engine and peripherals

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Renault 1997

77 11 194 226 JJJJUUUULLLLYYYY 1111999999997777 Edition anglaise

"The repair methods given by the manu facturer in this d ocument are based on thetechnical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by themanufacturer in the production of the various component units and accessoriesfrom wh ich his vehicles are constructed"

All copyrights reserved by Renault.

Copying or tran slating, in part or in full , of this documen t or use of the service partreference numbering system is forbidden without the prior written authority of Renault.

C

FC0A - FC0C - FC0D - FC0E - KC0A - KC0C - KC0D - KC0E

Engine and peripherals

ENGINE AND PERIPHERALS

TOP AND FRONT OF ENGINE

FUEL MIXTURE

FUEL SUPPLY -

DIESEL EQUIPMENT

ANTIPOLLUTION

STARTING - CHARGING

IGNITION - INJECTION

COOLING - EXHAUST - FUEL TANK -ENGINE SUSPENSION



Contents

Consumables

IdentificationOil consumptionOil pressureEngine - GearboxEngine and tran smission assemblySumpCrankshaft seal, timing endOil pu mp

10-1

10-110-210-310-410-9

10-2510-2910-30


Timing beltCylinder head gasketReplacement of valve adjusters

PagePage

11

Engine andperipherals

11-111-1111-29

ENGINE AND PERIPHERALS10 FUEL SUPPLY -

DIESEL EQUIPMENT

Fuel supplyFuel cut off in case of an imp actInjector ga lleryFuel filterPump flowFuel pressureAntipercolation device

Diesel equipment

GeneralSpecificationsLocation of compon ents

Advance solenoid valveAltimetric correctorFast idle LDACoded solenoid valveLoad potentiometerComputer configurationInjector with sensor (need lelift)Injection warning lightPre-postheating controlFast idle control

Injection/ air conditioningprogrammingComputerDefect mod esPumpPump -TimingIdle speed settings

13-113-213-613-713-8

13-12

13-1313-1413-16

13-1913-2213-2513-2613-2813-29

13-3113-3213-3313-35

13-3613-3613-3713-3813-3913-4113-46

13

FUEL MIXTURE

SpecificationsThrottle bodyInlet manifoldExhau st man ifoldInlet-exhaust m anifolds

12-112-7

12-1512-1812-20

12



Page

Cooling

SpecificationsFilling and bleedingTestingDiagramWater pum p

Exhaust

GeneralExhau st pipe assembly

Fuel tank

TankSender unitPump and send er unit assembly

Engine suspension

Suspend ed engine mountings

19-119-219-319-419-7

19-1219-15

19-1719-2919-30

19-32

COOLING - EXHAUST - FUEL TANK -ENGINE SUSPENSION

1916-116-7

STARTING - CHARGING

AlternatorStarter

16


Ignition

Static ign itionPlugs

Injection

GeneralLocation of compon entsCentralised coolant temperaturemanagementInjection fau lt war ning lightImmobiliser functionCompu ter configuration dep endingon gearbox type

17

14-1

14-214-7

14-11

ANTIPOLLUTION

Test for the presence of lead

Fuel vapour r ebreathingOil vapour r ebreathingExhau st gas recirculation(EGR)

14

17-1717-18

17-1917-2017-22


(continued)

Injection/ air conditioningprogrammingIdle speed correctionAdap tive idle speedcorrectionRichness regulationAdaptive r ichness correction

17

Page

17-117-3

17-417-8

17-1317-1417-15

17-16

Contents



ENGINE AND ENGINE PERIPHERALS

Consumables 10

Identification

Type Quantity Components

RRRRHHHHOOOODDDDOOOORRRRSSSSEEEEAAAALLLL 5555666666661111 Coat Driveshaft roll p in holes

LLLLooooccccttttiiiitttteeee FFFFRRRREEEENNNNBBBBLLLLOOOOCCCCLocking an d sealing resin

Coat Brake calip er mou nting bolts

LLLLooooccccttttiiiitttteeee FFFFRRRREEEENNNNEEEETTTTAAAANNNNCCCCHHHH

Locking an d sealing resinCoat Cran ksh aft p ulley m ou ntin g bolts

Exhaust pipe paste Coat For sealing the exhaust

Vehicle type EngineManual

gearbox

Capacity

(cm3)

Bore

(mm)

Stroke

(mm)Ratio

F/ K C0A D7F 710 JB1 1 149 69 76.8 9 .65/ 1

F/ K C0C E7J 780 JB3 1 390 75.8 77 9 .5/ 1

F/ K C0DF/ K C0E

F8Q 662F8Q 630

JB1 1 870 80 93 2 1.5 / 1

Engine Workshop Repair Manu als to be consulted d epending on the type of engine:

D7F E7J F8Q

Mot. D X

Mot. E X

Mot. F (D) X

Engine

Document

10-1




Oil consumption 10

OOOOIIIILLLL CCCCOOOONNNNSSSSUUUUMMMMPPPPTTTTIIIIOOOONNNN MMMMEEEEAAAASSSSUUUURRRREEEEMMMMEEEENNNNTTTT PPPPRRRROOOOCCCCEEEEDDDDUUUURRRREEEE

a) Filling to the maximum level

The operation must be carried ou t with the engine hot (one rotation of the cooling fan assembly) and af-ter settling for 15 minutes to allow all the oil to dra in into the sum p.

Check visually using the d ipstick.

Top u p to the m aximu m level.

Seal the drain p lug (with a paint m ark on both the filler plug and the sum p’s drain p lug) in ord er to beable to check later that it has not been removed.

b) Customer driving

Ask the customer to dr ive the vehicle for a period correspond ing to about 1250 miles (2,000 km) or beforethe minimu m level is reached.

c) Refilling to the maximum level

The operation must be carried ou t with the engine hot (one rotation of the cooling fan assembly) and af-ter a settling time of 15 minutes.

Check visually using the d ipstick.

Top u p to the m aximu m level.

Note th e quantity of oil and the m ileage covered since the last filling to th e maximu m level.

d) Measurement of the oil consumption

Quantity of topp ing up oil (in litres)OIL CONSUMPTION = ----------------------------------------

km (in thousands)

10-2



87363R1


Oil pressure 10

SSSSPPPPEEEECCCCIIIIAAAALLLL TTTTOOOOOOOOLLLLIIIINNNNGGGG RRRREEEEQQ Q Q UUUUIIIIRRRREEEEDDDD

Mot. 836 -05 Oil pressure measuring kit

EEEEQQ Q Q UUUUIIIIPPPPMMMMEEEENNNNTTTT RRRREEEEQQ Q Q UUUUIIIIRRRREEEEDDDD

22 mm long socket

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG

The oil pressure should be checked wh en the en-gine is warm (ap proximately 80°C).

Contents of kit Mot. 836-05.

USE

EEEENNNNGGGGIIIINNNNEEEE CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG

D engine

Idling 0.8 bar

4 000 rpm 3.5 bars

E engine

Idling 1 bar

3 000 rpm 3 bars

F engine

1 000 rpm 1.2 bars

3 000 rpm 3.5 bars

D engine E engine F engine

C + F C + E + F B + F

10-3




Engine - Gearbox 10

RRRREEEEMMMMOOOOVVVVAAAALLLL

Put the veh icle on a 2 post lift.

Disconnect:- the battery,- the electrical connectors from the engine

connection unit and its environment.

13034S

Drain:- the cooling circuit (bottom hose of the

radiator),- th e gearbox oil,- the engine oil if necessary.

Remove:- the battery,

- the bonnet,- the wheels,- th e air in take p ip e,- the expansion bottle and fix it to the engine.

Brake caliper guide bolt 4

Shock absorber base bolts 18

Driveshaft gaiter mounting bolt 2.5Wheel bolt 9

Left-hand suspended mounting bolt

on gearbox 6.2

Left-hand suspended mounting bolt

and nut on body 2.1

Right hand suspended

engine mounting bolt on engine 6.2

Right hand suspended

engine mounting bolt on body 6.2

TTTTIIIIGGGGHHHHTTTTEEEENNNNIIIINNNNGGGG TTTTOOOORRRRQQ Q Q UUUUEEEESSSS ((((iiiinnnn ddddaaaaNNNN....mmmm))))

D7F engine


B. Vi. 31-01 Set of three punches for roll

pins

Mot. 1202 Hose clip pliers

Mot. 1273 Tool for checking belt tension

Mot. 1311-06 Tool for removal of fuel pipe

Mot. 1379 Tool for retaining engine on

sub-frame

T. Av. 476 Ball joint extractor


Load posi tioner

10-4




Engine - Gearbox

Left-hand side of the vehicle

Remove:- the brake caliper mounting bolt , then fix it to

the shock absorber spring ,- the three driveshaft gaiter mounting bolts,- the t rack rod end with the aid of tool

T.Av.476,

- the shock absorber base bolts.

Tilt the hub to d isconnect the d riveshaft from th egearbox.

Right-hand side of the vehicle

Remove:- the driveshaft roll pins with the punches

B.Vi.31-01,

- the brake caliper mounting bolt , then fix it tothe shock absorber spring ,

- the t rack rod end with the aid of toolT.Av.476,

- the shock absorber base bolts.

Tilt the hub to d isconnect the d riveshaft from th egearbox.

Remove the earth strap mou nting bolt (gearboxside)

10D7F engine

10-5




Engine - Gearbox

- the heater hoses on the bulkhead side (withplastic un ions),

10

Disconnect the gear control at the position of thegearbox outp ut lever after releasing the gaiter.

93912R1

Slacken bolt (A) withou t removing it and removebolt (B) from the engine tie-bar.

92661R1

Disconnect:- the accelerator cable,- the canister pip e,- the brake servo vacuum p ipe,- the hoses between the radiator and the

engine block, on the engine block side,

13085R

(with metal un ions),

13084R

- the connectors of the oxygen sensor and fan,- the fu el p ip es.

D7F engine

10-6




Engine and transmission assembly 10



Disconnect:

- the battery,- the electrical connectors from the engineconnection unit and its environment.

13034S

Drain:- the cooling circuit (disconnect the bottom

hose of the radiator),- the gearbox oil if necessary,- the engine oil if necessary.

Remove:- the battery,- the wheels,- th e air in take p ip e,

- the upper radia tor moun tings,- the expansion bottle and fix it to the engine,- the power assisted steering fluid reservoir,

and secure it onto the engine.

Shock absorber base bolts 18

Track rod end 3.7

Front sub-frame mounting bolt 6.2

Rear sub-frame mounting bolt 10.5

Driveshaft gaiter mounting bolt 2.5

Wheel bolt 9

Mounting nut for rubber engine mounting

pad on left suspended engine mounting 6.2

Mounting bolt for front right suspended

engine mounting on the engine 6.2


engine mounting on the body 6.2

Steering shaft yoke bolt 2.5


D7F engine


B. Vi. 31-01 Set of punches for roll pins

Mot. 1040-01 D ummy sub-frame forremoving and refitting engine

and transmission assembly


Mot. 1311-06 Tool for removal of fuel pipe


sub-frame

T. Av. 476 Ball joint extractor

T. Av. 1233-01 Tool for sub-frame and axle

assembly

10-9




Engine and transmission assembly

Disconnect:- the accelerator cable,- the canister pip e,- th e br ake ser vo p ip e,

- the h eater h oses,- the oxygen sensor connector ,- the fu el p ip es.

Remove:- the shock absorber base bolts,- the steer ing shaft yoke bolt .

10

97390-1R

SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS FFFFOOOORRRR VVVVEEEEHHHHIIIICCCCLLLLEEEESSSS FFFFIIIITTTTTTTTEEEEDDDD WWWWIIIITTTTHHHH

DDDDRRRRIIIIVVVVEEEERRRR’’’’SSSS AAAAIIIIRRRR BBBBAAAAGGGG

WWWWAAAARRRRNNNNIIIINNNNGGGG

In order to avoid any risk of damage to the rotary

switch beneath the steering w heel, the follow ing

instructions should be followed:

• Before disconnecting the steering column from

the rack, the steering w heel MUST be immobi-

lised with the wheels straight with the aid of a

"steering w heel lock" throughout the opera-

tion.

• If there is any doubt about the rotary swi tch

being properly centred, the s teering wheel

must be removed in order to apply the centringmethod described in the Technical Note cove-

ring the 2nd generation air bag.

REMINDER: this kind of w ork must only be carried

out by properly trained and qualified staff.

Remove:- both the sub-frame reinforcements,- the earth st rap mounting bolt on the body

side,

- the exhaust downp ipe nu ts.

D7F engine

10-10




Engine and transmission assembly

Insert a wooden block between the gearbox andthe sub-frame.

Diagram show ing the holes dr illed in tool Mot.

1040-01 (dimensions in mm ).

10

Disconnect the gear control:- at the position of the gearbox output lever af-

ter releasing the gaiter,- at the level of the gear lever after removing

the central heat shield.

Pull the control lever (2) towards the rear of thevehicle.

10621R

Fit tool Mot. 1379 onto the sub-frame an d takethe w eight off the right-hand engine moun ting,using the threaded rod (1).

10267R1

93912R2

Fix tool Mot. 1040-01 und erneath the sub-frame,having first fitted th e shims Mot. 1379 onto thistool.

92442-1R2

D7F engine

10-11





Remove:- the gearbox suspended mounting nut, then

tap it with a copper h amm er to release thesuspended moun ting stud,

- the suspended engine mounting bolts on theengine.

Lower the lift un til the tool touches the groun d.

Remove the four m oun ting bolts of the sub-frame.

Take out the engine and tr ansm ission assembly bylifting th e body.

98755R

D7F engine

10-12





12924R4

Apply Rhodorseal 5661 to the d riveshaft roll pin h ole.

Press the brake ped al several times to bring the pistons into contact with the brake p ads.

Fill:- the gearbox with oil (if necessary),- the engine with oil (if necessary),- the cooling circuit and bleed it (see section 19).

