensor securing hole.
07-7
VALUES AND SETTINGS
Fitting the belt
When the timing belt is changed, it is essential to

change the timing tensioners and pulleys.
Check that the tensioner lug (1) is correctly posi-

tioned in the groove (2).
15201R
Refit:
- the timing belt,
- the pulleys (3) tightening
the mounting bolts to a tor-
que of:
• 5 daN.m for the M10 bolts
• 2.5 daN.m for the M8 bolts
- the crankshaft accessories
pulley bringing the bolt into
position without contact
with the pulley (clearance
between bolt and pulley
2 to 3 mm).
NOTE:
- the crankshaft accessories
pulley bolt can be re-used if
the length under the head
does not exceed 49.1 mm
(otherwise change it),
- do not coat a new bolt with
oil. However, if the bolt is
re-used, it is essential to coat
it with oil.
15578R
07-8
VALUES AND SETTINGS
Align marks (6) and (7) on the tensioner using a
6 mm hexagonal wrench at (B).
15256R
Pre-tighten the tensioner nut to a torque of 0.7

daN.m.
Tighten the crankshaft pulley bolt to a torque of

2 daN.m (Top Dead Centre pin Mot. 1054 still in
place).
NOTE: do not turn the tensioner anti-clockwise.
07-9
VALUES AND SETTINGS
Make a mark (C) indicating the
position of the camshaft pul-
leys in relation to the camshaft
bearing cap castings.
15778-1R
Remove camshaft setting tool Mot. 1526 and Top

Dead Centre pin Mot. 1054.
Carry out angular tightening of the crankshaft

pulley bolt to 115° ± 10°, while immobilising the
engine flywheel using a screwdriver.
15303S
07-10
VALUES AND SETTINGS
Turn the crankshaft two revolutions clockwise (ti- Incorrect position
ming end). Before the end of the two revolutions
(that is a half-tooth before alignment of the
marks on the camshaft pulleys and the camshaft
bearing cap castings), insert the Top Dead Centre
pin Mot. 1054 to be between the balancing hole
and the pinning hole, then bring the timing to its
setting point.
15163S
Remove the Top Dead Centre pin Mot. 1054.
Check that the tensioner marks are aligned and

repeat the tensioning procedure if they are not.
Then tighten the nut to a torque of 2.7 daN.m.
15163-2R
Checking the setting and the tension

Correct position
Checking the tension
Turn the crankshaft two revolutions clockwise (ti-

ming end), then pin the crankshaft just before the
end of the two revolutions aligning the camshaft
pulley and camshaft bearing cap casting marks
made previously.

15163-1S
07-11
VALUES AND SETTINGS
Checking the setting
Ensure that the tensioner

marks are positioned correctly
before checking the timing set-
ting.
Fit the Top Dead Centre pin

Mot. 1054 checking the ali-
gnment of the marks made
previously.
Fit (without using force) cams-

haft setting tool Mot. 1526
(the camshaft grooves should
be horizontal and offset down-
wards). If the tool does not en-
gage, the timing setting and
tensioning procedure must be
repeated.
15614S
16077R
07-12
VALUES AND SETTINGS
The second procedure is applied in the event of replacement of any
components which require slackening of the timing camshaft pulley(s).
Setting the timing
WARNING: it is essential to degrease the end of the crankshaft and the

crankshaft pinion bore, the crankshaft pulley contact surfaces and the
ends of the camshafts (timing end) and the camshaft pulley bores to
prevent sliding between the timing, the crankshaft and the camshaft
pulleys which could destroy the engine.
15614S
Position the camshaft grooves horizontally, as indicated on the diagram

above, using tool Mot. 799-01.
It is essential that the grooves are directed downwards.
This operation can be made easier by fitting the camshaft pulleys using
the old nuts, tightening them to a torque of 1.5 daN.m maximum.
07-13
VALUES AND SETTINGS
Fit tool Mot. 1526 which is secured to the end of Incorrect position
the camshafts.
15163S
16077R
Remove the old pulley nuts. It is essential to re-

place them with new nuts.
Pre-tighten the nuts, without locking them, with a

clearance of 0.5 to 1 mm between the nuts and
the pulleys.
Check that the crankshaft is pinned at Top Dead

Centre and not in the balancing hole (crankshaft
groove (5) should be between the two marks (1)
of the engine block).
Correct position
15114-1R
15163-1S
07-14
VALUES AND SETTINGS
When a timing belt is changed, it is essential to
Position the exhaust camshaft pulley mark oppo-

site the poition sensor thread.
NOTE: incorrect positioning of the exhaust cams-

haft pulley prevents starting of the engine.
Ensure that the tensioner lug (1) is correctly posi-

tioned in the groove (2).
15201R
Refit:
- the timing belt,
- the pulleys (3) tightening
the mounting bolts to a tor-
que of 5 daN.m in the case
of the ∅ 10 mm bolts and
2.5 daN.m in the case of the
∅ 8 mm. bolts.
15578R
Fit the crankshaft accessories pulley, pre-tightening the bolt (without fully tightening the bolt, clearance of
2 to 3 mm between the bolt and the pulley).
NOTE:
- the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed
49.1 mm (otherwise change it),
- do not coat the new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil.
07-15
VALUES AND SETTINGS
Check that there is still a clearance of 0.5 to 1 mm
between the camshaft nuts and pulleys.
Align tensioner marks (6) and (7) using a 6 mm

hexagonal wrench at (B).
15256R
Pre-tighten the tensioner nut to a torque of 0.7

daN.m.
Turn the timing face through six revolutions via

the exhaust camshaft pulley using tool Mot. 799-
01.
NOTE: during this operation, ensure that the pul-

leys do not come into contact with the nuts. If
they do, reposition them from time to time.
07-16
VALUES AND SETTINGS
Check that the tensioner marks are aligned and repeat the tensioning
procedure if they are not. Then tighten the nut to a torque of 2.8 daN.m.
Turn the exhaust camshaft pulley to position the mark opposite the pha-
sing sensor.
Tighten the crankshaft pulley bolt to a torque of 2 daN.m (Top Dead

Centre pin still in place in the crankshaft).
Make a mark (C) to indicate the position of the camshaft pulleys in rela-
tion to the camshaft bearing cap castings.
15578-1R
07-17
VALUES AND SETTINGS
Remove the Top Dead Centre pin. Incorrect position
Carry out angular tightening of the crankshaft

pulley bolt to 115° ± 10°, while immobilising the
engine flywheel using a screwdriver.
15163S
Fit camshaft pulley immobilising tool Mot. 1535

and secure it using a cover bolt.
15303S
Pin the crankshaft aligning the camshaft pulley

and camshaft bearing cap casting marks made
previously to ensure that the pin is correctly posi-
tioned in the pin hole and not in the crankshaft
balancing hole.
Correct position
16078R
Tighten the inlet camshaft pulley nut to a torque

of 3 daN.m, then turn it through an angle of 90°.
15163-1S
07-18
VALUES AND SETTINGS
Tighten the exhaust camshaft pulley nut to a tor-
que of 3 daN.m, then turn it through an angle of
45° then a second angle of 45° using tool Mot.
1368.
16218S
Remove camshaft setting tool Mot. 1526, cams-

haft pulley immobilising tool Mot. 1535 and Top
Dead Centre pin Mot. 1054.
Checking the setting and tension
Checking the tension
Turn the crankshaft two revolutions clockwise (ti-

ming side), then pin the crankshaft just before the
end of the two revolution aligning the camshaft
pulley and camshaft bearing cap casting marks.

07-19
VALUES AND SETTINGS
Checking the setting
Ensure that the tensioner

marks are positioned correctly
before checking the timing set-
ting.
Fit the Top Dead Centre pin

Mot. 1054 checking that the
marks made previously are ali-
gned.
Fit (without using force) cams-

haft setting tool Mot. 1526
(the camshaft grooves should
be horizontal and offset down-
wards). If the tool does not en-
gage, the timing setting and
tensioning procedure must be
repeated.
15614S
16077R
07-20
VALUES AND SETTINGS
Cylinder head tightening 07
CYLINDER HEAD TIGHTENING PROCEDURE
The bolts can be re-used if the length under the head does not exceed
137.7 mm (otherwise change all the bolts).
REMINDER: to obtain correct tightening of the bolts, remove any oil

from the cylinder head securing holes using a syringe.
Do not coat new bolts with oil. However, if the bolts are re-used, it is es-
sential to coat them with oil.
Tighten all the bolts to 2 daN.m in the order indicated below.
15659R
Check that all the bolts are correctly tightened to 2 daN.m then carry out
angular tightening (bolt by bolt) of 195° ± 6° in the order of tightening.
The cylinder head bolts are not re-tightened following application of

this procedure.
07-21
VALUES AND SETTINGS
Tyres - Wheels 07
Tyre pressure
when cold (in bar) (1)
Vehicle Rim Tyres
Front Rear
DA0 3 6.5 J 16 195/50 R 16 V 2.4 2.2
EA0 3 6.5 J 16 195/50 R 16 V 2.4 2.3
(1) During motorway use with full load.
Wheel nut tightening torque: 9 daN.m
Rim run-out: 1.2 mm
07-22
VALUES AND SETTINGS
Brakes 07
At the front At the rear
Vehicle Disc thickness (in mm) Disc thickness (in mm) Drum diameter (in mm)
Maximum Minimum Maximum Minimum Maximum (1) Minimum
DA0 3
24 21.8 8 6.3 - -
EA0 3
(1) Drum: maximum wear diameter (where applicable).
The disc run-out is 0.07 maximum
Lining thickness (in mm)
Vehicle Front (including support) Rear Brake fluid
New Minimum New Minimum
DA0 3 SAE J1703

18.3 6 11 5
EA0 3 DOT 4
07-23
VALUES AND SETTINGS
Brake compensator 07
BRAKING PRESSURE
Check pressure (1) (in bar)

Fuel level status
Vehicle
(driver in vehicle)
Front Rear
DA0 3 + 18
140 49 0
EA0 3
90966S
(1) The check is carried out using two pressure gauges arranged in an X formation.
07-24
VALUES AND SETTINGS
Underbody height 07
At the front At the rear Dimension X (in mm)
Vehicle
H1 - H2 = ... mm H4 - H5 = ... mm D and G
DA0 3 116 51 471
EA0 3 116 38 488
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 ex-
ceed 5 mm, the driver’s side always being the highest.
Any alteration to the underbody height also requires adjustment of the brake compensator (if fitted) and of
the headlights.
07-25
VALUES AND SETTINGS
Underbody height 07
MEASURING POINTS
16102R
H1 : radius of tyre under load

H2 : height measured between the lower surface of the sub-frame and the ground in line with the centre-
line of the wheel
H4 : radius of rear tyre under load
H5 : height measured between the centreline of the rear axle joint and the ground
88636-4R
07-26
VALUES AND SETTINGS
Front axle angle checking values 07
DA03
ANGLES VALUES POSITION OF THE SETTING

FRONT AXLE
CASTOR
4°03’ H5-H2 = 71 mm CANNOT BE

4°33’ ±30’ H5-H2 = 51 mm ADJUSTED
5°03’ H5-H2 = 31 mm
Maximum right /
left difference= 1°
93012-1S
CAMBER
- 0°12’ H1-H2 = 116 mm CANNOT BE
- 0°11’ ±30’ H1-H2 = 124 mm ADJUSTED
- 0°08’ H1-H2 = 130 mm
Maximum right /
93013-1S left difference= 1°
KINGPIN INCLINATION
10°36’ H1-H2 = 116 mm CANNOT BE

10°42’ ±30’ H1-H2 = 124 mm ADJUSTED
10°49’ H1-H2 = 130 mm
Maximum right /
93014-1S
PARALLELISM
Adjusted by
(For 2 wheels)
rotating track
rod sleeves
toe out
1 turn = 30’
UNLADEN (3 mm)
+ 0°10’ ± 10’
+ 1 mm ± 1 mm
93011-1S
POSITION FOR TIGHTENING RUBBER BUSHES
- UNLADEN -
81603S1
07-27
VALUES AND SETTINGS
Front axle angle checking values 07
EA03
ANGLES VALUES POSITION OF THE SETTING

FRONT AXLE
CASTOR
3°47’ H5-H2 = 83 mm CANNOT BE

4°17’ ±30’ H5-H2 = 63 mm ADJUSTED
4°47’ H5-H2 = 43 mm
Maximum right /
93012-1S
CAMBER
- 0°12’ H1-H2 = 116 mm CANNOT BE
- 0°10’ ±30’ H1-H2 = 125 mm ADJUSTED
- 0°06’ H1-H2 = 133 mm
Maximum right /
93013-1S left difference= 1°
KINGPIN INCLINATION
10°36’ H1-H2 = 116 mm CANNOT BE