RRRREEEEFFFFIIIITTTTTTTTIIIINNNNGGGG ((((ssssppppeeeecccciiiiaaaallll nnnnooootttteeeessss))))

Use tool T. Av. 1233-01 to position the engine and transm ission assembly in relation to the body.

Refitting is the reverse of rem oval.

Tighten the suspend ed engine moun ting bolts and nu ts to the recomm ended torque.

D7F engine

10-13








engine mounting cover on engine 6.2

Mounting nut for front right suspended

engine mounting cover 4.4

Mounting nut for rubber engine mounting pad

on front left-hand side member support 6.2

Shock absorber base bolt 18Brake caliper mounting bolt 4

Steering shaft yoke bolt 3

Wheel bolt 9




Disconnect the battery.

Drain:- the cooling circuit through the bottom hose

of the radiator,- the gearbox and the engine if necessary.

Remove:- the bonnet,- the front w heels,- the tie-rods between sub-frame and body,

- the mounting bolts (1); pull away the brakecalipers as shown in the diagram below andattach th em to the suspension springs,

12994R1

- the shock absorber base bolts,

E7J engine


Mot. 1040-01 Dummy sub-frame for removing

and refitting engine andtransmission assembly

Mot. 1159 Tool for maintaining engine on

sub-frame

Mot. 1202

Mot. 1448

Mot. 1311-06 Tool for removing fuel pipe

Hose clip pl iers

10-14





13085R

- the exhaust heat shield and the gear controlon the lever and gearbox sides,

12988R

- the exhaust pipe clamp between the catalyticconverter and the expansion cham ber,

- the earth strap on the gearbox,- the front bu mp er,- the air intake pipe from the air filter ,- the inject ion computer support after dis-

connecting the 55 track connector and that of the impact switch.

13088R2

Disconnect:- the wiring connect ions and the hoses on the

thermostat supp ort,- the hoses on the expansion bot tle,

- th e brake servo p ip e,- the heater hoses (there are two types of as-sembly to be disconnected, as show n in thediagrams below),

13084R

E7J engine

10-15





- the relay plate (4), the connector (5) and thefuse supp ort (6) by remov ing the fuse holder(7),

13034R

- the canister pip e,- the fuel supply and return pipes with the aid

of tool Mot. 1311-06, after removing the co-ver,

- the accelerator and clutch cables.

Unclip the p ower assisted steering reservoir andplace it on the engine.

Remove:- the upper mountings of the radiator and at-

tach it to the engine,- the nut and the eccentric bolt of the steering

shaft yoke, after pu shing back the guard .

97390S1

SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS FFFFOOOORRRR VVVVEEEEHHHHIIIICCCCLLLLEEEESSSS FFFFIIIITTTTTTTTEEEEDDDD WWWWIIIITTTTHHHH

DDDDRRRRIIIIVVVVEEEERRRR’’’’SSSS AAAAIIIIRRRR BBBBAAAAGGGG

99024R2


In order to prevent any risk o f damage to the ro-

tary sw itch beneath the steering w heel, the fol lo-

wing instructions should be observed:

• Before disconnecting the steering column and


lised with the wheels straight, using a "stee-

ring wheel lock", throughout the operation.

• If there is any doubt that the rotary sw itch is

properly centred, the steering wheel must be

removed in order to apply the centring method

described in section 88 "Air bag".



Fit too l Mot. 1159 between the sub-frame and thecylinder block.

E7J engine

10-16





RRRREEEEFFFFIIIITTTTTTTTIIIINNNNGGGG

The alignmen t of the sub-frame with the bodywill be mad e easier by positioning two thread ed

rods Mot. 1233-01 in the two front moun tings of the sub-frame on the body.

Tighten the sub-fram e mounting bolts to a torqueof:- 6.2 daN.m at the front,- 10.5 daN .m at the rear.

Refitting is the r everse of rem oval.

Fit the heat shields correctly.

Apply LLLLooooccccttttiiiitttteeee FFFFRRRREEEENNNNBBBBLLLLOOOOCCCC to the caliper mountingbolts and tighten them to the recommend ed tor-que.

Press the brake ped al several times to bring thepistons into contact with the brake p ads.

Fill:- the engine and gearbox with oil, if necessary,- the cooling circuit and bleed it (see section 19

"Filling - bleeding").

E7J engine

Fix tool Mot. 1040-01 und erneath the sub-frame.

98755R1


Remove the sub-frame moun ting bolts and takeout the engine and transm ission assembly by lif-

ting the body.

NNNNOOOOTTTTEEEE :::: for any operation requiring separation of the engine, gearbox and sub-frame assembly,take care to mark the position of Mot. 1159 on thesub-frame.

10-18






Mot. 1040-01 Dummy sub-frame for removing -

refitting the engine and

transmission assembly

Mot. 1159 Tool for maintaining engine on

sub-frame

Mot. 1202

Mot. 1448




Mounting bolt for front right suspended engine

mounting cover on engine 6.2

Mounting nut for front right suspended engine

mounting cover 4.4

Mounting nut for rubber engine mounting

pad on front l eft s ide member support 6.2

Shock absorber base bolt 18

Brake caliper mounting bolt 4Steering shaft yoke bolt 3

Wheel bolt 9





Drain:- the cooling circuit through the bottom hose

of the radiator,- the gearbox and the engine if necessary.

Remove:- the bonnet,- the front w heels,- the tie-rods between sub-frame and body,

- the mounting bolts (1); pull away the brakecalipers as shown in the diagram below and

attach th em to the suspension springs,

12994R1

- the shock absorber base bolts,

F8Q engine

Hose clip pl iers

10-19





12988R

- the exhaust heat shield and the gear controlon the lever and gearbox sides,

- th e exh au st d ow np ip e,- the earth st rap on the gearbox,

- the front bu mp er,- the air intake pipe of the air filter,- the fuel supply and return unions (A) and (B),- the connectors (2), (3), (4) and (5).

Unclip th e fuel pipes from the air filter unit andthe timing cover and un clip the d iesel filter fromits supp ort and m ove the assembly to one side.

13083-1R

F8Q engine

10-20





Remove:- the upper mountings of the radiator and at-

tach it to the engine,- the nut and the eccentric bolt of the steering

shaft yoke, after pushing back the guard .

97390S1

SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS FFFFOOOORRRR VVVVEEEEHHHHIIIICCCCLLLLEEEESSSS FFFFIIIITTTTTTTTEEEEDDDD WWWWIIIITTTTHHHHDDDDRRRRIIIIVVVVEEEERRRR’’’’SSSS AAAAIIIIRRRR BBBBAAAAGGGG


In order to prevent any risk o f damage to the ro-

tary sw itch beneath the steering w heel, the fol lo-

wing instructions should be observed:

• Before disconnecting the steering column and


lised with the wheels straight, using a "stee-

ring wheel lock", throughout the operation.• If there is any doubt that the rotary sw itch is

properly centred, the steering wheel must be

removed in order to apply the centring method

described in section 88 "Air bag".



F8Q engine

13084R

13034R

- the relay plate (4), the connector (5) and thefuse supp ort (6) by remov ing the fuse holders(7),

- the accelerator and clutch cables.

Unclip the p ower assisted steering reservoir andplace it on the engine.

10-22





Remove the suspend ed engine mou nting cover.

13086R1

13086R

Insert a w edge between the gearbox and the sub-frame.Remove:- the nut (1), then tap it with a copper hammer

to release the suspend ed engine mou ntingstud.

F8Q engine

99024R2

Fit tool Mot. 1159 between the sub-frame and thecylinder block.

Fit tool Mot. 1159 in place of the coolant p ipemou nting on the cylind er block.

99310R

10-23






The alignmen t of the sub-frame with the bodywill be mad e easier by positioning two thread ed

rods Mot. 1233-01 in the two front moun tings of the sub-frame on the body.

Tighten the sub-fram e mounting bolts to a torqueof:- 6.2 daN.m at the front,- 10.5 daN .m at the rear.


Fit the heat shields correctly.

Apply LLLLooooccccttttiiiitttteeee FFFFRRRREEEENNNNBBBBLLLLOOOOCCCC to the caliper mountingbolts and tighten them to the recommend ed tor-que.

Press the brake ped al several times to bring thepistons into contact with the brake p ads.

Fill:- the engine and gearbox with oil, if necessary,- the cooling circuit and bleed it (see section 19

"Filling - bleeding").

F8Q engine

Fix tool Mot. 1040-01 und erneath the sub-frame.

98755R1


Remove the sub-frame moun ting bolts and take

out the engine and transm ission assembly by lif-ting the body.

NNNNOOOOTTTTEEEE :::: for any operation requiring separation of the engine, gearbox and sub-frame assembly,take care to mark the position of Mot. 1159 on thesub-frame.

Remove the m oun ting bolts (3).

12993-1R3

10-24




Sump 10

Sump mounting bolt 1


Put th e vehicle on a 2 post lift.


Drain the engine.

Remove:- the oil level sensor using a 19 mm half-moon

wrench,- the engine-gearbox undert ray.

99900S

Remove the sum p m ounting bolts.

Rotate the sum p tow ard s the rear of the vehicle inorder to release the oil pum p strainer from thesump partitioning.

Clean the sealing su rfaces withou t scratching thealuminium.


Proceed in the reverse ord er of removal and fit anew gasket.

D7F engine

10-25




Sump 10



E7J sump bolt 1

F8Q sump bolt 1.5

Steering shaft yoke mounting bolt 3

Engine tie-bar bolt 6.2Wheel bolt 9





Drain the engine oil.

Remove:- the front w heels,- the nut and the eccentric bolt of the steering

shaft yoke, after pu shing back the guard ,

97390S1

- the lower ball joint mountings and the trackrod end s for the EEEE7777JJJJ engine,

- the sub-frame and body tie rods,- the gear control on the gearbox s ide,- bolt (1), and slacken engine tie-bar bolt (2),

without rem oving it,

EEEE7777JJJJ //// FFFF8888QQ Q Q

engines


Mot. 1233-01 Threaded rods for lowering the

sub-frame

13359R1

- the bottom mountings of the bumper ,- the exhaust downp ipe for the FFFF8888QQ Q Q engine.

Special notes for the E7J engine

Remove:- the exhaust manifold heat shield,- the ca ta ly tic conver ter,- the engine flywheel guard ,

- the power assisted s teering pipe mountingson the cylind er block and the multifun ctionmounting.

10-26




Sump 10

Engines of all types

Remove:- the moun ting bolts (3),

- the sub-frame mounting bolts, inserting thethreaded rods Mot. 1233-01 as you go.

12993-1R3


engines

13507R

Gradu ally lower the sub-frame w ith the aid of the threaded rods Mot. 1233-01 untildimensions X1 an d X2 are reached app roximately.

E7J engine

X1 = 9 cm X2 = 12 cm

Remove the sump .

F8Q engine

X1 = 7 cm X2 = 9 cm

10-27




Sump 10


Clean the sump .

E7J engine

App ly an approximately 3 mm w ide bead of RRRRHHHHOOOODDDDOOOORRRRSSSSEEEEAAAALLLL 5555666666661111 as shown in the diagram be-low.


engines

99179S

Do not forget to replace the two half-moon gas-

kets on each side of the sump.

F8Q engine

Fit a new after-sales gasket.


10-28




Oil pump 10

Crankshaft output mounting bolt 2 + 90°

Bolt mounting front right suspended

engine mounting on engine 6.2

Bolt mounting front right suspended

engine mounting on body 6.2

Timing belt tension wheel nut 5



Remove:- the t iming belt (see method described in

section 11 "Timing belt"),- the oil level sensor with the aid of a 19 mmhalf-moon w rench,

- th e oil d ip stick,- the crankshaft pulley and sprocket ,- the engine flywheel guard.

Lift the engine and gearbox assembly with the aidof tool Mot. 1379.

Remove the sump bolts.

Rotate the sump towards the rear of the vehicle inorder to release the oil pum p strainer from thesump partitioning.

Remove:- the oil pu mp strainer- the oil pump

Clean the sealing surfaces without scratching thealuminium.


Mot. 1054 TTTTDDDDCCCC ppppiiiinnnn

Mot. 1273 Tool for checking belt tensionMot. 1355 Tool for fitting oil pump

Mot. 1379 Tool for maintaining engine on sub-

frame


System atically rep lace the oil pressure seal (3).

99790R

App ly a bead of RRRRHHHHOOOODDDDOOOORRRRSSSSEEEEAAAALLLL 5555666666661111 to the sealingsurface.

98964S

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT : the oil pu mp is driven by two stud slocated on the crankshaft.

D7F engine

10-30




Oil pump 10

Refit:- the oil pump onto the engine and t ighten it to

a torque of 0.9 daN.m,

- the new seal onto the crankshaft output wi-

thout d amaging it when p assing the timingsprocket drive groove.

Position it with th e aid of tool Mot. 1355..

99788R

Refit the strainer w ith a new O-ring.

Clean the sealing su rfaces (cylinder block, sump).Refit the sump .

Tighten th e bolts to a torque of 1 daN.m.

Refit:- the t iming belt (see method described in

section 11 "Timing belt"),- the new alternator and power assis ted stee-

ring pum p belts (see tension values in section07 "Accessories belt tens ion").

D7F engine

10-31





Timing belt


Place the vehicle on a tw o post lift.


Remove :- the fron t r ight hand wheel,- the belt from the alternator and the power

assisted steering pu mp if fitted (see section07),

- the crankshaft accessories pulley.

11

10267R


Crankshaft accessories pulley

mounting bolt 2 + 90°

Mounting bolt for front right

suspended engine mounting

on engine 6.2

Mounting bolt for front right

suspended engine mounting

on vehicle body 6.2



Mot. 1135-01 Tool for tensioning timingbelt


Mot. 1379 Tool for securing engine to

subframe

Mot. 1386 Tool for pre-tensioning timing

belt

Fit too l Mot. 1379.

D7F engine

11-1




Timing belt 11

Tighten the tension wh eel nu t.

Turn the engine at least tw ice (never in the op-

posite direction to normal operation).

Insert the pin in the eng ine at TDC, then removethe pin .

Check that the tim ing is correct on the crankshaftand camshaft side.

Slacken the tension wheel nu t and turn it slightlyclockwise using tool Mot. 1135-01 un til the twoholes of the tension wheel are lined u phorizontally.

Retighten the tension wheel nut.

b) Turn the engine at least twice (never in the

opposite direction to normal operation).

Insert the pin in the engine at TTTTDDDDCCCC then re-move the pin.

Using tool Mot. 1386, app ly a p retensioningtorque of 1 daN.m between the crankshaftsprocket and the water pum p.

Fit too l Mot. 1273 and note the tension measure-ment, which should be 20±3333 UUUUSSSS (fitting ten sion),or simp ly ad just by varying the position of thetension wheel using Mot. 1135-01 and repeat the

tensioning p rocess in (b).

Tighten the tension wheel nut to a torqu e of 5 daN.m.

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT

Following each variation of the tension wheelposition, turn the engine at least twice beforeproceeding to measu re the tension .

App ly the pretensioning of 1 daN.m wh ich allowsall belt p lay to be eliminated.


Fit the suspend ed engine mou nting .

12924S1

10881R

D7F Engine

11-4




Timing belt


Place the veh icle on a 2 post lift.


Fit the engine sup port tool.

11

13370S


Mot. 591-02 Index pin

Mot. 591-04 Angle tightening w renchMot. 1135-01 Tool for tensioning timing

belt


Wheel bolts 9

Crankshaft pulley bolts 2 + 68° ± 6°

Tension wheel nut 5

Bolt for suspended engine mounting cover 6.2

Nut for suspended engine mounting cover 4.4

13359R

Remove :- the front r ight wheel along with the mud-

guard,- the suspended engine mounting cover ,


Engine support tool

- the belts for the alternator and the powerassisted steering pu mp .

TTTTIIIIGGGGHHHHTTTTEEEENNNNIIIINNNNGGGG TTTTOOOORRRRQQ Q Q UUUUEEEESSSS ((((IIIInnnn ddddaaaaNNNN....mmmm oooorrrr ////aaaannnndddd° )

E7J Engine

11-5




Timing belt 11

13362S

Bring the engine to the setting point.

Align th e markings (L) of the crankshaft sprocketwith the fixed marking (M); the marking (N) of

the camshaft sprocket must be in the position il-lustrated below.

Slacken the nu t (O) and and release the tensionwh eel , then rem ove the belt.

(1) Tensioner direction of rotation.

- the crankshaft pulleys and hub,- th e tim in g cover.

13506R

10072S

E7J Engine

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT : The camshaft sprocket bears fivemarkings, of which only the rectangu lar one onthe su rface of one of the teeth represents TDC;the other markings are intend ed as an aid for ad-

justing the valve rockers.

11-6




Timing belt 11


An arrow ind icating the direction of rotation andtwo d ashes for setting are m arked on the surface

of the belt .

Check that the engine is at the setting p oint.

Bring the belt mar kings in line with the sprocketmarkings .

Observe the mou nting d irection for the belt andbegin to position it on the crankshaft sprocket.

Carry ou t the tensioning of the belt using toolMot. 1135-01, until the fitting value is obtained

(see section 07 "Timing belt tension ").

Tighten the nut (O) of the tension wh eel to a tor-que of 5 daN.m.

It is essential to tighten the nut of the tension

wheel to a torque of 5 daN. to avoid any slacke-

ning w hich may cause a deterioration in the en-

gine .


Refit the crankshaft pu lley, being su re to tightenthe bolt to a torque of 2 daN.m with an an gle of 68° ± 6°.

Refit and tension the accessories belts (see section07 "Accessories belt tension").

Never refit a belt once removed , but rep lace it.

E7J Engine

11-7




Timing belt 11


Place the vehicle on a 2 post lift.


Remove :- the front r ight hand wheel and the mud-

guard,- the protective plastic covering over the sus-

pend ed engine mounting cover .

Fit the engine sup por t tool.





Engine support tool

14mm torx socket

13370S

Remove :- the accessor ies belt,

- the suspended engine mounting cover.

13086R1

Wheel bolts 9

Crankshaft pul ley bol t 2 + 115° ± 15°

Tension wheel nut 5

Bolt for suspended engine mounting

cover 6.2


TTTTIIIIGGGGHHHHTTTTEEEENNNNIIIINNNNGGGG TTTTOOOORRRRQQ Q Q UUUUEEEESSSS ((((iiiinnnn ddddaaaaNNNN....mmmm oooorrrr////aaaannnndddd °)

F8Q Engine

11-8




Timing belt 11

13095S

Adjusting the timing

Turn the cranksh aft so that the camshaft timingreference mark is visible through the timing win-

dow .

Remove the TTTTDDDDCCCC pin plug .

Fit the TDC pin, tool Mot. 1054.

12419R

Remove :- th e tim in g cover s,

12518R

- the crankshaft pu lley.

Slacken the tension w heel and remove the belt.

NNNNOOOOTTTTEEEE :::: Slackening the tension wheel bolt bymore than one turn m ay cause it to come loose .

F8Q Engine

11-9




Timing belt 11


Check that the p in Mot. 1054 is in place.

Fit the timing belt by aligning the belt markingswith those of the camshaft, injection pu mp andcrankshaft sprockets.

13096R

Tension the timing belt by tightening a bolt ( A )on the inner timing hou sing.

Fit too l Mot. 1273 and tension the belt un til thefitting value is reached (see section 07 "Timing

belt tension").

13094R

Tighten the tension wheel nu t to 5 daN.m.

NNNNOOOOTTTTEEEE :::: it is essential to tighten the tension wh eelnut to a torque of 5 daN.m to avoid any slacke-ning w hich m ay bring about a deterioration in theengine.

Replace the crankshaft pulley bolt .

Refit the crankshaft pu lley , being sure to tightenthe bolt to a torque of 2 daN .m with an an gle of 115° ± 15°.


Refit the accessories belt (see section 07

"Accessories belt tension").

NNNNOOOOTTTTEEEE : Never refit a belt once it has been remo-ved , but rep lace it.

F8Q Engine

11-10



12mm torx socket

Angular tightening wrench


Cylinder head gasket 11


Mot. 591-04 Angle w rench for tightening

cylinder head and index



Mot. 1379 Tool for securing engine to

subframe



Crankshaft output mounting bolt 2 + 90°




engine mounting on vehicle body 6.2


Wheel bolts 9



Remove the bonnet, and the right hand wh eel .


Drain the cooling circuit.

Fit the engine sup port tool, Mot. 1379.


section 11 "Timing belt"),- the d ip stick,- th e brake servo p ip e,- th e air filter,- the accelera tor cable,- the fuel supply and return pipes level with the

timing belt cover on the cylinder head

D7F Engine

11-11





- the canis ter pipe along with the fuel vapourrebreathing h oses on the solenoid valve,

- th e conn ectors :• of the ignition modu le,• of th e in jector s,• of the idle speed regulation stepping

motor,• of the throttle position potentiometer,• of the air temperature sensor .

Extract the hose connecting the w ater pu mp tothe hea ter matrix, and the electrical w iring loomfrom the heat sh ield on the rocker cover.

99940R

Disconnect :- the spark plug leads using tool (3) which is in-

tegrated to the plastic cover (4),

99894R1

D7F Engine

11-12





Remove :- the mounting bolts (5) for the throttle body retaining bracket on the

cylinder h ead,- the mounting nuts (3) for the manifold on the cylinder head

- the mounting bolts (4) of the manifold on the valve rocker cover- the inlet manifold, throttle body and injector gallery assembly.

- the thermosta t hoses,- the valve rocker covers,- the cy linder head mounting bolt s,

- th e cylind er head .

99937R1

D7F Engine

11-13





92076S

CCCCLLLLEEEEAAAANNNNIIIINNNNGGGG

It is very important not to scratch the gasket facesof the alum inium comp onents.

Use the Décapjoint prod uct to dissolve any p art of the gasket wh ich remains attached.

App ly the produ ct to the parts to be cleaned; waitabout ten m inutes, then remove it using awooden spatula.

Wear gloves wh ilst carrying out this opera tion.

Care must be taken whilst carrying out this ope-

ration in order to avoid any foreign bodies en te-

ring the oilw ays supplying oil under pressure to

the camshaft (oilw ays are located both in the cy-linder block and the cylinder head).

Failure to follow to this advice could lead to the

blocking o f the jets and thus cause rapid deterio-

ration of the cams and tappets.

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE GGGGAAAASSSSKKKKEEEETTTT FFFFAAAACCCCEEEE

Check for gasket face bow u sing a straight edgeand a set of shims .

Maximu m d eformation : 0.05 mm.

No regrinding of the cylinder head is permitted.


The cylind er head is centred by two d owels at therear of the engine.

RRRREEEEMMMMIIIINNNNDDDDEEEERRRR:::: in order to obtain the correct tighte-ning of the bolts, use a syringe to remove any oilwh ich may have entered the cylinder head moun -ting bolt holes .

Grease the threads and und er the bolt heads w ithengine oil.

Adjustment of the valve rockers and tightening

of the cylinder head should be carried out when

the engine is cold.

D7F Engine

11-14





99902S

Tighten the cylind er head using an angular tighte-ning w rench (see section 07 "Tightening the cy-

linder head").

Tighten using tool Mot. 591-04.

Line up the reference mar ks on the timing beltwith the markings on the sprockets.

10072S

Remove the TDC pin .

Refit the timing belt (see method described inchapter 11 "Timing belt ").

D7F Engine


: The cam shaft sprocket bears fivemarkings, of which only the rectangular one onthe sur face of one of the teeth represents TDC;the other markings are intend ed as an aid for ad-

justing the valve rockers.

11-15





AAAADDDDJJJJUUUUSSSSTTTTMMMMEEEENNNNTTTT OOOOFFFF VVVVAAAALLLLVVVVEEEE RRRROOOOCCCCKKKKEEEERRRRSSSS ((((IIIIFFFF

NNNNEEEECCCCEEEESSSSSSSSAAAARRRRYYYY))))

Partly refit the susp ended engine moun ting ti-

ming cover on the engine using two bolts.

Bring the engine to TDC , cylinder n. 1 in ignitionphase .

Turn the crankshaft clockwise (viewed from thetiming side ) to reach the first reference mark.

AAAADDDDJJJJUUUUSSSSTTTT :::: exhaust 1

exhaust 3

move forward to the second mark :

AAAADDDDJJJJUUUUSSSSTTTT:::: inlet 1

inlet 3

third mark :

ADJUST: exhaust 2

exhaust 4

fourth mark :

AAAADDDDJJJJUUUUSSSSTTTT:::: inlet 2

inlet 4

10072S

99905S


Remove the tool retaining the engine on the sub -frame, Mot. 1379.

NNNNOOOOTTTTEEEE :::: tightening the inlet manifold :- progressively hand tighten the six nuts untilthe inlet man ifold comes into contact with thecylinder head, then tighten them to a torqueof 1.5 daN.m,

- fit the upper bolts and tighten them to a tor-que of 0.9 daN.m.

Fill and b leed th e cooling circuit.

Ad just the accelerator cable.

VVVVAAAALLLLVVVVEEEE CCCCLLLLEEEEAAAARRRRAAAANNNNCCCCEEEE AAAADDDDJJJJUUUUSSSSTTTTMMMMEEEENNNNTTTT VVVVAAAALLLLUUUUEEEE

(in mm)

Inlet 0.05

Exhaust 0.15

D7F Engine

11-16






DDDDEEEEPPPPOOOOSSSSEEEE

Place the veh icle on a 2 post lift .


Remove :- th e bon net ,- the timing belt (see method described in sec-

tion 11, "Timing belt ").

Drain the cooling circuit through the lower rad ia-tor hose.

Fit too l Mot. 1159 between the engine subframe

and the cylind er block.

99024R2


Engine support tool

55mm torx socket

Mot. 588 Retaining bracket

Mot. 591-02 IndexMot. 591-04 Angle tightening angular

wrench


subframe




Tension wheel nut 5

Crankshaft pul ley bol t 2 + 68° ± 6°

Bolt for suspended engine mounting 6.2

cover


Wheel bolts 9

TTTTIIIIGGGGHHHHTTTTEEEENNNNIIIINNNNGGGG TTTTOOOORRRRQQ Q Q UUUUEEEESSSS ((((iiiinnnn ddddaaaaNNNN....mmmm oooorrrr ////aaaannnndddd °)

E7J Engine

11-17





13339S

- the cover on the air filter assembly,- the a ir filt er assembly ,

13338S

99310R

Remove :- the connector along with the pipe on the ab-

solute pressure sensor,- the stepping motor connector ,

Fit the bracket Mot. 1159 in place of the coolantpipe moun ting on the cylinder block, then rem ovethe engine supp ort tool.

- the throttle position potentiometer connec-tor,

- the accelerator cable- the air intake pipe, having disconnected the

air temp erature connector,

E7J Engine

11-18



- the heat shield along with the exhaust down-pipe,

- the alternator,- the mounting at (8) along with connector (9)

of the pressostat,- the mounting bolt for the power assisted

steering pu mp and move this to one side ,- the mounting bolts for the multi-function sup-

port and move this to one side,



13365S

13364R1

13360R

- the connectors and hoses on the thermostatsupport ,

- the connectors of the ignition coils, alongwith the connector at (1),

- the coil (2),- the pipes at (3) along with the connector (4),

- the p ip e at (5),- the lift ing bracket (6),- the fuel supply and return pipes (7) using tool

Mot. 1311-06,- the in jector connectors,- the cy linder head cover ,

E7J Engine

11-19





Unhook the wiring loom at (14).