10°44’ ±30’ H1-H2 = 125 mm ADJUSTED
10°52’ H1-H2 = 133 mm
Maximum right /
93014-1S
PARALLELISM
Adjusted by
(For 2 wheels)
rotating track
rod sleeves
toe out
1 turn= 30’
UNLADEN (3 mm)
+ 0°10’ ± 10’
+ 1 mm ± 1 mm
93011-1S
POSITION FOR TIGHTENING RUBBER BUSHES
- UNLADEN -
81603S1
07-28
VALUES AND SETTINGS
Rear axle angles checking values 07
VALUES POSITION OF THE
ANGLES SETTING
4 BAR AXLE REAR AXLE
CAMBER
CANNOT BE
- 0°50’ ± 15’ UNLADEN ADJUSTED
93013-2S
PARALLELISM
(For 2 wheels)
Toe-in CANNOT BE
UNLADEN ADJUSTED
- 0° 30’ ± 20’
- 3 mm ± 2 mm
93011-2S
POSITION FOR TIGHTENING

RUBBER BUSHES
- UNLADEN -
81603S1
07-29
ENGINE AND PERIPHERALS ASSEMBLY
Identification 10
Cubic
Type of Bore Stroke Compression
Engine Gearbox capacity
vehicle (mm) (mm) ratio
(cm 3)
DA03
F5R 740 JC5 1998 82.7 93 11.5/1
EA03
Manual to be consulted: Mot. F5R.
10-1
Oil pressure 10
Mot. 836 -05 Boxed kit for measuring oil

pressure
ESSENTIAL EQUIPMENT
Douille longue ou clé à tube de 22 mm
22 mm long socket or tube wrench
CHECK
The oil pressure check must be carried out while

the engine is warm (approximately 80 °C).
Contents of boxed kit Mot. 836-05.
87363R1
USE
B+F
Connect the pressure gauge in place of the oil

pressure switch.
Oil pressure
Idle 1 bar (minimum)
3,000 rpm 3 bars (minimum)
10-2
Engine and transmission assembly 10
Mot. 1040-01 Dummy mounting for

removing/refitting engine and
transmission assembly
Mot. 1159 Tool for retaining the engine on
the sub-frame
Mot. 1233-01 Threaded rods for lowering the
sub-frame
Mot. 1453 Tool for supporting the engine
TIGHTENING TORQUES (In daN.m) REMOVAL
Sub-frame front mounting bolt 6.2 Place the vehicle on a two post lift.
Sub-frame rear mounting bolt 10.5 Disconnect the battery.

Front right suspended engine mounting
cover to engine mounting bolt 6.2 Remove the engine undertray.
Front right suspended engine mounting
cover mounting nut 4.4 Drain:
- the cooling circuit via the lower radiator hose,
Rubber engine mounting to front left side - the gearbox and the engine (if necessary),
member support mounting nut 6.2 - the refrigerant circuit using filling equipment.
Shock absorber base mounting bolts 18
Brake caliper mounting bolt 4
Steering shaft yoke mounting bolt 3
Wheel bolt 10
Three point clamp nuts 2
Sub-frame - side member tie-rod bolts 3

10-3
Remove: SPECIAL FEATURES OF VEHICLES FITTED WITH A
- the front wheels and the mud shields, DRIVER’S AIR BAG
- the sub-frame - body tie-rods,
- the steering ball joints, WARNING
- the brake calipers (and the ABS sensors) and at-
tach them to the suspension springs, To prevent any risk of destruction of the rotary
- the shock absorber base bolts, switch under the steering wheel, follow the in-
- the heat shield (A) and the gearbox control ca- structions below:
ble, • Before the steering column and the rack are
- the protective plate (1) and unclip the fuel uncoupled, it is ESSENTIAL that the steering
pipes, wheel is immobilised with the wheels straight
- the fuel supply and return pipes. Fit plugs to using a "steering wheel immobiliser" tool for
maintain cleanness, the entire duration of the operation.
- the tie-rod (2) mountings, • If there is any doubt about the correct centring
- the catalytic converter clamp (3) and attach it to of the rotary switch, the steering wheel must
the body. be removed and the centring procedure descri-
bed in the "Air bag" section must be applied.
REMINDER: in this case, only qualified, trained

personnel must carry out the procedure.
Remove:
- the front bumper,
- the air filter unit and its support,
- the accelerator and clutch cables,
- the brake servo vacuum pipe (manifold end).
Remove the computer fasteners and fold back the

assembly on the engine.
15961R
- the horns,
- the two power steering pipe fasteners on the
sub-frame on the right-hand side,
- the steering shaft yoke nut and eccentric bolt
after pushing back the protector.
10-4
Remove: NOTE: it is essential to fit plugs on the pipes and
- the heating radiator hose using tool Mot. 1448, the pressure relief valve to prevent the
- the expansion bottle fasteners and move it introduction of moisture into the circuit and on
aside, the fuel pipes to keep them clean.
- the relay board and the electrical connector of
the engine connection unit, Fit engine retaining tool Mot. 1453 ensuring that
the strap is positioned correctly.
Remove the suspended engine mountings cover

and the engine tie-bar.
Place a shim between the gearbox and the sub-

frame.
Remove nut (1), then, using a copper hammer, tap

to detach the stud from the suspended engine
mountings fastener.
98756R
- the earth strap on the bulkhead,

- the air conditioning pipe fasteners on the
pressure relief valve,
- the starter supply wire.
15959R1
98754R
10-5
Fit the two tools Mot. 1159 as indicated below. Secure tool Mot. 1040-01 under the sub-frame.
98755R1
99024R2
Lower the lift until the tool comes into contact

with the ground.
Remove the sub-frame mounting bolts and re-

move the engine and transmission assembly by lif-
ting the body.
When starting to lift the body, be sure to remove

the catalytic converter and to extract the radiator
from its upper fasteners (then place it on the sub-
frame again).
NOTE: in the case of an operation which requires

separation of the engine/gearbox/sub-frame as-
sembly, take care to mark the position of the tools
15960R Mot. 1159 on the sub-frame.
10-6
REFITTING
The alignment of the sub-frame with the body

will be made easier by positioning two threaded
rods Mot. 1233-01 in the two front fasteners of
the body sub-frame.
Be sure to reposition the catalytic converter on lo-

wering the body onto the engine and transmis-
sion assembly.
Tighten the sub-frame mounting bolts to a torque

of:
- 6.2 daN.m at the front,
- 10.5 daN.m at the rear.
Refit in the reverse order to removal.
Fit the heat shields correctly.
Fit the caliper mounting bolts with Loctite

FRENBLOC and tighten them to the specified tor-
que.
Press the brake pedal several times to bring the

pistons into contact with the pads.
Carry out the following operations:

- fill the engine and gearbox with oil (if necessa-
ry),
- fill and bleed the cooling circuit (see section 19
"Filling - Bleeding").
Fill the refrigerant circuit using the filling equip-

ment.
10-7
Sump 10
T.Av. 1233-01 Tool for working on the sub-

frame - axle
TIGHTENING TORQUES (in daN.m)
Pre-tightening of sump bolts 0.8

Tightening of sump bolts 1.35 ± 0.15
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove the steering shaft yoke nut.
97390-1R2
10-8
Sump 10
Remove the sub-frame tie-rods mounting bolts and lower the sub-frame by approxi-
mately 100 mm.
13507R2
Drain and remove the sump.
10-9
Sump 10
REFITTING
Apply a spot of RHODORSEAL 5661 at (A) on ei-

ther side of bearing n° 1, and at (B) at the intersec-
tion of the crankshaft closing plate and the cylin-
der block.
15159-2R
Refit the sump with a new seal pre-tightening it

to a torque of 0.8 daN.m, then carry out a final
tightening of 1.35 daN.m in the order shown.
15195R
10-10
Multi-function support 10
TIGHTENING TORQUE (in daN.m)
Multi-function support bolts and stud 4.4 ± 0.4
REMOVAL
Remove:
- the alternator (see section 16 "Alternator").
- the air conditioning compressor fasteners and
attach it to the upper crossmember,
- the multi-function support removing the stud
(A).
15576R
REFITTING
Refit the support tightening the bolts and the

stud to a torque of 4.4 daN.m.
Refer to section 07 "Accessories belt tensioning"

for the tensioning procedure.
10-11
TOP AND FRONT OF ENGINE
Timing belt 11
Mot. 799-01 Tool for immobilising pinions

for toothed timing belt
Mot. 1054 Top dead centre pin
pulleys
pipes
Mot. 1453 Engine support
Mot. 1488 Tool for refitting camshaft co-
vers
seals
Mot. 1535 Tool for immobilising camshaft
pulleys
ESSENTIAL EQUIPMENT
TIGHTENING TORQUES (in daN.m or/and °) REMOVAL
Wheel bolt 10 Place the vehicle on a two post lift.

Pulley bolt: Disconnect the battery.
- M10: 5
- M8: 2.5 Remove:
- the front right wheel,
Tensioner nut 2.8 - the front right wheel arch and the engine un-
Crankshaft pulley bolt 2 + 115° ± 10° dertray.
Mounting bolt on suspended mounting 6.2 Fit the engine support Mot. 1453.
Intermediate timing cover bolt 2
High pressure pump mounting bolt 1
High pressure pipe union 2.5

98750R2
11-1
Timing belt 11
Remove : Remove:
- the suspended engine mountings cover and - the Top Dead Centre pin plug,
movement limiter assembly,
- the bolt (A) and slacken engine tie-bar bolt (B).
Raise the engine.
15102-1S
- the air resonator (1),

- the ignition coil and harness (2),
15424R3
Lock the accessories belt tensioner. To do this,

turn the tensioner towards the right and immobi-
lise it using a 6 mm hexagonal wrench (see section
07 "Accessories belt tensioning").
15617R
- the inlet manifold (3) (see section 12 "Inlet ma-

nifold"),
15579-1S
11-2
Timing belt 11
- the exhaust camshaft sealing plug (4),
- the high pressure fuel pipe using tool Mot.
1383 (5). For this operation, support the unions
using open wrenches.
Fit blanking pieces to maintain cleanness.
Remove:
- the high pressure fuel pump (6),
- the timing cover mounting bolts then remove
the covers (7).
15615R2
15578-3R
11-3
Timing belt 11
Setting the timing
Position the exhaust camshaft pulley mark (1) one

tooth before the phase sensor fastener (2). The
camshaft grooves must be towards the bottom
and almost horizontal as indicated below.
15740-1R
15614-1S
11-4
Timing belt 11
Insert pin Mot. 1054 to be between the balancing Correct position
hole and the setting groove of the crankshaft.
15163-1S
15163-2S
Incorrect position
Turn the engine slightly, in the same direction, en-

gaging pin Mot. 1054 at the setting point.
15163S
11-5
Timing belt 11
Remove the timing pulley immobilising the en-
gine flywheel using a screwdriver.
15303S
Slacken the timing belt using

the tensioner.
Remove the belt and the pul-

ley.
Take care not to let the cranks-

haft pinion fall as it does not
have a key.
WARNING: it is essential to de-

grease the end of the cranks-
haft, the crankshaft pinion
bore and the contact surfaces
of the crankshaft pulley to pre-
vent sliding between the ti-
ming and the crankshaft which
could destroy the engine.
15578S
11-6
Timing belt 11
REFITTING - the high pressure fuel pump and pipe (refer to
the procedure described in section 13 "High
When the timing belt is changed, it is essential to pressure pump"),
Replace the shim (1),
Refit:
- the timing belt (it is essential to follow the pro-
cedure described in section 07 "Timing belt ten-
sioning procedure"),
- the accessories belt (see section 07 "Accessories
belt tensioning procedure"),
- the Top Dead Centre pin plug applying a spot
of RHODORSEAL 5661 to the thread,
- the new exhaust camshaft sealing plug using
tool Mot. 1488,
16127R
Refit the inlet manifold (refer to the procedure

described in section 12 "Inlet manifold"),
15615S
15617S
- the air resonator and air intake pipe,

- the right-hand suspended engine mounting
tightening the bolts to the specified torque.
11-7
Cylinder head gasket 11
ESSENTIAL SPECIAL EQUIPMENT
Mot. 1054 Top Dead Centre pin

pulleys
pipes
Mot. 1488 Tool for refitting camshaft co-
vers
seals
Mot. 1530 Tool for removing injectors
Mot. 1532 Tool for removing the high
pressure rail
Mot. 1533 Tool for fitting injector seals
Mot. 1535 Tool for immobilising camshaft
pulleys
ESSENTIAL EQUIPMENT
Cylinder head testing equipment