Remove :- the cylinder head bolts except for (F) which

mu st simp ly be loosened, then p ivot the cylin-der head around the bolt.

92106R

- th e cylind er head .

Fit the cylind er liner retaining brackets, toolMot. 588.

92062R

- the moun ting a t (10),- the bolt (11) of the strut and slacken the nut

at (12),- the mounting bolt (13) of the dipstick guide

tube,

13336-1R1

E7J Engine


It is very important not to scratch the gasket facesof the alum inium components.

Use the Décapjoint prod uct to dissolve any p art of the gasket wh ich remains attached.

App ly the prod uct to the parts to be cleaned; waitabout ten m inutes, then remove it u sing awooden spatula.

Wear gloves wh ilst carrying out this operation.

Care must be taken whilst carrying out this ope-

ration in order to avoid any foreign bodies ente-

ring the oilw ays supplying oil under pressure to

the camshaft (oilw ays are located both in the cy-

linder block and the cylinder head).

Failure to fol low to this advice could lead to the

blocking o f the jets and thus cause rapid deterio-

ration of the cams and tappets.

11-20






Check for gasket face bow, using a straight ed geand a set of shims.

Maximu m deformation: 0.05 mm.



Remove the cylinder liner brackets Mot. 588.

Check for the presence of the centring dow el (A).

98713R1

Position the cylinder h ead gasket.

Grease the threads and und er the bolt heads .

Refit the cylind er head (shortest bolts on the inlet

side ).

Tighten the cylind er head (see section 07

"Tightening the cylinder head").

Refit the timing belt , (see section 11 "Timing

belt").

Correctly refit the heat shields.


Fill and bleed the cooling circuit, (see section 19

"Filling and Bleeding").

AAAADDDDJJJJUUUUSSSSTTTTMMMMEEEENNNNTTTT OOOOFFFF VVVVAAAALLLLVVVVEEEE RRRROOOOCCCCKKKKEEEERRRRSSSS ((((IIIIFFFF

NNNNEEEECCCCEEEESSSSSSSSAAAARRRRYYYY))))

Adjustment values (cold engine) (in mm) :

- inlet 0.10- exhaust 0.25

"Tilt" method

E7J Engine

Place the valves of thecylinder concerned inthe "end of exhau st-

beginning of inlet"position

Adjust the valve rockerclearance for the

cylinder concerned

1 4

3 2

4 1

2 3

11-21





Open exhaust valve method

Bring the exhau st valve of cylind er n° 1 to the fully open position, then ad just the inlet valve clearance forcylinder n° 3 and the exhaust valve clearance for cylind er n° 4.

Follow the same method for the other cylind ers, in the order show n by the table below.

Inlet valve to be ad ju sted . Exhau st valve to be ad ju sted .Exhau st valve to be opened .

78373R

E7J Engine

11-22





Remove :- th e exh au st d ow np ip e,

- the hoses and connectors of the cylinder headcoolant p ipe housing outlet,

- the connect ion at (1) using tool Mot. 1311-06,

13097R

99461R

- the air filter assembly by disconnecting theEEEEGGGGRRRR solenoid valve and the air temperaturesensor (unclip the fuel supp ly pipes from theair filter h ousing),

- th e air in let p ip e- the accelerator cable- the feeds for the heater p lugs ,- the connector of the injector with sensor,

along with the fast idle solenoid va lve connec-tor (5),

- the fuel supply and return unions at (A) and(B).

Disconnect conn ector (6) from the d iesel fuel fil-ter, remove it from its sup port and move the die-sel fuel filter p ipe assembly to one side.

Place bracket Mot. 1159 at the mou nting of thecoolant pipe on the cylinder block, then removethe engine supp ort tool.

99310R

F8Q Engine

11-24





13083-1R1

To release the qu ick release un ions, refer to thefollowing diagrams.

11734R

F8Q Engine

11-25





11733R

Remove the fuel pipe sup por t (7).

Slacken the mou nting bolts for the lower timingcover, without removing them . 99173-1R

13093R

Remove :- the accessories belt tensioning system,- the cy linder head bolts.

Release the cylinder head by setting aside thelower part of the lower camshaft housing,withou t causing the cylinder head to pivot, sincethis is centred by the two dowels at ( C ).

Using a syringe, extract any oil wh ich may haveentered the cylinder head mounting holes .

This is necessary in ord er to obtain the correcttightening of the bolts.

Protect the oil outlet duct in order to prevent anyforeign bod ies from entering the oilways in thecylinder h ead.

Failure to take this advice could lead to the

blocking of the oilways, resulting in a rapid dete-

rioration of the camshaft.

F8Q Engine

11-26





Wear gloves wh ilst carrying ou t this operation.

99180S


Check for gasket face bow, using a straigh t edgeand a set of shims.

Maximu m deformation: 0.05 mm.


Check the cylind er head for cracks.

F8Q Engine


It is very important not to scratch the gasket faces

of the alum inium comp onents.

Use the Décapjoint prod uct to dissolve any part of the gasket which remains attached.

App ly the prod uct to the parts to be cleaned; waitabout ten minutes, then remove it using awooden spatula.

11-27






Refit the cylind er head gasket selected previous-ly. This is centred by two dow els at (C).

99173-1R

Bring the pistons to m id-stroke position toprevent them from coming into contact w ith thevalves du ring the tightening of the cylind er head .

Centre the cylind er head on the d owels.

Lubricate the threads and und er the heads of themoun ting bolts.

Tighten the cylinder head (see section 07

"Tightening the cylinder head").


Refit the timing belt, (see method described insection 11 "Timing belt").

Fill and bleed the cooling circuit , (see section 9

"Filling -bleeding").

MMMMEEEEAAAASSSSUUUURRRRIIIINNNNGGGG TTTTHHHHEEEE TTTTHHHHIIIICCCCKKKKNNNNEEEESSSSSSSS OOOOFFFF TTTTHHHHEEEE CCCCYYYYLLLLIIIINNNNDDDDEEEERRRR

HHHHEEEEAAAADDDD GGGGAAAASSSSKKKKEEEETTTT

Checking piston protrusion

Clean the piston head s in ord er to eliminate anytraces of dep osits.

Turn th e crankshaft in its opera ting directiononce, to bring piston n° 1 close to TTTTDDDDCCCC ....

Fit tool Mot. 252-01 on the piston .

Fit tool Mot. 251-01, complete with d ial gaugeMot. 252-01. on the plate Ensure that the dialgauge measu ring pin is in contact with the cylin-der block; then locate the piston TTTTDDDDCCCC....

NNNNOOOOTTTTEEEE : All measu remen ts are to be carried ou t inthe longitud inal axis of the engine, in order to eli-minate an y errors du e to tilting of the piston.

99173R

Measure the piston protrusion.

OOOONNNNLLLLYYYY TTTTAAAAKKKKEEEE IIIINNNNTTTTOOOO CCCCOOOONNNNSSSSIIIIDDDDEEEERRRRAAAATTTTIIIIOOOONNNN TTTTHHHHEEEE

DDDDIIIIMMMMEEEENNNNSSSSIIIIOOOONNNNSSSS OOOOFFFF TTTTHHHHEEEE PPPPIIIISSSSTTTTOOOONNNN WWWWIIIITTTTHHHH TTTTHHHHEEEE

GGGGRRRREEEEAAAATTTTEEEESSSSTTTT PPPPRRRROOOOTTTTRRRRUUUUSSSSIIIIOOOONNNN....

For a m aximu m p iston protru sion:- low er than 0.868 mm, use a gasket marked by

a tab with tw o holes ,- included between 0.868 mm an d 1mm , use a

gasket marked by a tab w ith one hole,

- gr eater th an 1mm , use a gasket marked by atab with three holes.

F8Q Engine

11-28




Replacement of valve adjusters 11


Mot. 1366-01 Tool for removing valve adjusters

(additional item to Mot. 1366)


Studs for mounting manifolds on

cylinder head 1

Nut for mounting manifolds on

cylinder head 2.7

Mounting bolt for strut on inlet manifold 2.5

Mounting bolt for strut on cylinder block 2.5

Place the vehicle on a tw o-post lift


CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE VVVVAAAALLLLVVVVEEEE CCCCLLLLEEEEAAAARRRRAAAANNNNCCCCEEEE

Remove the air filter housing along with the cy-lind er head cover.

Place the valves of the cylinder concerned at the"end of exhaust - beginn ing of inlet" position andcheck the clearance .

86911-1S

1

3

4

2

4

2

1

3

Compare the two dimensions noted to the re-comm ended dimensions, and replace the ad jus-ters if necessary .

Clearance ( in mm ), when the engine is cold :

- Inlet: 0.10

- Exhaust : 0.25

F8Q Engine

11-29




Replacement of valve adjusters 11RRRREEEEPPPPLLLLAAAACCCCEEEEMMMMEEEENNNNTTTT OOOOFFFF VVVVAAAALLLLVVVVEEEE AAAADDDDJJJJUUUUSSSSTTTTEEEERRRRSSSS

In order to carry ou t this operation it is necessaryto remove the inlet and exhau st manifolds (seesection 12 Inlet/Exhaust Manifolds) .

Fully open the valve concerned (by turning theengine in its operating d irection).

Insert tool Mot. 1366-01 into the duct concerned .

11231R

For inlet valves

Turn the engine in the opera ting direction,inorder to bring the valve into contact with toolMot. 1366-01 (rotate the camshaft by 90° in

relation to the fully open position).

For the exhaust valves

It is v ital to turn the eng ine in the opposite direc-

tion to normal operation (in ord er to avoid thelocking of the engine), until the valve comes intocontact with tool Mot. 1366-01 (rotate camshaftby 90° in the relation to the fully open p osition).

Extract the valve adjuster using a screwd river and

a m agnetic tool.

11232-1R

NNNNOOOOTTTTEEEE : du ring the refitting of the valve adjuster,extract any oil which may be in the bottom of thepu shrod bore ( C ) .

98895R1



F8Q Engine

11-30



FUEL MIXTURE

Specifications 12

DDDDEEEESSSSCCCCRRRRIIIIPPPPTTTTIIIIOOOONNNN MMMMAAAAKKKKEEEE////TTTTYYYYPPPPEEEE SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS

Throttle body MAGNETI MARELLI

873 633

diam eter 36 mm

Idle speed regu lation steppingmotor

AIR PAX Voltage: 12 V (at high frequency)Resistance : tracks A-D 100 ± 10 Ω

tracks B-C 100 ± 10 Ω

Throttle positionpotentiometer

-

Voltage: 5 V

Resistance :

Fuel vapour rebreathingcanisterSolenoid valve

-Voltage: 12 Volts

Resistance : 35 ± 5 Ω

Heated oxygen sensor BOSCH Voltage at 850 °CRich m ixture > 625 mvolts

Lean mixture : 0 to 80 mvolts

Heating r esistance, tracks A-B : 3 to 15 Ω

Tightening torqu e : 5 daN.m

Diagnostic function FICHE n° 27CODE D13

SELECTOR S8

Throttle poten tiometer:Regulated idle speed : 10 ≤ # 17 ≤50

Full load : 185 ≤ # 17 ≤240

Idle speed R.C.O. : 4 %≤ # 12 ≤14 %

Adap tive idle speed R.C.O. :- 4.3 %≤ # 21 ≤+3.9 %

Adaptive richness operation : 106 ≤ # 30 ≤150

Adaptive idle speed r ichness : 106 ≤ # 31 ≤150

Track No load Full load

ABACBC

1300 Ω1360 Ω2300 Ω

1300 Ω2350 Ω1260 Ω

D7F engine

12-3



FUEL MIXTURE

Specifications 12

Vehicle Gearbox

Engine

Type SuffixBore

(mm)

Stroke

(mm)

Capacity

(cm3

)

RatioCatalytic

converter

Depollu-

tion

standard

XC0C Manual E7J 780 75.8 77 1390 9.5/ 1 C63 EU 96

Temperature in °C (± 1°) 0 20 40 80 90

Air temperature sensor

Type CTNResistance in Ohm s

7470 to11970 3060 to 4045 1315 to 1600 - -

Coolant temperature sensor

Type CTNResistance in Ohm s

6700 to 8000 2600 to 3000 1100 to 1300 270 to 300 200 to 215

Engine

Type Suffix

Tests at idle speed*

Enginespeed

[rpm]

Pollutant emission **

CO (%) (1) CO2 (%) HC (ppm) Lambda (λ)

Fuel***

(minimum octanerating)

E7J 780 750±50 0.5 max 14.5 min 100 max 0.97<λ<1.03 Unleaded (OR 95)

(1) at 2500 rpm , CO mu st be a maximu m of 0.3

* For a coolan t tem p er atu re abov e 80°C and after stable speed of 2500 rpm , for abou t 30 second s. Test to

be carried ou t after return to idle speed.** For legal values refer to your country specification.*** OR 91 unleaded compatible.

E7J engine

12-4



FUEL MIXTURE

Specifications 12


Computer SIEMENS

FENIX 5

55tracks

Injection - Multipoint with semi-sequential regulation

Ignition

-

Static with 2 du al outpu tmonobloc coilsPower mod ule integralin comp uterOne pinking sensor

tightening torque : 2.5 daN.m

TDC sensor - Resistance 220 Ω

Plugs EYQUEM : RFC52LSCHAMPION : RC10PYC

Gap: 0.9 mm

Tightening torque: 2.5 to 3 daN.m

Fuel filter - Mounted under vehicle in front of fuel tankReplaced d ur ing major service

Fuel pu mp WALBRO Subm erged in fuel tankFlow: at least 80 litres/ hour at a regulated pressure

of 3 bars and a voltage of 12 V

Pressure regulator-

Regulated p ressureZero vacuu m : 3 ± 0.2 bars

Vacuu m of 500 mbars : 2.5 ± 0.2 bars

Solenoid injectors SIEMENS Voltage: 12 Volts

Resistance : 14.5 ± 1 Ω

Tracks Res istance

1 - 2 0.5 Ω

1 - 32 -3

1 Ω

HT - HT 10 KΩ

E7J engine

12-5



FUEL MIXTURE

Specifications 12


Throttle body PIERBURG

714 227

diam eter 41 mm

Idle speed regu lation steppingmotor

- Voltage: 12 V (at high frequency)Resistance : tracks A-D 52 ± 5 Ω

tracks B-C 52 ± 5 Ω

Throttle positionpotentiometer

-

Voltage: 5 V

Resistance :

Fuel vapour rebreathingcanisterSolenoid valve

DELCO REMY Voltage: 12 Volts

Resistance : 35 ± 5 Ω

Heated oxygen sensor NGK Voltage at 850 °C

Rich m ixture > 625 mvoltsLean mixture : 0 to 80 mvolts

Heating r esistance, tracks A-B : 3 to 15 Ω

Tightening torqu e : 4.5 daN.m

Diagnostic function FICHE n° 27CODE D13

SELECTOR S8

Throttle poten tiometer:Regulated idle speed : 16 ≤ # 17 ≤50

Full load : 185 ≤ # 17 ≤243

Idle speed R.C.O. : 2 %≤ # 12 ≤15 %

Adap tive idle speed R.C.O. :- 2.4%≤ # 21 ≤+6.2 %Adaptive richness operation : 64 ≤ # 30 ≤192

Adaptive idle speed r ichness : 64 ≤ # 31 ≤192

Track no load full load

1-21-32-3

5440 Ω4500 Ω2160 Ω

2200 Ω4460 Ω5340 Ω

E7J engine

12-6



FUEL MIXTURE

Throttle body 12D7F engine

Throttle body mounting bol t on

inlet manifold 1

Throttle body stiffening bracket

mounting bolt on cylinder head 1


There are no special notes for removal - refi tting.

12-7



FUEL MIXTURE

Throttle body 12

Throttle body mounting bolt 1




Remove the air filter.

Remove the a ir intake p ipe (1).

Disconnect:- the accelerator cable,- the con nectors :

• of the stepping motor (2),• of the thrott le potent iometer (3).

E7J engine

Remove the four throttle body mou nting bolts (5)and remove the throttle body.


Replace the th rottle body seal.

Refitting is then th e reverse of rem oval.

13339R1

13338R

12-8



FUEL MIXTURE

Inlet manifold 12

Inlet manifold bolt and nut 2



Remove:- the air filter,- the injector gallery (see section 13).

Lift the vehicle.

Remove the stru t (1) (to gain access to the boltfixing the strut on th e right-hand side of the vehi-cle, remove the mu dgu ard and the right-hand

wheel).

E7J engine

13339R2

Disconnect th e accelerator cable an d the electrical

connectors (2) connected to th e throttle body.

Remove the bolts and nuts (3) secur ing the mani-fold.

Low er the vehicle.

Remove the air intake p ipe (A) connecting thethrottle body to the air filter.

13335-1R

13130R

12-10



FUEL MIXTURE

Inlet manifold 12

Remove the two bolts (4) moun ting the retainingbracket on the cylind er block.

E7J engine

13338R1

Extract the m anifold.


Replace the inlet man ifold gaskets.


12-11



FUEL MIXTURE

Exhaust manifold 12D7F engine

Manifold mounting nut 2.5

Manifold mounting stud 1

Exhaust downpipe mounting bolt 2.2


There are no special notes for the removal - refitting.

12-12



FUEL MIXTURE

Exhaust manifold 12

Manifold mounting bolt 2



Remove the mu ltifunction sup por t (1) (see section10).

Disconnect the exhaust man ifold / exhau st link(2).

Remove the heat sh ield (3).

Remove the exhau st manifold.

E7J engine

13239R2


Replace the m anifold gasket.


12-13



FUEL MIXTURE

Inlet/Exhaust manifolds 12F8Q engine

Manifold mounting studs on cylinder head 1

Manifold mounting nuts on cylinder head 2.7

Inlet manifold strut mounting bolt 2.5

Cylinder block strut mounting bolt 2.5



Remove the air filter (two m oun ting bolts at thetop, two moun ting nuts at the bottom (1)).

Remove, from above, the two n uts fixing the ex-haust d ownp ipe to the manifold.

Slacken, withou t remov ing it, the nu t on the

clamp connecting the d ownp ipe to the exhaustpipe.

Tilt the exhau st dow npipe tow ards the gearbox.

Remove the nuts securing the manifolds:- n uts (A) from above,- nu ts (B) from below.

PRO12.1

Special note

To remove nu t (C) located above the starter mo-tor, use a small ratchet (6.35 mm square) and aun iversal joint.

13047-1R1

13047R

12-14



FUEL MIXTURE

Inlet/exhaust manifolds 12F8Q engine


Replace the m anifold gaskets (metal part of thegasket on the m anifold side).

Replace the gaskets between the inlet man ifoldand the air filter.

Replace the steel gasket between th e exhaust ma-nifold and the exhaust down pipe.

For the other op erations, refitting is the r everse of removal.

12-15



FUEL SUPPLY

Fuel cut off in case of an impact 13

OOOOBBBBJJJJEEEECCCCTTTTIIIIVVVVEEEE

The main function of this feature is to avoid anyfires that may result from the leakage of fuel du -

ring an acciden t. In order to achieve this, allcomp onents pum ping fuel from the fuel tank willautomatically stop functioning du ring and imme-diately after the impact. They can then on ly bemade to op erate again by a m echanical action car-ried out by the driver or the repairer.

DDDDEEEESSSSCCCCRRRRIIIIPPPPTTTTIIIIOOOONNNN

The system consists simp ly of an inert ia switch (1),which:- d etects th e im pact,- and thus cuts off the electrical circuit.

13051R

This is fitted :• in petrol engines , between track 1 of the

pum p relay (236) and the + 12 V supply ,

• in diesel engines , between th e + supply andthe electrical solenoid (or the coded solenoidvalve if the vehicle is fitted w ith an engine im-mobiliser).

OOOOPPPPEEEERRRRAAAATTTTIIIINNNNGGGG PPPPRRRRIIIINNNNCCCCIIIIPPPPLLLLEEEE

Dur ing the impact, the ball of the inertia switchmoves up and interrup ts the electrical connec-tion.

In petrol engines , the + supp ly of the pum p relaycontrol circuit (236) is cut. Neither the p um p orthe injectors will receive any further sup ply of electricity .

The fuel contained in the tan k is actually isolated.

In diesel engines, the + sup ply of the electricalsolenoid or of the coded solenoid is cut off.

The pum p can n o longer take in fuel, and there isno longer any high pressure. All risk of fire due tothe outlet of diesel fuel at high pressu re onto theengine is removed.

RRRREEEESSSSEEEETTTTTTTTIIIINNNNGGGG AAAANNNNDDDD OOOOPPPPEEEERRRRAAAATTTTIIIINNNNGGGG TTTTHHHHEEEE SSSSWWWWIIIITTTTCCCCHHHH

In ord er to r eset the inertia sw itch, it is sufficientto press it dow n in ord er to replace the ball bea-ring in its original position .

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT:::: for petrol engines , , having resetthe sw itch, it is VVVVIIIITTTTAAAALLLL to erase the memory of thecomp uter, using the XXXXRRRR22225555. The injection compu-ter will memorise a pump relay fault once thesystem has gone into operation .

13-1



FUEL SUPPLY

Injector gallery 13

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT:::: du ring the op ening of the fuel cir-cuit , be sure to use a cloth to avoid possible pro-

jections of fuel du e to the r esidual p ressure.


Disconnect :- the battery,- the pressure measurement pipe (1) of the

pressure regu lator,- the fuel r etu rn p ipe (2),- the electrical connector of the injectors (3)

99937R3


Mot. 1311-06 Tool for removing the fuel

supply unions

Bolt mounting injector gallery on manifold 1


D7F Engine

13-2



FUEL SUPPLY

Injector gallery 13

To disconnect the unions, slip tool Mot. 1311-06

between the two stems (A) and (B).

Press on the tool to lift the two retaining clips,then pu ll on the un ion.

Remove the two bolts (5) moun ting the injectorgallery on the man ifold.Slide the injector gallery, along w ith the injectors,between the man ifold and the cylinder head .

Extract the injector gallery from the right han dside of the veh icle.

NNNNOOOOTTTTEEEESSSS ::::The fuel pressu re regulator (6) is clippedto the injector gallery.

There is an intermed iate connector (7) betweenthe injector connector (8) and the compu ter.

10046R

Disconnect the fuel supply pipe (4) using the toolMot. 1311-06 with the largest section (the fuelsupp ly pipe is equipped w ith a removal toolwhich is attached to the connection incorporated

in the vehicle ).

99375R

99461R1

D7F Engine

13-3



FUEL SUPPLY

Injector gallery 13

In order to extract an injector, remove the clip(9), then p ress on the fastener (10) before pu llingon the injector.

PRC13.1

10047R


Replace the O r ings at the base of the injector (if the injector has been rem oved, also replace the

seal wh ich is level with the injector head).

To ensur e that the fuel supp ly un ions are correct-ly fastened , it is necessary to hear a"click" whilstfastening.

For all other operations, refitting is the reverse of removal .

DF7 Engine

13-4



FUEL SUPPLY

Injector gallery 13

In order to remove an injector, remove the clips at(8), then pull on th e injector .

99373R

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT:::: du ring the op ening of the fuel cir-cuit , be sure to use a cloth to avoid possible pro-

jections of fuel d ue to the residual pressur e.



Remove the air filter.

Remove:- the fuel supp ly pipe (1)- the fuel r etu rn p ipe (2)- the fuel pressure regulator pipe (3) .

Remove the three bolts (4) mou nting the injectorgallery (5).

Remove the injector gallery.

E7J Engine

13244R


Replace the O r ings at the base of the injector (if the injector has been rem oved, also replace theseal wh ich is level with the injector head).

To ensur e that the fuel supp ly un ions are correct-ly fastened , it is necessary to hear a"click" sound

wh ilst fastening.

For all other operations, refitting is the reverse of removal .

13-5



FUEL SUPPLY

Fuel filter 13

LLLLOOOOCCCCAAAATTTTIIIIOOOONNNN

The fuel filter is located u nd er the vehicle, infront of the fuel tank.

Petrol

engines

99214R


Mot. 1265 Pl iers for removing quick re lease

unions

RRRREEEEPPPPLLLLAAAACCCCEEEEMMMMEEEENNNNTTTT

It is recommen ded to replace the fuel filter ateach vehicle major service.

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: du ring the op ening of the fuel cir-

cuit , be sure to use a cloth to avoid possible projections of fuel d ue to the residual pressur e.


Before removing the filter take p recautions tocatch fuel that w ill run ou t of the p ipes (the pipes

should not be clamped as they would be dama-

ged).

Remove the clips (1).

Disconnect the p ipes fitted with quick releaseun ions (2) using tool Mot. 1265.

96420R3

Remove bolt (3) and remove the fuel filter.


Observe the flow d irection of the fuel (marked byan arr ow on the filter).

Reconnect the pipes by hand (tool Mot. 1265 isnot required ).

Ensure tha t the qu ick release unions are correctly

fastened .

Refit the safety clips (1).

13-6



FUEL SUPPLY

Pump flow 13Petrol

engines

96093R2


Mot. 1265 Pl iers for removing quick re lease

unions


2 000 ml measuring cylinder

It is advised to check the p um p su pp ly flowthrough the fuel return pipe connected to thepu mp -fuel sender u nit assembly.


Dur ing this operation, it is essential :• to refrain from smoking and handling incan-

descent objects close to the working area,• to take precautions against possible fuel

projections which may occur d ue to the resi-du al pressure in the supp ly pipes wh en theyare removed.

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE PPPPUUUUMMMMPPPP FFFFLLLLOOOOWWWW

Disconnect the fuel return pipe (1) (Mot. 1265).

Connect a piece of pipe to the h ose and p lace this

into a 0-2 000 ml graduated measuring cylinder.

Shu nt term inals (3) and (5) of relay (K) on the DF7

engine, or for the EEEE7777JJJJ engine shunt at (L) on thefuel pu mp relay (which is located in the enginefuse box ). In one minute, the pum p flow mu st bea minimum of 1.3 litres with a voltage of 12

volts.

If the fuel flow is low, check the pu mp feed vol-tage (app roximately 10 % reduction in flow for avoltage drop of 1 Volt)

12839S

13-7



FUEL SUPPLY

Fuel pressure 13

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE FFFFUUUUEEEELLLL PPPPRRRREEEESSSSSSSSUUUURRRREEEE


Mot. 1311-01 Fuel pressure test kit (with a pressure

gauge 0; + 10 bar tool kit)

Mot. 1311-05 Junction tool (for union K)

Mot. 1311-06 Tool for removing fuel supply unions

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: du ring the op ening of the fuel cir-cuit , be sure to use a cloth to avoid possible pro-


Disconnect the fuel sup ply pipe using the toolMot. 1311-06 with th e largest section (see methoddescribed in section 13 "Injector gallery").

Connect tool Mot. 1311-05 to the injector gallery,then reconnect the fuel sup ply pipe to the toolitself.

99375R

99934R1

99939S

DF7 Engine

13-8



FUEL SUPPLY

Fuel pressure 13

Connect pressure gau ge 0 ; 10 bars along withthe flexible hose, Mot. 1311-01.

Shu nt termina ls (3) and (5) on the pu mp relay (K) ,which is situated in the engine fuse box.

99938-1R

12839S

The pressure m ust be 3 bars ± 0,2.

By app lying a pressure of 500 mbars to thepressure regulator, a fuel pressure of 2.5 bars ±

0.2 should be obtained.