TIGHTENING TORQUES (in daN.m or/and °) Follow the instructions regarding cleanliness and
Wheel bolt 10
Pulley bolt:
- M10: 5
- M8: 2.5
Tensioner nut 2.8
Crankshaft pulley bolt 2 + 115° ± 10°
Mounting bolt on suspended mounting 6.2
Intermediate timing cover bolt 2
Camshaft bearing cap casting bolt 1.2
Oil separator bolt 1.3
Injection rail mounting bolt 1.5
High pressure pump mounting bolt 1
High pressure pipe union 2.5
11-8
REMOVAL Remove:
- the air intake pipe and resonator,
Place the vehicle on a two post lift. - the ignition coil and harness,
- the inlet manifold (see section 12 "Inlet mani-
Disconnect the battery. fold"),
- the high pressure fuel pipe using tool Mot.
Remove: 1383 supporting the unions using open
- the front right wheel, wrenches.
- the front right wheel arch and the engine un-
dertray. Fit blanking pieces to maintain cleanness.
Drain the cooling circuit (via the lower radiator Remove:

hose). - the high pressure fuel pipe (see section 13
"High pressure pump"),
Fit the engine support tool Mot. 1159. - the suspended engine mountings,
- the exhaust camshaft sealing plug,
belt").
Position the engine at Top Dead Centre using the

pin Mot. 1054.
Remove the timing belt (see section 11 "Timing

belt").
Fit tool Mot. 1535 positioning the timing cover

bolt in hole (1), and remove the camshaft pulleys.
99024R2
16078R2
15960R
11-9
Remove the injection rail mounting bolts (fit the Remove:
sealing plugs). - the clips between the injectors and the rail,
- the injectors using tool Mot. 1530. To do this,
Fit the injection rail extraction tool Mot. 1532 (the turn the injector slightly to break the carbon
dowels and the threaded rods). deposit.
Extract the injector and position the plugs to

maintain cleanness.
16126R
16635R
Extract the injection rail. The injector retaining
clips remain in place and may allow the injection
rail to escape on removal.
11-10
Remove:
- the oil separator,
15612S
- the EGR valve/manifold

connecting pipe,
- the EGR valve support,
- the camshaft bearing cap
bolts.
15612-3S
11-11
Vertically detach the camshaft bearing cap casting
by tapping on the lugs (2) using a mallet and at
the same time, slide a screwdriver under the lug.
15660-1R
Remove:
- the camshafts,
15656S
11-12
- the earth strap,
- the catalytic converter/ ma-
nifold connecting bolts,
- the exhaust manifold strut,
- the harness supports,
- the coolant pipes on the ple-
num chamber,
- the tabs and the hydraulic
stops,
15657S
- the aluminium timing cover (1).
15574R
11-13
Remove the cylinder head.
15659S
Cleaning CHECKING THE MATING SURFACE
It is very important that the mating surfaces of Check whether the mating surface is deformed
the aluminium parts are not scratched. using a ruler and a set of feeler gauges.
Use the product Décapjoint to dissolve the part of Maximum deformation 0.05 mm
the gasket which remains attached.
Grinding of the cylinder head is prohibited.
Apply the product to the section to be cleaned;
wait approximately ten minutes, then remove it Test the cylinder head to detect any cracks.
using a wooden spatula.
It is advisable to wear gloves during this opera-

tion.
Do not allow the product to fall onto the paint-

work.
Your attention is drawn to the care which must

be taken when carrying out this operation to pre-
vent the introduction of foreign bodies into the
pressurised oil feed pipes leading to the cams-
hafts (pipes located both in the cylinder block and
in the cylinder head).
11-14
REFITTING Refit:
- the tabs,
When removing-refitting the cylinder head, - the camshaft lubricating the bearings.
observe the following points:
WARNING: do not apply oil to the cylinder head
- It is essential to reprime the hydraulic stops as cover mating surface.
they risk becoming empty after a very
prolonged time. NOTE: the camshafts are identified by a mark (A).
To check whether it is necessary to reprime
them, press the top of the stop at (A) with the
thumb. If the stop piston lowers, immerse it in
a container full of diesel.
15653-2R
Details of mark (A) :

- mark B is only used by the supplier,
- mark C identifies the camshafts:
A = Inlet,
E = Exhaust,
- mark D indicates the type of engine
For example:
15658R
F5RE616 330 11 38
D C B
11-15
Position the camshaft grooves as indicated on the diagram below (the
grooves must be horizontal and offset downwards).
15614S
NOTE: the mating surfaces must be clean, dry and

not greasy (avoid finger prints).
Using a roller (uneven) apply Loctite 518 to the

camshaft bearing cap casting mating surface until
it is reddish.
15641S
11-16
Refit:
- the camshafts.
15656S
- the camshaft bearing cap

castings. Tighten them to a
torque of 1.2 daN.m follo-
wing the order and the pro-
cedure indicated.
15612-2R
11-17
- the EGR valve support,
- the oil separator.
Using a roller (uneven) apply Loctite 518 to the

mating surfaces until they are reddish.
15643S
Tighten the oil separator to a

torque of 1.3 daN.m in the or-
der indicated.
15612R
11-18
Refit:
- the camshaft seals using tool Mot. 1512.
15644R
- the coolant pipes on the plenum chamber,

- the harness supports,
- the earth strap,
- the catalytic converter/manifold connecting
bolts,
- the exhaust manifold strut,
- the EGR valve/manifold connecting pipes,
- the EGR valve support.
11-19
Refit the injector seals using tool Mot. 1533 (refer to the procedure described in section 13 "Injection
rail/injectors").
Refit the injectors and the clips on the rail observing their positions.
16125S
Refit the injection rail (see section 13 "Injection rail/injectors").
11-20
Setting the timing
WARNING: it is essential to degrease the end of

the crankshaft, the crankshaft pinion bore and
the contact surfaces of the crankshaft pulley to
prevent sliding between the timing and the
crankshaft which could destroy the engine.
Refit:
- the timing belt (it is essential to follow the
procedure described in section 07 "Timing belt
tensioning procedure",
- the high pressure pump refitting the shim (1)
(see section 13 "High pressure pump"),
16127R
- the exhaust camshaft sealing plug using tool

Mot. 1488,
- the inlet manifold (see section 12 "Inlet
manifold"),
- the accessories belt (refer to the procedure
described in section 07 "Accessories belt"),
- the right-hand suspended engine mounting
and the engine tie-bar.
Before starting the engine, switch on the ignition

several times to run the petrol pump and prime
the fuel circuit.
IMPORTANT: if the exhaust manifold fastening

studs have been removed, change them and seal
using "LOCTITE FRENBLOC BLEUE".
11-21
FUEL MIXTURE
Specifications 12
Engine
Gear- Type of
Vehicle Cubic Emission
box Bore Stroke Compression Catalytic injection
Type Index capacity control
(mm) (mm) ratio converter
(cm 3) standard
Multipoint
direct
DA0 3 ◊ C110
JC5 F5R 740 82.7 93 1998 11.5/1 EU 96
EA0 3 ◊ C77
Static
ignition
Temperature in °C - 10 25 50 80 110
Air sensor 8525 to

1880 to 2120 760 to 860 - -
NTC type resistance in Ohms 10450
Coolant sensor
- 2140 to 2360 770 to 850 275 to 290 112 to 117
NTC type resistance in Ohms
Checks carried out at idle *

Fuel ***
Emissions of pollutants** (minimum
Idle speed (rpm) octane rating)
CO (%) (1) C02 (%) HC (ppm) Lambda (λ)
Super unleaded
750 ± 50 0.5 maximum 14.5 minimum 100 maximum 0.97 < λ < 1.03
(IO 95)
(1) at 2,500 rpm the CO should be 0.3 maximum.

* At a coolant temperature greater than 80 °C and after a constant engine speed of 2,500 rpm for
approximately 30 seconds.
** For the legislative values, refer to the specifications for the country concerned.
*** Compatible IO 91 unleaded.
12-1
FUEL MIXTURE
Specifications 12
DESCRIPTION BRAND/TYPE SPECIAL NOTES
Injection and ignition computer SIEMENS "SIRIUS 3H" 90 tracks

Injectors control computer SIEMENS "Driver" 55 tracks
Injection - Direct multipoint sequential
Ignition - Static with monobloc coil
Idle stepper motor PHILIPS Resistance : 53 ± 5 Ω at 25 °C
Incorporated in the throttle housing

CTS - MAGNETI
Throttle potentiometer Resistance of track : 1,200 ± 240 Ω
MARELLI
Resistance of cursor < 1,050 Ω
Magnetic sensor Variable reluctance type

ELECTRIFIL
(TDC and engine speed) Resistance = 200 to 270 Ω
Camshaft position sensor SAGEM Hall Effect sensor
Incorporated in the canister

Canister solenoid valve SAGEM
Resistance : 26 ± 4 Ω to 23 °C
Resistance of sensor track≈ 5 KΩ

Resistance of valve ≈ 6 KΩ
Track 1 : sensor signal
Track 2 : sensor earth
Track 3 : sensor supply
Track 4 : valve earth
Track 6 : valve supply
1 2 3
EGR solenoid valve SIEMENS
4 6
Resistance 1.78 ± 5 °C
Injector SIEMENS
Operation under high pressure
Fuel pressure sensor SIEMENS Resistance ≈ 3,8 Ω
Fuel pressure regulator SIEMENS Resistance between tracks 2 and 3 ≈ 2,084 Ω
Manifold pressure sensor DELCO Resistance ≈ 50 KΩ
Piezo-electric type.
Knock sensor SAGEM
Tightening to 2 daN.m
12-2
FUEL MIXTURE
Specifications 12
DESCRIPTION BRAND/TYPE SPECIAL NOTES
Heating resistance: 9 ± 1 Ω at 23 °C
Upstream oxygen sensor BOSCH Rich mixture > 750 ± 240 mV
Lean mixture < 150 ± 50 mV
Heating resistance : 3.4 ± 0.7 Ω at 23 °C

Downstream oxygen sensor BOSCH Rich mixture > 750 ± 70 mV
Lean mixture < 150 ± 50 mV
Monobloc coil with four outputs

Primary resistance≈ 0.5 Ω
Secondary resistance : 11 ± 1 KΩ
A : cylinder 1 and 4 coil supply

B : cylinders 2 and 3 coil supply
C : supply
D : common wire
Ignition coils SAGEM
A B C D
CHAMPION WARNING: long thread

Spark plugs
REC 14 PYC Tightening : 2.5 to 3 daN.m
Idle manifold pressure - 310 ± 40 mbars
upstream of the pre-catalytic

converter
1,500 rpm 59
Exhaust counter-pressure
3,000 rpm 176
4,500 rpm 409
5,500 rpm 520
Scavenge pump BOSCH Pressure : 4.5 ± 0.06 bars
12-3
FUEL MIXTURE
Inlet manifold 12
Inlet manifold ∅ 8 mounting bolt 2.5

Inlet manifold ∅ 6 mounting bolt 1
Side mounting bolt 2.5
Throttle housing bolt 1
REMOVAL - the pressure sensor (2) and air temperature sen-

sor (3) connectors,
Disconnect the battery. - the ignition coil,
- the ignition harness,
Remove:
- the air intake pipe,
- the air resonator (1),
15616R1
- the manifold side bolt (4),

- the inlet manifold mounting bolts and nuts.
15618R
12-4
FUEL MIXTURE
Inlet manifold 12
REFITTING
Replace the manifold seal and the EGR valve.
Refit:
- the inlet manifold replacing the seals and ob-
serving the tightening torque of the ∅ 6 mm
and ∅ 8 mm bolts and nuts.
15617R1
- the manifold side bolt,

- the coil (3) and the ignition harness (4),
- the air resonator and air intake pipe.
In the case of removal of the throttle housing, re-

fer to the procedure described in section 12
"Throttle housing").
12-5
FUEL MIXTURE
Exhaust manifold 12
Mot. 1495 Tool for removing the oxygen

sensor
TIGHTENING TORQUES (in daN.m) REMOVAL
Catalytic converter/manifold connecting nuts 1.2 Place the vehicle on a two post lift.
Exhaust manifold mounting nuts 1.8
Engine tie-bar 6.2
Oxygen sensor 4.5 Remove:
Shock absorber lower bolts 17 - the idle regulation solenoid valve (1),
- the EGR pipe (2),
Lower ball joint 6
16080R

- the front right mud shield,
- the ABS sensor connector,
- the front right brake caliper,
- the right lower ball joint mounting bolt,
- the lower shock absorber mounting bolts,
- the front right driveshaft,
- the oxygen sensor (3) using tool Mot. 1495,
12-6
FUEL MIXTURE
Exhaust manifold 12
- the exhaust strut (1),
- the manifold heat shields,
- the engine tie-bar,
- the manifold to catalytic
converter connection moun-
ting bolts.
Slacken the catalytic converter