DF7 Engine

13-9



FUEL SUPPLY

Fuel pressure 13

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE FFFFUUUUEEEELLLL PPPPRRRREEEESSSSSSSSUUUURRRREEEE


Mot. 1311-01 Fuel pressure test kit (with a pressuregauge 0; + 10 bar tool kit)

Mot. 1311-05 Junction tool (for union J)

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: du ring the op ening of the fuel cir-cuit , be sure to use a cloth to avoid possible pro-


Disconnect the fuel sup ply pipe.

Fit tool Mot. 1311-04 on the injector gallery, thenreconnect the fuel supply p ipe to the tool itself.

13244-1R

EF7 Engine

Connect the p ressure gau ge 0; + 10 bars withthe flexible pipe Mot. 1311-01.

99376R

13-10



FUEL SUPPLY

Fuel pressure 13E7J Engine

Shu nt terminals (3) and (5) of the fuel pu mp relay(L) located in the engine fuse box .

12839S

The pressure m ust be 3 bars ± 0.2.

By app lying a pressure of 500 mbars to thepressure regulator, a fuel pressure of 2.5 bars ±

0.2 should be obtained.

13-11



FUEL SUPPLY

Antipercolation device 13

When the ignition is switched off, the coolant temp eratu re monitoring mod e begins.

E7J Engine

Monitoring mod e

Water temperatur e≥ 101°C

Coolant temp erature ≤ 96°CCooling fan assembly control time

≥ 10 minu tes

Cooling fan assembly stops

Exit from m onitoring mod e

The mon itoring mod e is left 2 minutes after switching off the ignition in cases where th e coolanttemperature is not greater than or equal to 101°C or once the coolant temp eratu re falls below 92°C.

no

yes

no no

yesyes

High sp eed cooling fan assembly comm and

13-12



DIESEL EQUIPMENT

General 13

The use of electronic injection in Diesel engines has a llowed th e operationa l power of these engines to beoptimised, thus redu cing the emission rate of pollutan t gases.

The system consists of a comp uter, w hich receives information from:

- the coolant temperature sensor,- the a ir temperatu re sensor ,- the engine speed sensor ,- the vehicle speed sensor ,- the load poten tiometer ,- the injection start sensor, which forms part of the injector of cylinder n° 3 (injector with sensor).

It controls :- th e in jection pu m p :

• the a ltimet ric corrector (F8Q 630) via a relay• the advance so lenoid valve.

- the cold engine starting system (heater plugs and pre-postheating unit),- the exhaust gas recycling system (EGR),- the diesel injection fault warning light,- the preheating warning light,- the solenoid valve controlling the fast idle speed LDA,- the relay controlling the power assisted steering electric pu mp assembly (for vehicles with air conditio-

ning), the pum p assembly is sup plied once the engine speed exceeds 650 rpm.

It carries out a self d iagnosis procedure wh ich may be visua lised throu gh the XXXXRRRR22225555.

SSSSPPPPEEEECCCCIIIIAAAALLLL FFFFEEEEAAAATTTTUUUURRRREEEESSSS

On the injection p um p it is possible to replace:- the load poten tiometer ,- the advance so lenoid valve,- the a lt imet ric corrector ,- the elect rica l so lenoid .

13-13



DIESEL EQUIPMENT

Specifications 13

Vehicles Gearbox

Engine

Type SuffixBore

(mm)

Stroke

(mm)

Capacity

(cm3

)

RatioCatalytic

converter

Depollution

standard

XC0D JB F8Q 662 80 93 1 870 21.5/ 1 C67 EU96

XC0E JB F8Q 630 80 93 1 870 21.5/ 1 C67 EU96

Vehicles

EEEENNNNGGGGIIIINNNNEEEE SSSSPPPPEEEEEEEEDDDD ((((rrrrppppmmmm))))

Idle speedno load

maximum

full load

maximum

SSSSMMMMOOOOKKKKEEEE OOOOPPPPAAAACCCCIIIITTTTYYYY

Homologation value Legal maximum

XC0D 825 ± 50 4 600 ± 100 4 100 ± 100 1.05 m -1 (35 %) 2.5 m -1 (64 %)

XC0E 825 ± 50 4 600 ± 100 4 100 ± 100 1.11 m -1 (36 %) 2.5 m -1 (64 %)

Temperature in °C (± 1°) 0 20 40 80 90

Air temperature sensor

Siemens CTN typeResistance in Ohm s

7470 to11970

3060 to 4045 1315 to 1600 - -

Coolant temperature sensor

Siemens CTN typeResistance in Ohm s

- 3060 to 4045 1315 to 1600 300 to 370 210 to 270

13-14



DIESEL EQUIPMENT

Location of components 13

1 EGR valve and solenoid valve2 Air temperature sensor (white connector)3 Coolant temperature sensor (white connector)4 Diesel inject ion computer5 Fu el filter6 Pre-postheat ing plug relay housing7 TDC sensor8 Fast id le solenoid valve9 Electrical solenoid / coded solenoid

10 Digital DPC inject ion pump

11 Load poten tiometer12 Advance solenoid valve13 Alt imetric corrector14 Injector with sensor (needle lift)

12874

13-16



DIESEL EQUIPMENT


20 EGR valve

13047-1R

7 Engine speed sensor

13048R

87970R

17 Diesel injection fault warning light18 Preheating warn ing lightWarn ing light illum inates when ignition isswitched on d uring pr eheating p hase.

12839S

C Power assisted steering pump assembly relayH Altimetric corrector relayL Injection locking relayM Diesel heating relay

13-18



DIESEL EQUIPMENT

Advance solenoid valve (1) 13

10314-1R


Mot. 997-01 Tool for removing injector and

advance solenoid valve

Advance solenoid valve 3



Disconnect th e electrical connector from thepump.

Remove the two terminal connectors for the ad -vance solenoid from the 10 track pump connec-tor.

13-19



DIESEL EQUIPMENT


13342R

To remove the terminals from the p um p

connector :

1) Pull the yellow guide to release the terminalconnectors, then p ress on the two tabs oneach side of the connector.

2) Extract the yellow guide.

3) Pull the wire to be removed.

4) The terminal connector is secured by twotabs, one on each side ; using a screwd river,move on e of these to one side (the action of pu lling on the wire prevents the tab fromgoing back into p lace).

5) Using a screwdriver, move the other tab toone side.

The terminal connector can now be removed fromthe connector.

Remove the p rotective sheath group ing the pu mp

actuators.

Remove the p rotective cover from th e solenoidvalve.

Remove the solenoid valve using tool Mot. 997-

01.

10579R1

A Passage of connector

13-20



DIESEL EQUIPMENT


ITB191917


It is VVVVIIIITTTTAAAALLLL to remove the small filter (3) situated a tthe bottom of the system, using a pair of thin-

nose pliers, and replace with a new filter.

The outer part serves as a seal and locks ontightening the actuator.

Replace, in the following order : the seal at (4) of the "banjo" retu rn connection (5) ; the newactivator (1) fitted with an external filter, alongwith the the two seals at (6) and (7).

Tighten the actuator to a torque of 3 daN.m

using socket Mot. 997-01.

Place the n ew protective cover (2)on the actuator.

Reconnect the two terminals to the connector.

Reconnect the connector itself.

Replace the protective sheath on the w iring,along with the retaining clip.

Bleed the d iesel circuit using the priming pu mpbefore starting the engine.

It is IMPERATIVE to erase the computer memory

by pressing G0**.

It is vital to road test the vehicle after theoperation.

13127R

13-21



DIESEL EQUIPMENT

Altimetric corrector 13

13129R


Mot. 997-01 Tool for removing injector

Mot. 1140 Tool for removing altimetric

corrector




Remove the h igh pressure p ipes.

Remove the injector with sensor(cylind er n° 3),using tool Mot. 997-01.

Remove the electrical connector from the p um p.

Remove the tw o termina ls for the altimetric cor-rector from th e 10 track pu mp connector.

F8Q 662

13-22



DIESEL EQUIPMENT


13342R

To remove the terminals for the pu mp

connector:

1) Pull the yellow guide to release it from theterminals, then press the two tabs on eitherside of the connector.

2) Extract the yellow guide.

3) Pull the wire to be removed.

4) The terminal is held in place by two small tabs,one on each side; using a screwdr iver, moveone of the tabs to one side (the action of pu lling on the w ire prevents the tab fromgoing back into p lace.

5) Using a screwdriver move the other tab to oneside.

The terminal may now be removed from theconnector.

Remove the p rotective sheath group ing the pu mp

actuators.

Remove the p rotective cover from th e solenoidvalve.

Remove the altimetric corrector (1) using toolMot. 1440.

10579R2

A Connector passage

F8Q 662

13-23



DIESEL EQUIPMENT



It is VVVVIIIITTTTAAAALLLL to remove the sm all filter (2) situa ted a tthe bottom of the system u sing a pair of thin -

nosed p liers, and replace it with a n ew one.

Tighten the actuator (1) to a torqu e of 3 daN.m

using th e socket Mot. 1440.

Place a new protective cover on the actuator.

Reconnect the tw o termina ls to the connector.

Reconnect th e connector.

Replace the protective sheath on the wiring,along with the retaining clip.

Bleed the d iesel circuit using the priming pu mpbefore starting the engine.

It is IMPERATIVE to erase the computer memory

by pressing G0**.

It is vital to road test the vehicle after thisoperation.

13128R

F8Q 662

FFFFUUUUNNNNCCCCTTTTIIIIOOOONNNN :::: it acts on the flow in prop ortion to altitud e ; if the vehicle is runn ing atan altitud e greater than or equal to 1 000 metres, the compu ter redu ces the flow by3 mm3 / stroke. The conven tional flow is reestablished if the vehicle runs at an alti-tud e lower than 900 metres.

13-24



DIESEL EQUIPMENT

Coded solenoid valve 13

On this type of vehicle, the replacement of thesolenoid valve and of the coded electronic un it (A)requ ires the removal of the injection pum p fromthe engine.


With the pum p on the bench, remove the protec-tive fittings at (B).

These are secured by shea r bolts which may be re-moved either :- using a small cold chisel or a punch and hitting

on the conical heads of bolts (C), (D) and (E)to loosen them,

- using tool Mot. 1372 for bolt (F), drilling it

using the 4 mm diameter drill (drilling depthapproximately 4 mm) and the large diameterdr illing guide tube on the fitting side (2).Use extractor (3) and its handle to remove it .


Tighten the fuel cut off solenoid v alve to a torqueof 2 daN.m.

Refit a heat shrink cover on the fuel cut off sole-

noid, ensuring th e wiring is correctly routed .

Refit the fittings using shear bolts and observingtheir location and th at of the spacers,(depen ding on fitting).

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: using a torque wrench, tighten thebolts, then rem ove the bolt head s by bendingthem u sing a tube inserted in the bolt heads.

Location of bolts :

D : ∅ 5 x 25 mm ; torque = 0.55 daN .m

C and F : ∅ 6 x 40 mm ; torqu e = 1.2 daN.m

E : ∅ 5 x 33 mm ; torque = 0.55 daN .m

Refit the cable of the fast idle speed LDA andtighten the cable grip, leaving 2 mm play.

Refit the injection p um p on the engine.

13-27



DIESEL EQUIPMENT

Load potentiometer 13

In the factory, vehicles are prog ram med with the full load p osition. (memorising the voltage delivered by thepoten tiometer in the full load position). This value is used to ad just the load p otentiometer after it has beenreplaced. It is therefore essential, if the diesel injection compu ter has to be replaced du ring the vehicle’s li-fetime , to carry out this program ming (G31*).

If it is necessary to replace the load potentiometer, in order to adjust it we comp are the voltage delivered bythe potentiometer in full load position, w ith the value mem orised. The new potentiometer is said to be cor-rectly adjusted w hen the two voltages are equal. This is displayed on th e XXXXRRRR22225555. G32* indicates the d iffe-rence in voltage between the value mem orised and the one from the potentiometer. The ad justm ent is cor-rect if this value is equal to 0 in the full load p osition.

The potentiometer and the compu ter cannot be replaced at the same time (if necessary, replace the poten-tiometer first and then the computer).

RRRREEEEPPPPLLLLAAAACCCCEEEEMMMMEEEENNNNTTTT OOOOFFFF TTTTHHHHEEEE LLLLOOOOAAAADDDD PPPPOOOOTTTTEEEENNNNTTTTIIIIOOOOMMMMEEEETTTTEEEERRRR ((((ooooppppeeeerrrraaaattttiiiioooonnnn ttttoooo bbbbeeee ccccaaaarrrrrrrriiiieeeedddd oooouuuutttt bbbbyyyy ttttwwwwoooo ppppeeeeoooopppplllleeee))))

Remove the three terminals for the load p otentiometer from the 10 track pu mp connector (see methoddescribed in section 13 "Advance sol enoid valve").

Remove the two bolts mou nting the faulty potentiometer, extract this, and fit the new potentiometer .Han d tighten the tw o bolts mou nting the potentiometer bu t do not lock them - it should be p ossible to turnthe potentiometer body .

Connect the XXXXRRRR22225555, and sw itch on th e ignition.

Set the selector to S8 .

Enter code

Press dow n on the accelerator ped al (full load p osition). Do not act directly on the load lever.

Holding the full load position, turn the potentiometer body un til the value 0 app ears on the XR25 display (if you are too far from the 0 value, the screen will display HL , which m eans "Hors Limite"= "Off limits". Justto turn the potentiometer body to obtain the display of a decimal value).

Tighten the two bolts mou nting the potentiometer in the full load position, when the value read is 0.

D 3 4 then G 3 2 *

13-28



DIESEL EQUIPMENT

Computer configuration 13

CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR CCCCOOOONNNNFFFFIIIIGGGGUUUURRRRAAAATTTTIIIIOOOONNNN IIIINNNN RRRREEEELLLLAAAATTTTIIIIOOOONNNN TTTTOOOO AAAAIIIIRRRR CCCCOOOONNNNDDDDIIIITTTTIIIIOOOONNNNIIIINNNNGGGG....

For vehicles equipp ed w ith air conditioning , enter G50*3* on the XXXXRRRR22225555

For vehicles withou t air conditioning , enter G50*4* on the XR25 .

CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR CCCCOOOONNNNFFFFIIIIGGGGUUUURRRRAAAATTTTIIIIOOOONNNN IIIINNNN RRRREEEELLLLAAAATTTTIIIIOOOONNNN TTTTOOOO TTTTHHHHEEEE PPPPAAAASSSS ((((PPPPOOOOWWWWEEEERRRR AAAASSSSSSSSIIIISSSSTTTTEEEEDDDD SSSSTTTTEEEEEEEERRRRIIIINNNNGGGG PPPPUUUUMMMMPPPP AAAASSSSSSSSEEEEMMMMBBBBLLLLYYYY))))

The vehicle may have tw o types of PPPPAAAASSSS assembly :- a PPPPAAAASSSS assembly including a high pressure pu mp driven by a belt. In this case, the comp uter mu st be

configured without PAS : enter G50*9* on the XXXXRRRR22225555,- a PPPPAAAASSSS assembly with a pu mp assembly which is driven electrically and controlled by the injection compu -

ter. ( this type of PPPPAAAASSSS is fitted in all vehicles which are also equipp ed w ith AC). In this case, the compu termu st be configured with PAS : enter G50*8* on the XR25.

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: accord ing to the above explanations, only two types of combination are possible for the illumi-nation of bargraphs 18 an d 19.

Vehicle with AC

and PAS pump assembly

Vehicle without AC and PAS pump assembly

(with conventional PAS)

18

19

18

19

DA

CA

NNNNOOOOTTTTEEEE :::: if the comp uter has been replaced, remember to carry out the program ming of the load potentio-meter full load position (see "Load potentiometer "section ).

13-30



DIESEL EQUIPMENT

Injector with sensor (needle lift) 13

10579R1

PRM1315

The needle lift sensor is integrated to the injectorholder (cylinder n° 3). Its function is to tran smitthe m ovemen ts of the injector needle to thecompu ter. This allows the start of injection to beded uced. The compu ter processes this informa-tion and uses it to comp are the advan ce reques-ted to the ad vance corrector on the pu mp to theadvance actually app lied . In this way, the systemwor ks as a closed loop.

Tooling requ ired for the removal of the injector :Mot. 997-01.

Tightening torque: 7 daN.m.

NNNNOOOOTTTTEEEE :::: it is possible to m odify tool Mot. 997 bymilling the socket at (A), throu gh which passesthe connector of the injector w ith sensor (B).

1 Plunger rod2 Spacer3 Injector4 Spring5 Wind ing

13-31



DIESEL EQUIPMENT

Pre-postheating control 13

The pre-postheating function is controlled by thecomputer, which controls the preheating plug re-lay housing.

1) Ignition - Preheating

The preheating p rocess is divided in twophases :

a) Variable preheating

This is dep end ent on the coolant temp era-ture, on the battery voltage and on alti-tud e (internal comp uter sensor) wh en theignition is switched on (the preh eating

warning light illuminates).

b) Fixed preheating

After the p reheating w arning light hasextingu ished (variable prehea ting), the

plugs remain fed for 8 seconds before theengine is started .

2) Starting the engine

Dur ing the action of the starter motor, thefour plugs are fed continuou sly.

3) Engine running - Postheating

The postheating also may be d ivided in twophases:

a) Fixed postheating

After starting the engine, the plugs aresupp lied simu ltaneously for a period of 10

seconds .

b) Variable postheating

Variable postheating begins wh en fixedpostheating end s. The time d uring w hich

the plugs ar e fed (continuously) dependsupon :- the coolant temperature- the engine speed ,- the load (load potentiometer on pump

lever ).

Maximum p reheating limit (battery vol-tage lower th an 9.3 volts and altitud e hi-gher than 2 000 m).

Minimum preheating limit (batteryvoltage greater than 10.5 volts altitudelower than 350 m).

13041S

13-33



DIESEL EQUIPMENT

Pre-postheating control 13

- 20

180

time (s)

For an idle speed and load leverposition

Coolant temp erature °C

0 20 40 60

Variable postheating may be interrupted :- permanently, if the coolant temperature is >

60°C,- temporarily , if the unit receives full load

information for more than 3 seconds; thefunction is established once again if theengine returns to idle speed or low load,

- temporarily again if the battery voltage is>16 V; the function is restored if Ubatt

< 15 V .

In all cases, the total du ration of the postheatingfunction w ill never exceed 3 minutes.

13-34



DIESEL EQUIPMENT

Fast idle speed control 13

- if the engine speed fa lls to 650 rpm and thevehicle speed is lower than 15 mph (25 km/ h)(engine start improvement program ming).The fast idle speed is cut off once the speedbecomes > 850 rpm

NNNNOOOOTTTTEEEE ::::

- Fast id le speed operational :• so lenoid valve not operated ,• cable loose, and not tensioned.

- N om in al id le sp ed :• solenoid valve operated• cable ten sion ed

SSSSPPPPEEEECCCCIIIIAAAALLLL FFFFEEEEAAAATTTTUUUURRRREEEESSSS :::: once the AC has beenselected on the instru men t pan el, the fast idlespeed function is activated .

The fast idle speed function is controlled by thecompu ter via a solenoid valve operating the d ia-phr agm (versions with or without air conditio-ning).

The fast idle speed control becomes opera tional :- if, on switching on the ignition, the coolant

temp eratur e is below 10°C,

Coolant

temperature

on sw itching

ignition on (°C)

Fast idle speed

cut-off

temperature

(°C)

Fast idle speed

cut-off

temperature

(°C)

1050

- 10- 20

2020304050

1115202530

F8Q 662 F8Q 630

13-35



DIESEL EQUIPMENT

Injection/air conditioning programming 13

CCCCOOOONNNNNNNNEEEECCCCTTTTIIIIOOOONNNN BBBBEEEETTTTWWWWEEEEEEEENNNN AAAAIIIIRRRR CCCCOOOONNNNDDDDIIIITTTTIIIIOOOONNNNIIIINNNNGGGG AAAASSSSSSSSEEEEMMMMBBBBLLLLYYYY AAAANNNNDDDD IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR

The electrical conn ection :- from the air cond itioning computer to the diesel injection computer consists of one wire. This track only

carries the information that the AC is operating. From this, the d iesel injection compu ter dedu ces the ACselection information : track 11,

- from the diesel injection compu ter to the air conditioning comp uter consists of one wire. This trackcarries all information regard ing authorising and preventing opera tion of the compressor : track 19.

CCCCOOOOMMMMPPPPRRRREEEESSSSSSSSOOOORRRR OOOOPPPPEEEERRRRAAAATTTTIIIIOOOONNNN PPPPRRRROOOOGGGGRRRRAAAAMMMMMMMMIIIINNNNGGGG

Dur ing certain stages of opera tion, the diesel injection comp uter stop s the compressor from functioning.

Engine start programming

After the engine has started runn ing, the compressor is prevented from functioning for 3 seconds .

Performance return programming

If the full load position is detected, the AC compressor is preven ted from functioning for 8 seconds.

Stalling prevention programming

If the engine speed is lower th an 650 rpm., the compressor is automatically cut off. It will only be allowed tofunction again if the engine speed exceeds 775 rpm.

13-36



DIESEL EQUIPMENT

Computer 13

PRM1316

CCCCOOOONNNNNNNNEEEECCCCTTTTIIIIOOOONNNN

1 -<-

2 -----

3 -----

4 -->-

5 -->-

6 -->-

7 -<--

8 -<--

9 -->-

10 -<--11 -<--

12 -<--

13 -><-

Computer supply

Compu ter earth

Sensor earth

Potentiometer lever supply

EGR solenoid control

Advance corrector control

Need le lift signal

Engine speed signal

Preheating warning light control

Fault find ing information line LAC status

Vehicle speed signal

Fault find ing information line K

Plug relay control

Altimetric corrector relay control

Fast idle speed control

Load lever p osition information

Fault finding w arning light control

AC prevention control

Power assisted steering p um p assemblyrelay control

Engine speed information

Not used

Load lever signal

Air temperature signal

Coolant temperature signal

14-->-

15 -->-

16 -->-

17 -->-

18 -->-

19 -->-

20 -->-

21 -----

22

23 -<--

24 -<--

25 -<--

13-37



DIESEL EQUIPMENT

Defect modes 13

If there is a fau lt with one of the comp onents listed below, the comp uter en ters "defect mode", which mean sthat replacement values are u sed to ensure engine operation.

Faulty

component

Set values (for replacement)

Advance

corrector

Pre-postheating

timeEGR function Fast idle speed AC function

Coolant sensorRunning time

function

Preheating : -30°CPostheating :80°C

Cu tRunning time

function-

Air sensorTemperature

= 22°C- Cut - -

Loadpotentiometer

100 % load leverposition

Postheating:30 % load leverposition

Cut -20 % load lever

position

Altitud e sensorAltitude= 900 m

Altitude= 900 m

Cut - -

Battery16 V < U < 6 V

Ubatt = 13.5V Not controlled - - -

TDC sensor

Minimum

advanceSolenoid v alve

fully openposition

Postheating :Not controlledun til ignition isswitched off then on again

Cu tSpeed

= 2 000 rpmSpeed

= 2 000 rp m

Needle liftsensor

Defect mod eadvance

(Carto softF8Q 662)

Maximumadvance

(F8Q 630)

- - - -

Vehicle speedsensor

- -Position :

V = 175 km/ hPosition :

V = 175 km/ hPosition :

V = 175 km/ h

Heater plugsrelay housing

- Cut - - -

13-38



DIESEL EQUIPMENT

Pump 13


Disconnect the battery. Then remove :

- the suspended engine mounting housing (1),- the inject ion pump pulley housing (2).

DI1302-1

Pin the engine using tool Mot. 1054. For thisoperation, turn the engine so that the ind ex of the camshaft sprocket is in line with the m arkingon the timing cover (use a mirror).



Mot. 1200Pump-pulley retaining tool

Mot. 1317

99183R

Nut mounting the pump shaft

to the RAM pulley 4.5

Pump mounting bolt 2.2


13-39



DIESEL EQUIPMENT

Pump 13

Remove :- the fuel supp ly pipe (A),- the fuel return p ipe (B),- the pump connector (C),

- the accelerator cable (D),- the vacuum pipe (E) connected to the fastidle speed LDA,

- the high pressure wiring loom using tool Mot.

1383,

10578R

- the rear suppor t mounting bolt .

12869R

Fit tool Mot. 1200 or Mot. 1317 , for retaining thepum p pu lley.

12410R

Inserting a torx screwd river in the gaps of theRRRRAAAAMMMM pulley , slacken:

- the three bolts mou nting the pu mp

- the central nut securing the pump shaft to theRRRRAAAAMMMM pulley.

Slacken the centra l nut an d all three of the boltsmoun ting the p um p u ntil they are comp letelyfree.

Extract the p um p.


Clean the pu mp shaft very thoroughly, using sol-vent to eliminate all trace of grease.

Refit the pum p.

Tighten the three bolts moun ting the p um p .

Pretighten the central nut of the pu mp to 2

daN.m.

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: it is vital to carry ou t a p retighte-ning op eration before the final tightening; tigh-

ten the central pum p nu t to a torque of 4.5daN.m.Carry out the timing opera tions (see "Pump -

Timing").

For all other operations, refitting is the r everse of removal.

13-40



DIESEL EQUIPMENT

Pump - Timing 13

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: the engine mu st only be rotated byturning a wheel, in 5th gear, and in its operatingdirection; if it is accidentally tu rned in theopp osite direction, repeat th e operations forchecking and ad justing the timing.

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE SSSSEEEETTTTTTTTIIIINNNNGGGG OOOOFFFF IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN PPPPUUUUMMMMPPPPSSSS

FFFFIIIITTTTTTTTEEEEDDDD WWWWIIIITTTTHHHH RRRRAAAAMMMM PPPPUUUULLLLLLLLEEEEYYYYSSSS

Turn th e engine twice in the op erating d irection

(moving one w heel and having engaged 5thgear).

Remove the timing shaft plug situated on th epum p cover.

Fit tool Mot. 1079 and zero the dial gauge onpu mp cam "rest" zone (this operation w ill bemad e easier by tu rning the engine in its operatingdirection).

NNNNOOOOTTTTEEEE :::: in order to obtain a precise adjustment,

and to avoid br inging the d ial gauge to its limit, itis advisable to ad just it to 1 mm .



Mot. 1079 LUCAS pump timing kit

Mot. 1200

Mot. 1317

Mot. 135 Set of tools for operations on a

Mot. 1359 RAM pulley (micrometric adjustment)

91258R2

RAM pulley nut (adjustment locking) 9


Pump-pulley retaining tool

13-41



DIESEL EQUIPMENT

Pump - Timing 13

Components of tool Mot. 1079

A Tim ing p inB Dia l gauge suppor t

C 30 mm dial gauge

91285R

Lock the eng ine using tool Mot. 1054, accordingto the following procedu re :

- Turn the engine in i ts operating direction (clo-ckwise from timing end ).

- Locate the spot on the camshaft pulley wherethe reference mar k will appear .

- Stop the engine from turn ing half a tooth be-fore the two reference mar ks align.

DI1303-1

- Fit the p in , tool Mot. 1054.

12419R

- Keep a constant pressure on the pin.

- Turn the engine s lowly until the pinpen etrates into the slot in the crankshaft .

- Check the pump piston lift , which may be readon the d ial gauge.

- The value is marked on the loadpotentiometer lever.

- If the value is incorrect, adjust the timing (seefollowing method).