/ exhaust line connection
clamp to move the catalytic
converter back a few centime-
tres.
Remove the exhaust manifold

nuts.
Tilt the engine and detach the

manifold from underneath.
15619R
REFITTING
Replace all the seals removed and the EGR pipe

clamps.
It is essential to tighten all the bolts to the speci-

fied torque.
Refit the heat shield.
IMPORTANT: in the case of removal of the ex-

haust manifold mounting studs, replace them and
seal using "LOCTITE FRENETANCH BLEUE".
16079S
12-7
FUEL SUPPLY
Specifications 13
The fuel supply circuit is composed of:
- the low pressure supply pump (placed in the gauge/pump assembly in the tank (1),
- a fuel filter located at the front of the tank (2),
- a high pressure mechanical pump located at the end of the camshaft (3),
- an injection rail (high pressure) fitted with the pressure sensor and regulator (which cannot be remo-
ved) (4),
- four electromagnetic injectors opening directly into the combustion chamber (5).
16310R
Removal of the interior of the high pressure pump and the injectors is prohibited. The pressure regulator
cannot be separated from the injection rail, it is essential to replace the assembly.
OBSERVE THE RULES REGARDING CLEANLINESS DESCRIBED IN THIS DOCUMENT (SECTION 17) STRICTLY
WHEN WORKING ON THE FUEL SUPPLY SYSTEM.
13-1
FUEL SUPPLY
Supply pump 13
The low pressure supply pump is immersed in the
fuel tank.
It is installed on the pump/gauge assembly and

has a low pressure regulator (4).
15754R
For the removal of the low pressure supply pump,

refer to the procedure described in section 19
"Pump - gauge" of Workshop Repair Manual
MR 312.
13-2
FUEL SUPPLY
Supply pressure / Pump output 13
Mot. 1311 Fuel pressure checking kit with

pressure gauge and adapters
ESSENTIAL EQUIPMENT
2,000 ml graduated receptacle
SUPPLY PRESSURE CHECK SUPPLY PUMP OUTPUT CHECK
Disconnect the fuel supply union (1) on the high Disconnect the supply union (R) located after the
pressure pump and fit in its place a "T" union fit- fuel filter and place it in the graduated receptacle.
ted with the checking pressure gauge Mot. 1311.
Run the supply pump shunting the control relay or
Start the engine to run the low pressure fuel using the diagnostic equipment.
pump.
Minimum output measured: 165 litres/hour.
Pressure measured: 4.5 ± 0.06 bars
Maximum pressure: 6 bars
15615R 15755R1
WARNING: THE PRESSURE READ UNDER THE

"FUEL PRESSURE" PARAMETER ON THE
DIAGNOSTIC EQUIPMENT CANNOT BE MEASURED
USING A PRESSURE GAUGE.
NO ATTEMPT MUST BE MADE TO READ IT IN ANY
CIRCUMSTANCES.
13-3
FUEL SUPPLY
High pressure pump 13
ESSENTIAL SPECIAL EQUIPMENT
Mot. 1383 Tool for removing high pressure

unions
TIGHTENING TORQUES (in daN.m) Disconnect the low pressure fuel supply and re-
turn unions (1). Fit appropriate plugs to maintain
High pressure pump mounting bolt 1 cleanness.
High pressure pipe union 2.5 Remove:

- the inlet manifold (refer to the procedure des-
cribed in section 12 "Inlet manifold"),
The high pressure pump is a mechanical pump lo-
cated at the end of the inlet camshaft.
Removal of the interior of the high pressure pump
is prohibited, it is sold complete.
WARNING: when removing the injectors, the rail

or the high or low pressure pumps, be aware of
the quantity of the fuel in the unions. Protect
areas susceptible to damage.
REMOVAL
WARNING:
Before carrying out any work, connect the after
sales service diagnostic equipment, enter into dia-
logue with the injection computer and check that 15615R3
the pressure in the rail is below 5 bars. Be aware
of the fuel temperature.
- the high pressure pipe (2) using tool Mot. 1383.
To do this, support the pump’s intermediate
Place the vehicle on a two post lift. steel union during slackening (3) and the rail
union (4),
Disconnect the battery. - the pump mounting bolts (5),
- the intermediate shim between the pump and
the cylinder head and clean its mating surface.
THE RULES REGARDING CLEANLINESS MUST BE
OBSERVED STRICTLY.
13-4
FUEL SUPPLY
High pressure pump 13
REFITTING
Replace the intermediate shim between the pump

and the cylinder head.
16127S
Fit:
- the pump on its support and tighten the bolts
to the specified torque,
- the pipe and tighten the unions to the specified
torque using tool Mot. 1383. To do this, sup-
port the intermediate steel unions of the pump
and the rail.
WARNING:
After all work, check that there are no leaks on
the fuel circuit. Run the engine at idle until the co-
oling fan assembly cuts in, then accelerate several
times while stationary. Check that there are no
leaks.
13-5
FUEL SUPPLY
Injection rail / Injectors 13
Mot. 1383 Tool for removing high pressure

unions
Mot. 1530 Tool for extracting injectors
Mot. 1532 Tool for removing the injection
rail
Mot. 1533 Tool for replacing injector seals
Rail mounting bolt 1.5 ± 0.2

High pressure pipe union 2.5 ± 0.3
Pressure sensor 2 ± 0.2
NOTE: removal of the intermediate union located

between the rail and the high pressure pipe and
removal of the pressure regulator is prohibited. In
this case, replace the injection rail.
The injectors are secured to the injection rail by

means of clips. They open directly into the cylin-
der head combustion chamber.
13-6
FUEL SUPPLY
REMOVAL
WARNING:
logue with the injection computer and check that
the pressure in the rail is below 5 bars. Beware of
the fuel temperature.

OBSERVED STRICTLY.
Disconnect the injection rail

and injector connectors.
Remove the inlet manifold (see

section 12 "Inlet manifold").
WARNING: when removing

the injectors, the rail or the
high or low pressure pumps,
be aware of the quantity of
the fuel in the unions.
Protect areas susceptible to
damage.
15613S
13-7
FUEL SUPPLY
Remove the high pressure union using tool Mot. NOTE: the injectors are secured to the rail by re-
1383 supporting the unions on the rail and on the taining clips. It is not necessary to remove them to
pump (1). extract the injection rail.
Fit blanking pieces to maintain cleanness. Remove the injector clips
Fit extraction tool Mot. 1530.
Rotate to break the carbon deposit on the injector

nozzle.
15615R4
Remove the fuel return pipe (low pressure).
Remove the rail mounting bolts.

16635R
Extract the rail using tool Mot. 1532.
Remove the injectors.
16126R
13-8
FUEL SUPPLY
REPLACEMENT OF THE INJECTOR NOZZLE SEAL • the seal on the cone and fit it slowly by hand,
It is essential to replace the Teflon injector seals.
To do this:
- clean the injector soaking it in a suitable, clean
thinner. The use of a metal brush, sandpaper,
or an ultrasound cleaner is prohibited,
- wipe the injector nozzle using a lint-free wipe,
- cut the seal carefully using circlip pliers taking
care not to mark the injector, clean the injector
again.
16375S
- remove the cone and retract the seal from the

injector using the body of tool Mot. 1533 pus-
hing it to its limit.
16373S
- place:
• the cone of tool Mot. 1533 on the injector,
16376R
16374R
13-9
FUEL SUPPLY
REFITTING
Change:
- the O-rings,
- the clips,
- the injector Teflon seals.
Position the injectors on the injection rail.
Fit the injector retaining clips taking care to position them correctly.
16125S
Fit:
- the injection rail,
- the pipe and tighten it to the specified torque using tool Mot. 1383 taking care not to place it under stress.
Refit the connectors.
WARNING:
After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan as-
sembly cuts in, then accelerate several times while stationary. Check that there are no leaks.
13-10
FUEL SUPPLY
Pressure sensor 13
Mot. 997 -01 Socket for removing the

pressure sensor
Injection rail pressure sensor 2 ± 0.2
REMOVAL
WARNING:
logue with the injection computer and check that
the pressure in the rail is below 5 bars. Be aware
of the fuel temperature.

OBSERVED STRICTLY.
Disconnect the injection rail connectors.
WARNING: when removing the injectors, the rail

or the high or low pressure pumps, be aware of
the quantity of the fuel in the unions. Protect
areas susceptible to damage.
13-11
FUEL SUPPLY
Pressure sensor 13
Disconnect the pressure sensor
(1) and unscrew it.
Fit a blanking piece to main-

tain cleanness.
15613R
REFITTING
Change the seal.
Fit the sensor then tighten it to the specified tor-

que.
Refit the connector.
WARNING:
After all work, check that there are no leaks on
the fuel circuit. Run the engine at idle until the co-
oling fan assembly cuts in, then accelerate several
times while stationary. Check that there are no
leaks.
WARNING: removal of the fuel pressure regulator

is strictly prohibited.
13-12
FUEL SUPPLY
Anti-percolation system 13
PRINCIPLE OF OPERATION
The anti-percolation system is controlled directly

by the injection computer.
The coolant temperature information is taken

from the injection coolant temperature sensor
(see section 17 "CCTM").
When the ignition is switched off, the injection

computer changes to monitoring mode. If the en-
gine coolant temperature exceeds the threshold
of 100 °C during the two minutes which follow
switching off of the engine, the fan low speed re-
lay is supplied.
If the temperature again falls below 96 °C, the fan

assembly relay is cut off (operation of the fan as-
sembly cannot exceed a duration of 10 minutes).
13-13
ANTI-POLLUTION
Oil vapours rebreathing 14
BASIC DIAGRAM OF THE CIRCUIT
13042R
1 Engine
2 Oil separator
3 Air filter housing
4 Inlet manifold
CHECK
To ensure correct operation of

the anti-pollution system, the
oil vapours rebreathing circuit
must be kept clean and in
good condition.
15612S
14-1
ANTI-POLLUTION
Exhaust gas recirculation E.G.R. 14
PRESENTATION OF CIRCUIT
16080R1
3 Inlet manifold
4 Exhaust manifold
5 EGR valve
14-2
ANTI-POLLUTION
Exhaust gas recirculation E.G.R. 14
TIGHTENING TORQUES (in daN.m) PRINCIPLE OF OPERATION
EGR valve mounting bolt 2.7 The valve is controlled by an RCO signal emitted
by the injection computer. The RCO signal permits
EGR valve support 1
modulation of the opening of the valve, and
consequently, the quantity of exhaust gas direc-
ted back towards the inlet manifold.
REMOVAL OF THE VALVE
The computer continuously carries out a test to
Remove: detect the position of the EGR valve flap.
- the lower gas recirculation clip (pipe/valve),
- the mounting bolts,
- if necessary, the valve support (1). OPERATING CONDITIONS
The parameters which determine the activation of

the EGR solenoid valve are as follows:
- air temperature,
- coolant temperature,
- atmospheric pressure,
- accelerator pedal position,
- engine speed,
- vehicle speed,
- battery voltage.
EGR is authorised if:

- the air temperature is greater than 10 °C,
- the coolant temperature is greater than 70 °C,
- the manifold pressure is between 300 and 650
mbars,
- the engine speed is between 1,700 and 3,800
rpm,
- a map (torque/engine speed/load potentiome-
ter) is above a given threshold.
15615R5
The computer controls the EGR except in the follo-
wing cases:
- in the case of a fault on one of the following:
REFITTING • coolant temperature sensor,
• air temperature sensor,
It is essential to change the valve seal. • pressure sensor,
• vehicle speed information,
• EGR valve.
PURPOSE OF THE EGR SYSTEM
The recirculation of the exhaust gas is used to re-

duce the nitrogen oxide (NOx) content of the ex-
haust gas.
Passage of the gas is authorised by the control of

an electromagnetic valve by the injection compu-
ter.
Programming conditions:
- engine speed 2,800 ± 100 rpm,
- manifold pressure of 630 ± 150 mbars,
- for a duration of approximately 30 seconds.
14-3
ANTI-POLLUTION
Fuel vapours rebreathing 14
BASIC DIAGRAM OF THE CIRCUIT CANISTER PURGE CONDITION
The canister purge solenoid valve is controlled by

track 4 of the computer when:
- the coolant temperature is greater than 70 °C,
- the air temperature is greater than 10 °C,
- the throttle position potentiometer is not at
no-load and is outside idle regulation.
It is possible to display the canister purge solenoid

valve opening cyclic ratio using the diagnostic
equipment by consulting the parameter "Canister
purge solenoid valve RCO".
The solenoid valve is closed if the value is below

1.5 % (minimum value).
CANISTER PURGE OPERATION CHECK
A system malfunction may result in an unstable

97393-1R1 idle or stalling of the engine.
1 Inlet manifold Check the conformity of the circuit (refer to the

2 Incorporated canister purge solenoid valve basic diagram) and the condition of the pipes to
3 Fuel vapours absorber (canister) with solenoid the tank (refer to Workshop Repair Manual
valve MR 312).
4 Tank
M Breather
14-4
STARTING - CHARGING
Alternator 16
IDENTIFICATION
Vehicle Engine Alternator Intensity
DA0 3
F5R 740 BOSCH 14 V 53 98 A 100 A
EA0 3
CHECK
After 15 minutes of warming up under a voltage of 13.5 volts.
RPM 100 Amperes
2,000 63 A
3,000 86 A
4,000 95 A
16-1
STARTING - CHARGING
Alternator 16
REMOVAL Lock the accessories belt tensioner using a ∅ 8
mm pin, then remove the belt (see section 07
Place the vehicle on a two post lift. "Accessories belt tensioning").
Remove:
- the wiring and computer fasteners and fold it
back onto the engine,
- the front right wheel arch.
15579-1S
Remove the power steering reservoir support fas-

teners and unclip the power steering reservoir.
Move aside the power steering reservoir and sup-

port assembly to allow access to the alternator.
98710S
Remove:
- the power steering pump pulley,
15576-2S
16-2
STARTING - CHARGING
Alternator 16
- the power steering pump. REFITTING
NOTE: on refitting, use the upper alternator and

power steering support mounting bolt to position
the alternator.
Take care not to crush the wiring between the

compressor and the power steering support.
Refer to section 07 "Accessories belt tensioning"

for the tensioning procedure.
15576-4S
Disconnect the alternator.
Remove the alternator mounting bolts.
15576-3S
Remove the alternator from above.
16-3
STARTING - CHARGING
Starter 16
IDENTIFICATION
Vehicle Engine Starter
DA0 3
F5R BOSCH 0001 106 012
EA0 3
REMOVAL From above
Place the vehicle on a two post lift. Disconnect the starter energising connector.
Disconnect the battery. Remove the starter mounting bolts.
From below
Remove:
- the manifold/catalytic converter connecting
rod,
- the pre-catalytic converter lower heat shield,
- the right-hand lower wishbone ball joint
mounting bolt,
- the shock absorber strut upper bolt,
- the starter supply wire.
Detach the ball joint and tilt the shock absorber

strut to uncouple the right-hand driveshaft.
Remove the air intake pipe and the resonator.
16316S
Remove the starter.

To do this:
- tilt the starter downwards,
- free the fastener on the engine block side.
REFITTING
15618S
16-4
IGNITION
Static ignition 17
Ignition coil bolts 1 to 1.5

Spark plugs 2.5 to 3
DESCRIPTION
The ignition system is of the static type supplied with signals from the engine speed and exhaust camshaft po-
sition sensors.
The power module is incorporated in the injection computer.
16124S
WARNING: the spark plugs fitted to the F5R engine are specific and have a long thread.
17-1
INJECTION
General 17
SPECIAL FEATURES OF THE MULTIPOINT DIRECT INJECTION FITTED TO THE F5R ENGINE
• SIEMENS "SIRIUS 3H" 90-way computer controlling the injection and the ignition. 55-way computer
controlling the opening of the injectors.
• Multipoint direct injection operating in sequential mode from the time the engine is started.
• Injection warning light on the instrument panel.
• Use of the engine overheating warning light in the event a major fault on the high pressure circuit.
• Special precautions relating to the engine immobiliser.

Adoption of a 2nd generation type engine immobiliser making a special computer replacement procedure
necessary.
• High pressure fuel circuit with an electric scavenge pump (low pressure) and a mechanical high pressure
pump.
• Idle speed
- nominal idle when warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rpm
• Idle speeds corrected in line with:

- air conditioning,
- power steering,
- coolant temperature,
- electrical balance.
• Maximum engine speeds:

- maximum engine speed when the coolant temperature is below 75 °C . . . . . . . . . . . . . . . . . . . . 5,900 rpm
- maximum engine speed for T > 75 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,500 rpm
• Canister purge solenoid valve controlled by opening cyclic ratio (RCO).
• Electric exhaust gas recirculation (E.G.R.) valve controlled by opening cyclic ratio (RCO).
• Use of two oxygen sensors placed upstream and downstream of the catalytic converters.
• Automatic configuration for AC operation by exchange of signals between computers.
• Control of the fan assemblies and of the coolant temperature warning light on the instrument panel by
the injection computer (CCTM).
17-2
INJECTION
Installation 17
16219
1 Fuel vapours absorber with solenoid valve

2 Injection computer
3 Pressure regulator
4 Manifold pressure sensor
5 Fuel pressure sensor
6 Idle stepper motor
7 Electric E.G.R. valve
8 Throttle position potentiometer
9 High pressure pump
10 Engine speed sensor
11 Ignition coil
12 Air temperature sensor
13 Knock sensor
14 Power steering pressure switch
15 Injectors control computer
17-3
INJECTION
Installation 17
3 Pressure regulator
5 Fuel pressure sensor
16 High pressure injection
rail
17 Oil separator
15613R1
4 Manifold pressure sensor 7 Electric E.G.R. valve

6 Idle stepper motor 8 Throttle position potentiometer
9 High pressure pump 19 Oxygen sensor (upstream)
11 Ignition coil
13 Knock sensor
18 Coolant temperature sensor
15617R2
16079R
17-4
INJECTION
Special features of direct injection 17
The multipoint direct injection operates in sequential mode from the time the engine is started.
The computer uses a camshaft sensor to detect the position of the engine and to determine which cylinder to
inject into and which spark plug to supply.
98406R1
A 1 revolution of the crankshaft

B 1 revolution of the camshaft
C Top dead centre 1 - 4

D Top dead centre 2 - 3
1 Cylinder 1 intake
2 Cylinder 2 intake
3 Cylinder 3 intake
4 Cylinder 4 intake
5 Long tooth
6 84° or 14 teeth
7 30 teeth
X Engine flywheel target

Y Camshaft target
Z Voltage supplied by the cylinder position sensor
NOTE: all values are expressed in degrees top dead centre.
The injection time is corrected in line with the fuel supply pressure.
IMPORTANT: IT IS ESSENTIAL TO FOLLOW THE INSTRUCTIONS REGARDING CLEANLINESS AND SAFETY

DESCRIBED ON THE NEXT PAGE WHENEVER ANY WORK IS CARRIED OUT.
17-5
INJECTION
Cleanliness / Safety 17
INSTRUCTIONS REGARDING CLEANLINESS WHICH IT IS ESSENTIAL TO FOLLOW WHEN WORKING ON THE
HIGH PRESSURE DIRECT INJECTION SYSTEM
RISKS RELATING TO CONTAMINATION
The petrol direct injection system is very sensitive to contamination. The risks incurred by the introduction of
contamination are:
- damage to or destruction of the high pressure injection system,
- seizing of a component or a component which is not sealed,
- destruction of the engine (by continuous injection into the cylinder).
All after sales service operations must be carried out under extremely clean conditions. This means that no im-
purities (particles a few microns in size) have penetrated into the high pressure injection system during remo-
val or into the circuits via the fuel unions.
The principles of cleanness must be applied from the filter to the injectors.
WHICH ELEMENTS CAUSE CONTAMINATION?
The elements which cause contamination are:

- metal or plastic splinters,
- paint,
- fibres:
• cardboard,
• brush,
• paper,
• clothing,
• cloth.
- foreign bodies such as hair,
- ambient air,
- etc...
WARNING: it is possible to clean the engine using a high pressure washer at the risk of damaging the connec-
tions. Also, the moisture may stagnate in the connectors and cause electrical connection problems.
The water may also be stored in the recesses of injectors and spark plugs opening directly into the cylinder.
17-6
INJECTION
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
• Ensure that the plugs for the unions which you wish to open are available (bag of plugs sold by the Parts
Department).
The plugs can be used only once. After use, they must be thrown away. (Cleaning is not sufficient to make
them reusable).
• Ensure that plastic bags which will hermetically seal several times are available for storing removed parts.
There is less risk of parts stored in this way being subjected to impurities. The bags can be used only once.
After use, they must be thrown away.
• Ensure that lint-free cleaning wipes are available (wipes with SODICAM part numbers). The use of conven-
tional cloth or paper is prohibited. In fact, these create lint and may contaminate the system’s fuel circuit.
Each wipe can be used only once.
CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE THE FUEL CIRCUIT IS OPENED
• Use new thinner for each operation (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinner to clean the parts to be removed, the tools which will be used and the part of the
workbench used.
• Wash your hands before and during the operation if necessary.
• When using protective gloves, cover leather gloves with latex gloves (available from SODICAM).
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is opened, it is essential to plug the openings which could allow contamination to en-
ter. The plugs to be used are available from the Parts Department. They must not be reused in any circum-
stances.
• Reseal the bag hermetically, even if it has to be re-opened only a short time later. The ambient air carries
contaminants.
• All components of the injection system which are removed must, after being plugged, be stored in a her-
metically sealed plastic bag.
• After opening the circuit, the use of a brush, thinner , a blower, a scraper, or a conventional cloth is strictly
prohibited. In fact, these elements are liable cause the entry of impurities into the system.
• If a component is replaced with a new one, do not remove this from its packaging until it is to be fitted on
the vehicle.
• When cleaning a mating surface, use lint-free absorbent paper. Start from the centre of the part and clean
gradually towards the outside to push away any impurities.
17-7
INJECTION
DI1325
17-8
INJECTION
Operation 17
OPERATION OF THE DIRECT INJECTION
The low pressure pump (also called the scavenge pump) supplies the HP pump, via the filter, under a pressure
of 4.5 bars.
The sole purpose of the HP pump is to supply the output which it directs towards the rail. The pressure regula-
tor located on the rail modulates the high pressure values in line with the requirements of the computer and
the pressure sensor data. The fuel circulates in the rail to supply each injector.
The computers:
- determine the pressure value necessary for correct operation of the engine, then control the pressure re-
gulator. They check that the pressure value is correct by analysing the value transmitted by the HP sensor
located on the rail.
- determine the injection time necessary to supply the correct quantity of fuel, and the start of the injection.
After determining these two values, they control each injector individually. The system can inject fuel into
the engine at a pressure between 50 to 100 bars,
- control the ignition.
The system consists of:

- a low pressure pump (1) located in the intake assembly,
- a fuel filter (2),
- a high pressure pump (3) located at the end of the camshaft,
- a pressure regulator and a pressure sensor (4) installed on the rail,
- an injection rail (5),
- four electromagnetic injectors (6),
- various sensors (coolant and air temperature, pressure sensor, ...),
- a 90-way injection computer and a 55-way injector control computer.
16310R1
17-9
INJECTION
Injection fault warning light 17
Vehicles which operate with the multipoint direct injection system use two injection warning lights illumina-
ted for a few seconds every time the ignition is switched on:
- the injection warning light used in the event of a minor fault,
- the coolant temperature warning light:
• illuminated if the coolant temperature is above 118 °C,
• flashing in the event of a major injection fault making it necessary to stop the engine as soon as possi-
ble.
PRINCIPLE OF ILLUMINATION OF THE MINOR INJECTION FAULT WARNING LIGHT
In the event of a minor high pressure injection system fault, the warning light illuminates. These faults are:
- injector failure,
- low pressure operation fault,
- inter-computer connection problem,
- fuel pressure sensor fault,
- excessive pressure.
If a fault is present when the ignition is switched on, the warning light illuminates for a few seconds, extin-
guishes briefly then illuminates again depending on the fault.
PRINCIPLE OF ILLUMINATION OF THE COOLANT TEMPERATURE WARNING LIGHT
In the event of a major high pressure injection system fault, the engine overheating warning light flashes. In
this case, it is essential to switch the engine off as soon as possible. These faults are:
- fuel pressure regulator fault (pressure above 125 bars),
- pressure sensor fault (pressure above 125 bars),
- jamming of the EGR valve.
In this situation, the scavenge pump (low pressure), the ignition and the injection are cut off after a few se-
conds.
17-10
INJECTION
Engine immobiliser function 17
This vehicle is fitted with an engine immobiliser system which is controlled by a random rolling code key reco-
gnition system.
REPLACEMENT OF AN INJECTION COMPUTER
The injection computers are supplied without a code but they can all be programmed with one.
When a computer is replaced, it must be programmed with the code of the vehicle and the correct operation
of the engine immobiliser function must be checked.
To do this, simply switch on the ignition for a few seconds without starting the engine then switch it off. With
the ignition off, the engine immobiliser function comes into operation after approximately 10 seconds (the
red engine immobiliser warning light flashes).
WARNING:
In the case of this engine immobiliser system, the computer retains the engine immobiliser code for life.
Furthermore, this system does not have a security code.
Consequently, it is prohibited to carry out tests using computers borrowed from the warehouse or another
vehicle which must then be returned.
It will not be possible to erase the code.
17-11
INJECTION
Injection / AC strategy 17
THE COMPRESSOR IS OF THE VARIABLE CUBIC CAPACITY TYPE
INJECTION COMPUTER/AC COMPUTER CONNECTION
The injection computer is connected to the AC computer by two wires:

- one wire from the injection computer to track 10 of the AC computer. The compressor operation authori-
sation or prohibition information is sent along this wire.
- one wire from the AC computer to track 23 of the injection computer. This is for a power absorbed infor-
mation signal.
When the AC switch is pressed, the AC computer requests operation of the compressor.
The injection computer authorises or prohibits engagement of the compressor and imposes a modified idle
speed. In this case, the engine speed may reach 200 rpm.
COMPRESSOR OPERATION STRATEGY
During certain phases of operation, the injection computer prohibits operation of the compressor.
Engine starting strategy
Compressor operation is prohibited for 10 seconds after the engine is started.
Overheating protection strategy
The compressor is not engaged if the coolant temperature is above 110 °C.
17-12
INJECTION
Idle speed correction 17
IDLE SPEED CORRECTION IN LINE WITH THE TEMPERATURE
COOLANT (° C) Idle speed reference (rpm)
- 40 1,360
- 30 1,264
- 20 1,200
- 10 1,200
0 1,200
10 1,152
20 1,104
30 1,056
40 992
50 880
60 800
70 752
80 752
90 752
100 752
110 800
120 848
IDLE SPEED CORRECTION IN LINE WITH THE INLET MANIFOLD PRESSURE
In the event of failure of the manifold pressure sensor, the idle sped is increased to 1,020 rpm.
17-13
INJECTION
Idle speed correction 17
POWER STEERING PRESSURE SWITCH - INJECTION COMPUTER CONNECTION
The injection computer receives information from the power steering pressure switch (which can be dis-
played on the diagnostic equipment). This depends on the pressure in the hydraulic circuit and on the fluidity
of the power steering fluid. The higher the pressure, the more energy is used by the power steering pump.
The injection computer alters the engine idle speed to a speed of 815 rpm.
ELECTRICAL CORRECTION IN LINE WITH THE BATTERY VOLTAGE AND THE ELECTRICAL BALANCE
The purpose of this correction is to compensate for the drop in voltage due to operation of a power consu-
ming component while the battery is at low charge. To do this, the idle speed is increased, thus permitting
the rotation of the alternator to be increased and, consequently, the battery voltage.
The lower the voltage, the more significant the correction. Therefore the engine speed correction is variable.
It begins when the voltage falls below 12.7 Volts. The idle speed may reach a maximum 910 rpm.
ADAPTIVE IDLE SPEED CORRECTION
The adaptive idle speed correction only takes effect if the coolant temperature is above 70 °C, 30 seconds af-
ter starting the engine and if the idle regulation phase is active (no-load and vehicle stationary).
The idle adaptation value makes it possible to reset the regulation in line with the age and variations of the
engine.
PARAMETER F5R 740 engines
Nominal idle speed X = 750 rpm
Idle RCO 9 % ≤ X ≤ 15 %
Idle RCO adaptation value Limit:

- minimum : - 6 %
- maximum : +6 %
Every time the engine is switched off, the computer resets the stepper motor to its lower limit.
IMPORTANT: it is essential, after erasing the computer memory, to start the engine and then switch it off to
permit resetting of the potentiometer. Start the engine again and let it run at idle so that the adaptive cor-
rection can take place.
17-14
INJECTION
Fuel pressure regulation 17
The fuel pressure is regulated by the computer by supplying a regulator (1) located on the injection rail. This
regulator is controlled by a reference value which takes into account the variations and the age of the en-
gine. This control reference value can be displayed by the diagnostic equipment in "parameters" mode.
The fuel pressure regulation takes into account the following components:
- the injection rail pressure sensor,
- the coolant temperature sensor (for the starting phase),
- the engine speed sensor,
- the throttle position potentiometer.
15613R2
The pressure read under the "fuel pressure" parameter should be between 45 and 100 bars (engine running)
when the pressure regulation is active (Status: "Pressure regulation: CONFIRMED").
The "Fuel regulation solenoid valve RCO" parameter should fluctuate between 20 and 30 %.
NOTE: a regulation error (Parameter: "Fuel pressure regulation error") results in illumination of the fault
warning light.
17-15
INJECTION
Mixture regulation 17
OXYGEN SENSOR HEATING ENTRY INTO THE MIXTURE REGULATION PHASE
The upstream oxygen sensor is heated by the in- Entry into the mixture regulation phase takes ef-
jection computer from the time the engine is swit- fect after a given starting delay if the coolant tem-
ched on. perature is above 20 °C and if the upstream sensor
is ready (sufficiently warm).
The downstream oxygen sensor is heated after a
given period determined in line with the coolant The starting delay depends on the coolant tempe-
temperature and the engine speed. rature (between 20 °C and 80 °C) and is between
20 and 320 seconds.
Heating of the upstream oxygen sensor is stop-
ped: Before entry into the mixture regulation phase,
- if the vehicle speed is above 70 mph (140 km/h) the value of the parameter is 128.
(value given for information),
- in the event of high engine loads,
- in the case of a significant engine speed. Unlooping phase
The downstream sensor is heated continuously. In the mixture regulation phase, the phases of
operation during which the computer does not
take into account the value of the voltage sup-
UPSTREAM SENSOR VOLTAGE plied by the upstream sensor are:
- at full-load if the engine speed is above 3,200
The value read on the diagnostic equipment un- rpm,
der the parameter: "upstream sensor voltage" re- - during heavy acceleration,
presents the voltage (expressed in millivolts) sup- - during deceleration with the no-load informa-
plied to the computer by the oxygen sensor. tion,
When the engine is looped, the voltage should - in the event of failure of the oxygen sensor,
fluctuate rapidly between two values: - in the event of limitation of the engine speed
- 150 ± 100 mV for a lean mixture, (excessive pressure, failure...).
- 750 ± 100 mV for a rich value.
The smaller the gap between the maximum and DOWNGRADED MODE IN THE EVENT OF FAILURE
minimum values, the less reliable is the informa- OF THE OXYGEN SENSOR SENSOR
tion from the sensor (this gap is usually at least
500 mV). If the voltage supplied by the oxygen sensor is in-
correct during the mixture regulation phase for a
NOTE: in the case of a small gap, check the hea- minimum duration of 10 seconds, the computer
ting of the sensor. switches to downgraded mode.
If a failure is detected and if the failure has alrea-

MIXTURE CORRECTION dy been stored, the system goes straight into an
open loop (mixture correction value 128).
The value read on the diagnostic equipment un-
der the parameter: "mixture correction" repre-
sents the average of the mixture corrections made
by the computer in line with the richness of the
carbonised mixture seen by the oxygen sensor.
The correction value has a mid-point of 128 and li-

mits of 0 and 255 :
- value below 128: leaner mixture required,
- value above 128: richer mixture required.
17-16
INJECTION
Adaptive mixture correction 17
PRINCIPLE
In the looping phase the mixture regulation corrects the injection time to obtain a dosage as close as possible
to mixture 1. The correction value is close to 128, with limits of 0 and 255.
The adaptive correction makes it possible to offset the injection map to realign the mixture regulation
around 128.
Therefore, it is necessary, following reinitialisation of the computer (return to 128 of the adaptive correc-
tions), to carry out a special road test.
PARAMETER F5R 740 engines
Operating mixture adaptation 96 ≤ X ≤ 192

value
Idle mixture adaptive value 32 ≤ X ≤ 224
ROAD TEST
Conditions:
- engine warm(coolant temperature > 75 °C),
- do not exceed an engine speed of 3650 rpm.
Pressure zones which must be passed through during the test
Range n° 1 Range n° 2 Range n° 3 Range n° 4 Range n° 5

(mbars) (mbars) (mbars) (mbars) (mbars)
221 321 421 521 621 780

F5R 740
Average 271 Average 371 Average 471 Average 571 Average 700
Following this test, the corrections are operational.
The test must be followed by normal, smooth and varied driving for a distance of 3 to 6 miles (2 to 10 kilome-
tres).
After the test, read the mixture adaptation values. Initially 128, they should have changed. If they have not,
repeat the test taking care to observe the conditions strictly.
INTERPRETATION OF THE VALUES GATHERED FOLLOWING A ROAD TEST
In the case of a lack of fuel (injectors clogged, pressure and flow of fuel too low, ...), the mixture regulation
increases to obtain a mixture as close as possible to 1. The adaptive mixture correction increases until the mix-
ture correction again fluctuates around 128.
In the event of an excessive amount of fuel the reasoning is reversed: the mixture regulation decreases and
the adaptive correction decreases as well to realign the mixture correction around 128.
17-17
INJECTION
Centralised coolant temperature management 17
CCTM This system is fitted with a single coolant tempera-
ture sensor which is used by the injection, the fan
assembly and the temperature warning light on
the instrument panel.
Operation
Sensor 244 enables:

- the coolant temperature to be indicated on the
instrument panel,
- the injection computer to be informed of the
engine coolant temperature.
Depending on the coolant temperature, the injec-

tion computer controls:
- the injection system,
- the fan assembly relays:
• the fan assembly is controlled at low speed if
the coolant temperature exceeds 99 °C and
stops when the temperature falls below
15615S 96 °C,
• the fan assembly is controlled at high speed
244 Coolant temperature sensor (injection and if the coolant temperature exceeds 102 °C
coolant temperature indication on the ins- and stops when the temperature falls below
trument panel). 99 °C,
Three-way sensor, two for the coolant tem- • the fan assembly may be controlled for the
perature information and 1 for the indica- AC and in the event of a temperature sensor
tion on the instrument panel. failure.
- the coolant temperature warning light.
In the event of failure of the coolant temperature

sensor, the fan assembly is controlled continuous-
ly at low speed.
COOLANT TEMPERATURE WARNING LIGHT
The coolant temperature warning light is control-

led by the injection computer if the coolant tem-
perature exceeds 118 °C.
When the ignition is switched on, the warning
light illuminates for a few seconds.
The engine overheating warning light flashes in

the event of a major HP injection system fault.
17-18
INJECTION
Computer 17
ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS
1 → IGNITION COIL 2-3 CONTROL

3 --- POWER EARTH
4 → CANISTER PURGE CONTROL
6 → FUEL PRESSURE REGULATOR CONTROL
8 → FAN ASSEMBLY 1 RELAY CONTROL
9 → COOLANT TEMPERATURE WARNING LIGHT
10 → AC COMPRESSOR CONTROL
11 → FUEL CONSUMPTION OUTPUT INFORMATION
12 → IDLE REGULATOR CONTROL (TRACK B)
13 ← COOLANT TEMPERATURE SENSOR INPUT
15 --- PRESSURE SENSOR EARTH
32 → IGNITION COIL 1-4 CONTROL
33 --- POWER EARTH
34 → OBD WARNING LIGHT CONTROL
37 → FAULT WARNING LIGHT CONTROL
38 → FAN ASSEMBLY 2 RELAY CONTROL
39 → ACTUATOR RELAY CONTROL
41 → IDLE REGULATOR CONTROL (TRACK A)
42 → IDLE REGULATOR CONTROL (TRACK C)
43 ← THROTTLE POTENTIOMETER SIGNAL
44 ← DOWNSTREAM OXYGEN SENSOR SIGNAL
45 ← UPSTREAM OXYGEN SENSOR SIGNAL
62 → EGR VALVE CONTROL
63 → UPSTREAM OXYGEN SENSOR HEATING CONTROL
65 → DOWNSTREAM OXYGEN SENSOR HEATING CONTROL
66 --- +AFTER IGNITION
68 → FUEL PUMP RELAY CONTROL
70 → TDC ENGINE SPEED INFORMATION
72 → IDLE REGULATOR CONTROL (TRACK D)
73 --- COOLANT TEMPERATURE SENSOR EARTH
THROTTLE POTENTIOMETER AND FUEL PRESSURE
74 --- SENSOR SUPPLY
THROTTLE POTENTIOMETER AND FUEL PRESSURE
75 --- SENSOR EARTH
PRO15097
17-19
INJECTION
Computer 17
ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS (cont)
16 ← MANIFOLD PRESSURE SENSOR SIGNAL INPUT

18 ← EGR VALVE POSITION SIGNAL
19 --- KNOCK SENSOR SHIELDING
20 ← KNOCK SENSOR SIGNAL INPUT
23 ← AC COMPRESSOR POWER ABSORBED INFORMATION
24 ← ENGINE SPEED SENSOR SIGNAL INPUT
26 --- DIAGNOSTICS
27 --- INTER-COMPUTER CONNECTION
28 --- POWER EARTH
29 --- +AFTER IGNITION
30 --- +BEFORE IGNITION
46 ← CAMSHAFT SENSOR SIGNAL
49 ← AIR TEMPERATURE SENSOR INPUT
53 ← VEHICLE SPEED INPUT
54 ← ENGINE SPEED SENSOR SIGNAL INPUT
56 --- DIAGNOSTICS
58 ← ENGINE IMMOBILISER SYSTEM
59 → INJECTOR 1 CONTROL (TO CONTROL COMPUTER)
76 ← DOWNSTREAM OXYGEN SENSOR SIGNAL
77 --- AIR TEMPERATURE SENSOR EARTH
78 --- PRESSURE SENSOR SUPPLY
79 --- KNOCK SENSOR EARTH
80 --- UPSTREAM OXYGEN SENSOR EARTH
82 --- EGR VALVE EARTH
83 --- EGR VALVE SUPPLY
85 → POWER STEERING PRESSURE SWITCH INFORMATION
88 ← ELECTRIC HEATED WINDSCREEN SIGNAL
PRO15097
17-20
INJECTION
Computer 17
ALLOCATION OF INJECTOR CONTROL COMPUTER INPUTS AND OUTPUTS

2 ← INJECTOR 3 CONTROL INFORMATION (COMPUTER)
4 → TDC INFORMATION
22 --- POWER EARTH
23 --- POWER EARTH
25 --- + AFTER IGNITION
34 --- + BEFORE IGNITION
35 → INJECTOR 1 CONTROL
51 --- POWER EARTH
PRN15557
17-21
INJECTION
Wiring diagram 17
16414G
17-22
INJECTION
Wiring diagram 17
16414D
17-23
INJECTION
Wiring diagram 17
PARTS LIST
104 Engine immobiliser system

107 Battery
120 Injection computer
146 Knock sensor
193, 194
195, 196 Injectors
199 Fuel gauge
222 Throttle potentiometer
224 Power steering pressure switch
225 Diagnostic socket
242 Oxygen sensor
244 Coolant temperature sensor
247 Instrument panel
250 Speed sensor
273 Speed threshold sensor
371 Canister solenoid valve
419 AC control unit
565 Throttle housing
597 Engine compartment fuse box and relays
645 Passenger compartment ECU transponder
777 Power fuse board
778 Ignition coil
927 Impact sensor
17-24
COOLING
Filling - Bleeding 19
The circulation in the heater matrix is continuous, BLEEDING
thus contributing to the cooling of the engine.
Run the engine for 20 minutes at 2,500 rpm, until
the fan(s) cut in (time required for automatic de-
FILLING gassing).
Open the bleed screw located on the plenum Check that the fluid level is close to the
chamber. "Maximum" mark.
Fill the circuit via the expansion bottle opening. DO NOT OPEN THE BLEED SCREW WHILE THE
ENGINE IS RUNNING.
Close the bleed screw when the liquid starts to
flow in a continuous stream. RETIGHTEN THE EXPANSION BOTTLE PLUG WHILE
THE ENGINE IS WARM.
Start the engine (2,500 rpm).
Adjust the level by overflow for approximately Location of the bleed screw (1) on the plenum
4 minutes. chamber
Close the reservoir.
15615R6
19-1
COOLING
Diagram 19
14887-2R1
1 Engine Coolant pump

2 Radiator
3 "Warm" reservoir with degassing in line with
thermostat Thermostat
4 Heater matrix
5 Thermostat support Bleed screw
6 ∅ 3 mm nozzle
7 ∅ 8 mm nozzle The expansion bottle valve calibration value is 1.6
bar (brown).
19-2
COOLING
Coolant pump 19
Mot. 1202 Circlip pliers
TIGHTENING TORQUE (in daN.m) Cleaning
Coolant pump bolt 1.7 It is very important that the mating surfaces are
not scratched.
Use the Décapjoint product to dissolve the part of

REMOVAL the seal which remains attached.
Place the vehicle on a two post lift. Apply the product to the section to be cleaned,
wait approximately ten minutes, then remove it
Disconnect the battery. using a wooden spatula.
Drain the cooling circuit via the lower engine ra- It is advisable to wear gloves during the opera-
diator hose. tion.
Remove: Do not allow any of the product to fall onto the

- the right-hand mud shield and the two engine paintwork.
undertrays,
belt tensioning"), REFITTING
- the lower timing cover mounting bolt and
move it aside, Refit:
- the coolant pump pulley, - the coolant pump (fitted with a new seal) tigh-
- the coolant pump. tening the bolts to a torque of 1.7 daN.m,
- the accessories belt an tension it (see section 07
"Accessories belt tensioning").
Fill and bleed the cooling circuit (see section 19

"Filling - Bleeding").
19-3
COOLING
Catalytic converter 19
T.Av. 1233 -01 Tools for working on the sub-

frame - axle
REMOVAL - the sub-frame tie-rod mounting bolts and lo-

wer the sub-frame by 40 mm at the front and
Place the vehicle on a two post lift. 90 mm at the rear,
Remove the mounting nuts of the connection of

the manifold and the catalytic converter.
Slacken the catalytic converter / exhaust line

connecting clamp to move the catalytic converter
back a few centimetres.
Remove:
- the steering shaft yoke bolt,
15870R
- the catalytic converter.
REFITTING
Change the catalytic converter/exhaust manifold

connection seal and the exhaust clamp.
IMPORTANT: ensure that the steering shaft yoke

97390-1S1 bolt is positioned correctly.
19-4
CLUTCH
Cover - Disc 20
VEHICLE ENGINE
COVER DISC
TYPE TYPE
26 splines VM : Moss Green

D = 215 mm V : Green
E = 6.8 mm BC : Capri Blue
BL : Light Blue
DA0 3
F5R 740
EA0 3
85873S
90693-2R16
94990R1
215 CPON 4400
Monodisc clutch operating dry, cable controlled.
Clutch stop in constant contact.
20-1
CLUTCH
Cover - Disc 20
REPLACEMENT (following removal of the gearbox)
Mot. 582 -01 Immobilising tool
TIGHTENING TORQUE (en daN.m) REFITTING
Cover mounting bolt 2 Clean the clutch shaft splines and refit the assem-
bly without any lubricant.
REMOVAL Fit the disc (hub offset gearbox side).
Fit immobilising tool Mot. 582-01. Align it.
Remove the cover mounting bolts and remove the

clutch disc.
Check and change any faulty parts.
95414S
Gradually screw in the bolts in a star formation,

then tighten the cover mounting bolts to the spe-
99055R1 cified torque.
Remove immobilising tool Mot. 582-01.
Coat with MOLYKOTE BR2 grease:

- the tube guide,
- the fork pads.
20-2
CLUTCH
Cover - Disc 20
After refitting the gearbox, place the cable on the NOTE: in the event of an operation which does
clutch fork and check the operation of the play not require removal of the gearbox, or after fit-
compensation system. ting the gearbox, DO NOT LIFT the fork as it may
come free of the notch (A) of the stop.
Check the clutch release travel.
The fork travel should be:
X = 25.4 to 25.9 mm
99054R
97758-1R
20-3
CLUTCH
Flywheel 20
REPLACEMENT OF THE FLYWHEEL
Mot. 582-01 Immobilising tool
Flywheel bolt 5.5
REMOVAL
After removing the clutch disc, remove the engine

flywheel mounting bolts (the bolts cannot be reu-
sed).
Reworking of the clutch face is prohibited.
REFITTING
Clean the flywheel mounting bolt threads on the

crankshaft.
Degrease the contact surface of the flywheel with

the crankshaft.
Refit the flywheel immobilising it using tool

Mot. 582-01.
COMMENT: the flywheel mounting bolts must al-

ways be replaced.
20-4
MANUAL GEARBOX
Identification 21
"MEGANE" vehicles with F5R engines are fitted with JC5 manual gearboxes.
Workshop Repair Manual "B.V. JB/JC" deals with the complete repair of this component.
14834-1R
A mark (1), located on the gearbox casing, indi-

cates:
A Type of gearbox
B Gearbox index
C Manufacturing number
D Factory of manufacture
A JCX 000 B
D X 000000 C
90775R
Gears
JC5
Speedo-
Step down Reverse
Index Vehicle meter drive 1st 2nd 3rd 4th 5th
ratio gear
gear
16 Without 11 21 28 31 42 11
DA0 3
106 -- speedo- -- -- -- -- -- --
EA0 3
57 meter 41 43 39 34 31 39
21-1
MANUAL GEARBOX
Capacity - Lubricants 21
CAPACITY (in litres)
5-speed gearbox
JC5 3.1
Grade - Viscosity
TRX 75W 80W
LEVEL CHECK
92081S
Fill to the level of the opening.
21-2
MANUAL GEARBOX
Consumables 21
TYPE PACKAGING PART NUMBER UNIT
Right-hand sun wheel splines

Fork pivot
MOLYKOTE BR2 1 kg box 77 01 421 145
Stop guide Clutch
Fork pads
LOCTITE 518 24 ml syringe 77 01 421 162 Casing assembly surfaces
Threaded plugs and switches

Bearing plugs
RHODORSEAL 5661 100 g tube 77 01 404 452
Ends of the roll pins on the driveshafts
LOCTITE FRENBLOC Input and output shaft nuts

(locking and sealing 24 cc vial 77 01 394 071 Fixed gear and hub of 5th
resin) Differential lock drive stud
Parts which must always be changed
When they have been removed:

- lip seals,
- O-rings,
- stop guide tubes,
- output shaft and differential nuts,
- bushes under the gears.
21-3
MANUAL GEARBOX
Special features 21
Drain plug 2.2

Brake caliper bolt 3.5
Driveshaft gaiter bolt 2.5
Lower ball joint nut 6.5
Shock absorber base bolt 17
Gearbox surround and starter bolt 3
Suspended engine mounting to gearbox
bolt 6
Wheel bolt 10
The removal and refitting of the gearbox remains

identical and does not present any difficulties in
relation to MEGANE vehicles fitted with a "JB"
gearbox and "K4M and K4J" petrol engines.
NOTE: when refitting the gearbox, it is preferable

to support the clutch control fork using string (1)
to prevent it from coming free from its ball joint
(located on the clutch housing).
14834R
21-4
REAR BEARING ELEMENTS
Hub / Brake disc 33
The brake discs cannot be ground. The disc must
be changed if it significantly worn or scratched.
Caliper mounting bolt 6

Wheel bolt 10
Stub axle bolt 17.5
REMOVAL
Remove
- the brake linings,
- the two caliper mounting bolts,
99582S
- the disc.
REFITTING
Fit the hub/disc and secure it using the stub axle

nut.
Tighten the nut to the specified torque.
Coat the bolt with Loctite FRENBLOC.
Fit the caliper and tighten the bolts to the speci-

fied torque.
Press the brake pedal several times to bring the

piston into contact with the linings.
99583-1R1
- the stub axle nut,
33-1
REAR BEARING ELEMENTS
Hub/disc bearing 33
TIGHTENING TORQUES (in daN.m) REFITTING
Caliper mounting bolt 6 By means of a press, refit the bearing using

Wheel bolt 10 tubes (C) and (D).
Stub axle nut 17.5
REMOVAL
Remove:
- the brake/hub disc; to do this refer to the pro-
cedure described on the previous page,
- the circlip.
By means of a press, remove the bearing using

tubes (A) and (B).
16214R
IMPORTANT: ensure that the bearing is positio-

ned correctly: the dust cover should be at the rear.
NOTE: the bearing dust cover plastic protector

should be removed at the last moment.
Refit:
- the circlip,
- the hub/disc.
16215R
NOTE: ensure that the disc is positioned correctly

for the removal of the bearing. The ABS crown
wheel should be facing upwards.
33-2
STEERING ASSEMBLY
Mechanical power steering pump 36
Mot. 453 -01 Hose clamps
Place the vehicle on a two post lift. REFITTING

REMOVAL
Fill and bleed the circuit turning from lock to lock
Disconnect the battery. with the engine running.
Remove the accessories belt (see section 07 NOTE: the power steering pump cannot be repai-
"Accessories belt tensioning procedure"). red. In the event of a fault, change it.
Fit a clamp Mot. 453-01 on the supply pipe. The power steering pump pressure should be bet-
ween 86 and 93 bars.
Disconnect the high and low pressure pipes, be
prepared for the flow of power steering fluid.
Remove:
- the pulley (3 bolts),
- the power steering pump (4 bolts).
16213S
36-1
STEERING ASSEMBLY
Mechanical power steering pump 36
Dir. 1083 -01 Tool for refitting the pulley

T.Ar. 1094 Tool for extracting differential
bearing
REPLACEMENT OF THE HUB
Place the pump on the workbench, in a vice.
Fit tool T.Ar. 1094 and extract the hub.
14836R
Observe the fitting dimension:

X = 41.5 mm
14837R X
NOTE: insert a bolt (1) between the pump shaft

and the push rod of tool T.Ar. 1094.
1
Position the hub (new) and fit it using tool Dir.
1083-01. Coat it with multipurpose grease first to
make refitting easier.
NOTE: insert a shim (2) of approximately 25 mm

between tool Dir. 1083-01 and the hub.
1 Power steering pump

2 Hub
36-2
STEERING ASSEMBLY
Power steering unit 36
T.Av. 476 Tool for extracting ball joints

Mot. 453 -01 Hose clamps
TIGHTENING TORQUES (in daN.m) In the engine compartment:
Wheel bolt 10 Fit hose clamps Mot. 453-01 onto the power stee-
ring reservoir hoses.
Universal joint bolt 2.5
Engine tie-bar nut: Remove the air filter unit.
- on gearbox 6.5
- on sub-frame 7.5
Steering unit to sub-frame mounting nut 5
Steering ball joint nuts 3.5
REMOVAL
Remove:
- the two wheels,
- the engine undertray.
Disconnect the steering ball joints using tool T.Av.

476.
16209S
Disconnect the high and low pressure pipes on the

steering unit. Plug the pipes to prevent the entry
of impurities.
Remove the universal joint bolt. To do this, direct

the nut upwards and fit a steering wheel immobi-
lising tool to retain the same position for refitting.
36-3
STEERING ASSEMBLY
Underneath the vehicle: - the steering unit mounting nuts,
- the left-hand sub-frame/body tie-rod (2 bolts).
Remove the front engine tie-bar bolt.
Uncouple:
- the exhaust downpipe from the exhaust assem-
bly,
- the gearbox control lever.
Fit a shim to move the engine forwards.
16210S
Removal of the tie-rod makes it possible to re-

move the steering unit easily.
Remove the steering unit from the left-hand

scuttle panel side by means of successive rotations
to detach the steering with its valve/ram pipes.
16212S Never unscrew the steering rack axial ball joints

unless they are to be changed.
Remove: If a steering unit is to be changed, the steering

- the heat shield on the steering unit (2 bolts), ball joints must be retained.
16211S
36-4
STEERING ASSEMBLY
REFITTING
In the case of a new steering assembly
Fit the steering ball joints.
Refit in the reverse order to removal observing

the tightening torques.
Bleed the power steering circuit, turning from

lock to lock with the engine running.
NOTE: it is ESSENTIAL to observe the marking of

the steering ball joints (one mark for the right-
hand ball joint, two marks for the left-hand ball
joint).
Adjust the parallelism if necessary.
36-5
MECHANICAL COMPONENT CONTROLS
Master cylinder 37
TIGHTENING TORQUES (in daN.m) REFITTING
Pipes on master cylinder 1.7 Refit in the reverse order to removal.

Mounting nuts on brake servo 2.3
Check the length of the push rod.
Dimension X = 22.3 mm.

Adjustment according to model using rod (P).
REMOVAL
Remove the air filter unit.
91101R
NOTE: these vehicles are fitted with a master cy-

linder incorporated in the brake servo. The sealing
of the brake servo is directly connected to the
master cylinder. When carrying out any work, a
16209S new seal (A) must be fitted.
Position the master cylinder in alignment with the

Move aside the expansion bottle. brake servo so that the push rod (P) correctly en-
ters the master cylinder location.
Disconnect the accelerator cable.
Drain the brake fluid reservoir and remove it.
Disconnect the pipes on the master cylinder mar-

king their position.
Remove the two master cylinder mounting bolts

and remove it.
DI3718
37-1
Master cylinder 37
Fill the brake fluid reservoir and bleed the brake
circuit.
MASTER CYLINDER (REPLACEMENT)
The kit sold by the Parts Department consists of:

- a master cylinder (four outlets or two outlets in
the case of ABS),
- two plugs (A),
- two mounting nuts (B).
DI3719
37-2
Brake servo 37
TIGHTENING TORQUES (en daN.m) - the acoustic mass on the left-hand side member
(2 nuts), this will make removal of the brake
Pipes on master cylinder 1.7 servo easier.
Mounting nuts on brake servo 2.3
Brake servo nuts on bulkhead 2
The brake servo cannot be repaired. Work is only

permitted on the:
- air filter,
- check valve.
REMOVAL
Remove the air filter unit.
16208R
Unhook the clutch fork cable.
16209S
Move aside the expansion bottle.
Disconnect the accelerator cable.
Remove: 89204S
- the master cylinder (see previous page),
Disconnect the vacuum hose on the brake servo.
37-3
Brake servo 37
In the passenger compartment REFITTING
Remove the pin (A) of the yoke connecting the Before refitting, check:
brake pedal to the push rod by acting on the clip, - dimension L = 104.8 mm,
- dimension X = 22.3 mm.
97860R
Remove:
- the stiffener,
- the pedal assembly pin nut,
91101R2
Before refitting the clutch pedal, coat the pin and

the grooved sector with grease.
Ensure that the clutch cable is positioned correctly

on the grooved sector.
PRG37.9
Remove the pin to detach the clutch and brake

pedals.
NOTE: it is not necessary to unhook the cable

from the clutch pedal grooved sector.
It is necessary to remove the pedals to gain access

to the mounting nuts securing the brake servo to
the bulkhead.
Remove:
- the four brake servo mounting nuts,
- the brake servo.
37-4
Brake servo 37
Refit the cable on the clutch fork. Check the fork travel.
Check that the assembly operates correctly. It should be: X = 27.4 to 30.7 mm.
With the pedal at rest, in the clutch engaged

position, pull the cable at the clutch fork on the
gearbox.
The cable should have at least 2 cm "slack".
91830R1
Bleed the brake circuit.
89204S
37-5
Brake servo 37
Mot. 1311-01 Pressure gauge and unions for

measuring pressure
SEALING CHECK
When checking the sealing of the brake servo, ensure that the sealing between the brake servo and the mas-
ter cylinder is perfect. If there is a leak, change seal (A) (refer to the procedure described on page 37-1).
The sealing of the brake servo must be checked on - assemble the pipes with the connecting "T",
the vehicle. the vacuum pressure gauge and the assembly
(1) (use union B from kit Mot. 1311-01 and a
Fit Mot. 1311-01 between the brake servo and the clamp with a worm screw (2)).
vacuum source (inlet manifold).
14213R
- position the assembly connecting the valve on

the brake servo on one side and the manifold
outlet pipe on the other.
14287R
NOTE: ensure that the closing valve is on the ma-
To do this: nifold side.
- remove the vacuum pipe completely,
- retain the check valve/hose assembly (1), remo- Run the engine at idle for one minute.
ving the clamp,
Close the valve and switch off the engine.
The vacuum in the circuit is approximately

613 mbar, if the vacuum falls to 33 mbar in 15 se-
conds, there is a leak which may be located either:
- at the check valve (change it),
- at the push rod diaphragm (in this case, change
the brake servo).
14216R
37-6
AIR CONDITIONING
General 62
CONSUMABLES
- DELPHI HARRISON V5 compressor oil:

PLANETELF PAG 488 : 220 cm3 ± 15
(to be ordered from ELF)
- Refrigerant:
R134a : 750 g ± 30
- Compressor:
DELPHI HARRISON V5
62-1
AIR CONDITIONING
Compressor 62
TIGHTENING TORQUES (In daN.m) Remove the two R134a connecting pipes (B) on
the compressor.
Pressure relief valve on evaporator bolt 0.6
Fit plugs to prevent the entry of moisture.
Connecting pipes on pressure relief valve
nut 0.8 Remove:
Connecting pipes on dehydration canister - the four fasteners (B) of the power steering
retaining bolt 0.8 pump assembly with its support then move it
aside on the engine,
Connecting pipes on condenser - the compressor from above (3 bolts).
retaining bolt 0.8
Condenser connecting pipe on compressor
retaining bolt 0.8
Pressure relief valve connecting pipe on
compressor retaining bolt 0.8
Compressor retaining bolt 2.1
Circuit pressure sensor 0.8
REMOVAL
Drain the R134a refrigerant circuit using the fil-

ling equipment.
Remove:
- the wheel arch protector,
- the accessories belt.
15575R
Move aside the power steering reservoir.
Disconnect the compressor clutch. REFITTING
Check the condition of the seals and coat them

with oil.
If the compressor is changed, it is supplied filled

with oil.
Create a vacuum, then fill the R134a refrigerant

circuit using the filling equipment.
IMPORTANT: when changing the compressor, it is

essential to top up the oil correctly.
62-2
AIR CONDITIONING
Condenser 62
REMOVAL Fit plugs to prevent the entry of moisture.
Drain the R134a refrigerant circuit using the fil- Remove the two cooling assembly upper faste-
ling equipment. ners.
Remove:
- the air inlet on the upper crossmember,
- the six upper crossmember mounting bolts,
15901R1
Remove the cooling assembly and move it back as

far as possible.
98838S Remove the four mounting bolts securing the

condenser on the radiator and remove it carefully.
- the mounting nut of the connecting pipes on
the condenser.
15975R
62-3
AIR CONDITIONING
Condenser 62
REFITTING

with oil.

IMPORTANT: when changing the compressor add

30 ml of oil to the circuit.
62-4
AIR CONDITIONING
Connecting pipes 62
LOW PRESSURE PIPE HIGH PRESSURE PIPE BETWEEN THE PRESSURE
RELIEF VALVE AND THE DEHYDRATION CANISTER
REMOVAL
REMOVAL
Drain the R134a refrigerant circuit using the fil-
ling equipment. Drain the R134a refrigerant circuit using the fil-
ling equipment.
Remove:
- the air filter unit, Remove:
- the air filter unit support, - the air filter unit,
- the connecting pipes on pressure relief valve - the air filter unit support,
retaining bolt. - the connecting pipes on pressure relief valve re-
taining bolt.
Move aside the power steering reservoir. - the mounting bolt which secures the pipes on
the dehydration canister.
Remove the mounting bolt securing the low pres-
sure pipe on the compressor. Fit plugs to prevent the entry of moisture.
Fit plugs to prevent the entry of moisture.
Remove the pipe.
PRG62.4
Unclip the pipe from the body and remove it.

PRG62.2
REFITTING
REFITTING Check the condition of the seals and coat them

with oil.
with oil. Refit in the reverse order to removal.
Refit in the reverse order to removal. Create a vacuum, then fill the R134a refrigerant
circuit using the filling equipment. IMPORTANT: when changing a pipe, add 10 ml of
oil to the circuit or if a pipe bursts (rapid leak), add
IMPORTANT: when changing a pipe, add 10 ml of 100 ml of oil.
oil to the circuit or if a pipe bursts (rapid leak), add
100 ml of oil.
62-5

N.T. 3218A DA03 - EA03: Follow The Instructions Regarding Cleanliness When Working On This Vehicle

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

N.T. 3218A DA03 - EA03: Follow The Instructions Regarding Cleanliness When Working On This Vehicle

Uploaded by

Copyright:

Available Formats

N.T.

SPECIAL FEATURES OF THE

Follow the instructions regarding cleanliness

77 11 205 759 JULY 1999 Edition Anglaise

07 VALUES AND SETTINGS 13 FUEL SUPPLY

Capacities - Grades 07-1 Specifications 13-1

11 TOP AND FRONT OF ENGINE

17 IGNITION - INJECTION 21 MANUAL GEARBOX

Static ignition 17-1 Identification 21-1

Filling - bleeding 19-1

Master cylinder 37-1

Cover - Disc 20-1

Petrol engine When European Union countries and Turkey

ACEA A2/A3 15W40-15W50

ACEA A1*/A2/A3 10W30-10W40-10W50

ACEA A1*/A2/A3 0W30-5W30

ACEA A1*/A2/A3 0W40-5W40-5W50

ACEA A1-98 standard

API SH/SJ 15W40-15W50

API SH/SJ 10W40-10W50

API SH/SJ 10W30

API SH/SJ 5W30

API SH/SJ 5W40-5W50

Oil for fuel economy:

* Adjust using a dipstick

JC5 All countries: TRANSELF TRX 75 W 80 W

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

When refitting the belt, it is essential to ensure

Mot. 799-01 Tool for immobilising pinions for

Angular tightening wrench

There are two very distinct procedures for setting

The first procedure is applied in the event of re-

Follow the instructions regarding cleanliness and

WARNING: it is essential to de-

Position the camshaft grooves

It is essential that the grooves

Fit tool Mot. 1526 which is secured at the end of

When the timing belt is changed, it is essential to

Check that the tensioner lug (1) is correctly posi-

Pre-tighten the tensioner nut to a torque of 0.7

Tighten the crankshaft pulley bolt to a torque of

NOTE: do not turn the tensioner anti-clockwise.

Remove camshaft setting tool Mot. 1526 and Top

Carry out angular tightening of the crankshaft

Remove the Top Dead Centre pin Mot. 1054.

Check that the tensioner marks are aligned and

Checking the setting and the tension

Turn the crankshaft two revolutions clockwise (ti-

Remove the Top Dead Centre pin Mot. 1054.

Check that the tensioner marks are aligned and

Ensure that the tensioner

Fit the Top Dead Centre pin

Fit (without using force) cams-

Setting the timing

WARNING: it is essential to degrease the end of the crankshaft and the

Position the camshaft grooves horizontally, as indicated on the diagram

It is essential that the grooves are directed downwards.

Remove the old pulley nuts. It is essential to re-

Pre-tighten the nuts, without locking them, with a

Check that the crankshaft is pinned at Top Dead

Position the exhaust camshaft pulley mark oppo-

NOTE: incorrect positioning of the exhaust cams-

Ensure that the tensioner lug (1) is correctly posi-