13-42



12338R

DIESEL EQUIPMENT

Pump - Timing 13

MMMMOOOODDDDIIIIFFFFIIIICCCCAAAATTTTIIIIOOOONNNN OOOOFFFF TTTTOOOOOOOOLLLL MMMMooootttt.... 1111333355558888

For the adjustm ent of HHHHTTTTDDDD2222 pu llies, carry out thefollowing modification:

File down the th ree brackets on the tool by 1.5mm .

12275S

TTTTIIIIMMMMIIIINNNNGGGG AAAADDDDJJJJUUUUSSSSTTTTMMMMEEEENNNNTTTT OOOOFFFF IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN PPPPUUUUMMMMPPPPSSSS

FFFFIIIITTTTTTTTEEEEDDDD WWWWIIIITTTTHHHH RRRRAAAAMMMM PPPPUUUULLLLLLLLEEEEYYYYSSSS

Remove the the RAM pulley protective cover.

Fit tool Mot. 1317 or Mot. 1200 to imm obilise thepulley.

98694R2

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: slightly loosen the bolt (1) usingtool Mot. 1359 (take care - left hand thread) sothat the flange (B) can rota te freely.

12411R

13-43



DIESEL EQUIPMENT

Pump - Timing 13

Fit tool Mot. 1358 into the three openings of flange (B).

Turn the tool - flange assembly so that the three

pins of the tool fit into the three slots in the ad - justing ring bolt.

12312R2

Turn the tool-flange assembly clockwise until toolMot. 1358 locks, thu s allowing the pu lley to beplaced at th e start of timing position .

Remove the immobilising tool Mot. 1317 orMot. 1200.

Turn the engine tw ice in its operating d irection(moving one w heel and having engaged 5thgear).

Fit too l Mot. 1079 and zero the dial gauge onthe pum p cam "rest" zone (this operation will bemad e easier by tu rning the engine in its operatingdirection).

NNNNOOOOTTTTEEEE :::: in order to obtain a precise adjustment,and to avoid br inging the d ial gauge to its limit, itis advisable to ad just it to 1 mm .

91258R2

Components of tool Mot. 1079

A Tim ing p inB Dia l gauge suppor tC 30 mm dial gauge

91285R

13-44



DIESEL EQUIPMENT

Pump - Timing 13

DI1303-1

- Fit pin Mot. 1054.

12419R

- Keep a constant pressure on the pin.

- Turn the engine s lowly until the pinpen etrates in the slot in the crankshaft.

- Using tool Mot. 1358, set the timing,turn ing the tool anticlockwise until the timing

value is obtained .

- The value is marked on the load lever.

NNNNOOOOTTTTEEEE : if the timing va lue is exceeded d ur ingad justm ent, bring the engine back by onerevolution , to recuperate the play using toolMot. 1358 , then rep eat the previous timingphase.

Leave pin Mot. 1054 in p lace.

Slightly pretighten bolt (1) using tool Mot. 1359,

to a torque n ot exceeding 2 daN.m (left handthread).

IMPORTAN T : the torque wrench used for this

operation must operate to the left .

Remove the pin Mot. 1054.

Fit too l Mot. 1377 or 1200 to imm obilise thepulley.

Turn the eng ine by hand anticlockwise to bringthe locking tool into contact w ith the p ulley.

Tighten bolt (1) to a torque of 9 daN.m, usingtool Mot. 1359.

Turn the engine over twice and check the pu mptiming once again.

Lock the eng ine using tool Mot. 1054, accordingto the following procedu re :

- Turn the engine in i ts operating direction (clo-ckwise from timing end ).

- Locate the spot on the camshaft pulley wherethe reference mar k will appear .

- Stop the engine from turn ing half a toothbefore the two reference marks align.

13-45



DIESEL EQUIPMENT

Adjusting idle speed 13

12870R

It is vital to make these adjustments w hen the en-gine is warm , and after the engine cooling fanhas operated at least twice.

The idle speed adjustment and anti-stalling

function adjustment must be carried out

correctly, since these operations directly

influence the behaviour of the engine at idle

speed and in the deceleration phase (hesitation

idle speed lasts too long, etc.).1 Idle speed adjustment screw2 Load lever

3 Residu al flow adjustment screw (anti-stallingfunction)

4 Fast id le lever5 Id le speed cable gr ip

FFFFAAAASSSSTTTT IIIIDDDDLLLLEEEE SSSSPPPPEEEEEEEEDDDD

Without app lying a vacuu m to the LDA, positionthe cable grip (5) at 2 ± 1 mm from the fast idlespeed lever (4).

NNNNOOOOTTTTEEEE :::: the fast idle speed value is not directly ad- justable; it is ad justed on the injection unit.

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE MMMMAAAAXXXXIIIIMMMMUUUUMMMM SSSSPPPPEEEEEEEEDDDD

Whilst the engine is warm, accelerate to full load ;the engine speed mu st be between 4 500 an d4 700 rpm (this adjustm ent can only be carriedout in a Renault Injection Centre workshop).

IIIIDDDDLLLLEEEE SSSSPPPPEEEEEEEEDDDD AAAANNNNDDDD RRRREEEESSSSIIIIDDDDUUUUAAAALLLL FFFFLLLLOOOOWWWW AAAADDDDJJJJUUUUSSSSTTTTMMMMEEEENNNNTTTT

(anti-stalling)

a) Ensure tha t the fast id le speed function is notopera tional .

b) Adjust the idle speed to 825 ± 25 rpm. usingscrew (1).

c) Place a 4 mm shim between the load lever (2)and the residu al flow screw (3).

d) Adjust the engine speed to 1 250 ± 50 rpm.

using the residu al flow screw (3).

e) Remove the 4 mm shim then acceleratesharply twice.

f) Check the conformity of the idle speed ; if

necessary, repea t the idle speed ad justm entand check the residual flow once more.

13-46



93703S

This test can only be carried out using a lead testing kit suppl ied by NAUDER.

To obtain a testing ki t, contact your local After Sales Head Office.

Part nu mbers : - Com plete kit : T900

- 40 test papers : T900/1

ANTIPOLLUTION

Test for the presence of lead 14

MMMMEEEETTTTHHHHOOOODDDD

a - Test conditions :

- Engine s tationary.- Exhaust p ipes warm.

- Do not test when the temperature is below 0°C.

b - If necessary use a soft cloth to clean the inside of the exhaust p ipe so any soot deposits are removed.

c - Wearing the gloves, take a test paper an d m oisten it slightly with d istilled w ater (the pap er is noteffective if it is too w et).

d - Press the damp p aper onto the cleaned exhaust pipe immediately and hold it there firmly for about aminute.

e - Remove the test paper and allow to dry. The test paper will turn red or pink if lead is present.

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT : The test for lead should only be carried out on the exhaust pipe, never on the oxygen

sensor.

Petrol

engine

14-1



ANTIPOLLUTION

Fuel vapour rebreathing 14E7J Engine

OOOOPPPPEEEERRRRAAAATTTTIIIINNNNGGGG DDDDIIIIAAAAGGGGRRRRAAAAMMMM OOOOFFFF TTTTHHHHEEEE CCCCIIIIRRRRCCCCUUUUIIIITTTT

1 In let m an ifold2 Fuel vapour absorber (canis ter)3 RCO control solenoid4 Throttle bod yR Pipe from fuel tank

13123R

14-3



ANTIPOLLUTION

Fuel vapour rebreathing 14

CCCCOOOONNNNDDDDIIIITTTTIIIIOOOONNNN FFFFOOOORRRR BBBBLLLLEEEEEEEEDDDDIIIINNNNGGGG TTTTHHHHEEEE CCCCAAAANNNNIIIISSSSTTTTEEEERRRR (((( DDDD7777FFFF

engine)

• Coolant temp erature greater than+ 15 °C

• Air temperature greater than +10 °C.

• No load position not recognised (if there is afault in the throttle potentiometer sensor, thecondition of no load p osition not r ecognised isreplaced by an engine speed cond itionR > 1500 rpm.).

It is possible to visualise the cyclical opening ratiofor the canister bleed solenoid using the XXXXRRRR22225555

an d #23. The solenoid is closed if #23 = 0.7 %

CCCCOOOONNNNDDDDIIIITTTTIIIIOOOONNNN FFFFOOOORRRR BBBBLLLLEEEEEEEEDDDDIIIINNNNGGGG TTTTHHHHEEEE CCCCAAAANNNNIIIISSSSTTTTEEEERRRR ((((EEEE7777JJJJ

engine)

During richness regulation

Coolant temp erature greater than 50°C.

Air temp erature greater than 15°C.

No load p osition not recognised (if there is a fau ltin the throttle potentiometer sensor, thecondition of no load p osition not recognised isreplaced by an engine speed cond ition

R > 1500 rpm.).

Outside richness regulation

• Coolant temp erature greater than 50°C.

• Air temp erature greater than 15°C.

• Full load position recognised (function of engine speed and manifold pressure).

If there is a fault in the oxygen sensor, bleeding is

permitted outside of no load conditions.

It is possible to visualise the cyclical opening ra tiofor the canister bleed solenoid using the XXXXRRRR22225555

an d #23. The solenoid is closed if #23 = 0.7 %

(minimu m value).

14-4



ANTIPOLLUTION

Fuel vapour rebreathing 14

LLLLOOOOCCCCAAAATTTTIIIIOOOONNNN----RRRREEEEMMMMOOOOVVVVAAAALLLL OOOOFFFF CCCCOOOOMMMMPPPPOOOONNNNEEEENNNNTTTTSSSS

CCCCAAAANNNNIIIISSSSTTTTEEEERRRR BBBBLLLLEEEEEEEEDDDD SSSSOOOOLLLLEEEENNNNOOOOIIIIDDDD VVVVAAAALLLLVVVVEEEE (1)

E7J Engine

It is mou nted above the inlet manifold,und erneath the cover

D7F Engine

It is mou nted at the front, on the lifting bracket.

13242R2

99939-1R3

RRRREEEEMMMMOOOOVVVVAAAALLLL OOOOFFFF TTTTHHHHEEEE FFFFUUUUEEEELLLL VVVVAAAAPPPPOOOOUUUURRRR AAAABBBBSSSSOOOORRRRBBBBEEEERRRR (1)

This is located in the front right hand w heel arch.


Disconnect the p ipe connecting the canister to theinlet manifold, from the top of the vehicle.

From the bottom, remove the wh eel arch .

Disconnect the pipe at (2) connecting thecanister to the fuel tank .

Remove the three bolts at (3) mou nting thecanister (1) then extract it.

13049R

14-6



ANTIPOLLUTION

Oil vapour rebreathing 14

CCCCIIIIRRRRCCCCUUUUIIIITTTT DDDDIIIIAAAAGGGGRRRRAAAAMMMM

1 Cylinder head cover2 In let m an ifold3 Oil vapour rebreathing pipe connected upstream from the throttle body (the circuit is used

for med ium and high loads)4 Oil vapour rebreathing pipe connected downstream from the throttle body5 Air pipe6 Throttle bod y

99932R

D7F Engine

14-7



ANTIPOLLUTION


CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE CCCCIIIIRRRRCCCCUUUUIIIITTTT

To ensure the correct operation of theantipollution system, it is impor tant to keep the

oil vap our r ebreathing system clean and in goodworking condition.

PRC14.2

D7F Engine

14-8



ANTIPOLLUTION

Oil vapour rebreathing 14E7J Engine

CCCCIIIIRRRRCCCCUUUUIIIITTTT DDDDIIIIAAAAGGGGRRRRAAAAMMMM

1 Cylind er head2 In let m an ifold3 Oil vapour rebreathing pipe connected

up stream from the throttle body (the circuit is

used for med ium and high loads)4 Oil vapour rebreathing pipe connected

dow nstream from the throttle body


To ensure the correct operation of theantipollution system, it is impor tant to keep theoil vap our r ebreathing system clean and in goodworking condition.

13335R

14-9



ANTIPOLLUTION


1 Engine2 Oil d ecanter3 Air filter4 In let m an ifold

13042R

F8Q Engine

14-10



ANTIPOLLUTION

Exhaust gas recirculation (EGR) 14

1 EGR valve2 EGR solenoid (ON/ OFF)3 Vacuum pump4 Engine5 Exh au st m an ifold6 In let m an ifold7 Air filter8 In jection compu ter9 Coolant temperature sensor

13046R

F8Q Engine

13045R

14-11



ANTIPOLLUTION

Exhaust gas recirculation (EGR) 14

SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS

In order to rem ove the steel pipe connecting theEGR valve to the air filter, it is necessary toremove the EEEEGGGGRRRR valve .

12871R1

F8Q Engine

13047-1R2

To remove the EEEEGGGGRRRR solenoid (2), remove the airfilter .

To remove the EEEEGGGGRRRR valve (1), rem ove th e air filterfirst, and replace the seal between th e solenoidvalve and th e inlet manifold after each remova l

operation.

14-12



ANTIPOLLUTION

Exhaust gas recirculation (EGR) 14The EGR is controlled by the comp uter v ia anON/ OFF solenoid valve.

The operation of the EEEEGGGGRRRR solenoid valve is de-pend ent up on the following param eters :

- th e air tem p eratu re,- the coolant temperatu re ,- the altitu de,- the posit ion of the load lever ,- th e veh icle s peed ,- the engine sp eed .

The EGR function is cut if :- the air tem peratu re < 16°C or- the coolant temperatu re < 45°C or- the engine speed/ load potent iometer value is

greater than a certain threshold .The EGR is cut after operating at id le speed for 40

seconds (at zero veh icle speed).

Once the vehicle speed > 25 mph (40 km/ h), theEGR is operational aga in. It w ill be cut again after 40 seconds of operating at idle speed at zero ve-hicle speed.

XR 25 bargrap h 14 RH is illum inated if the EGR

function is permitted. In order to determ ine if the

EGR is actually controlled, u se #24. if the valu e isdifferent from 0, the EGR is activated .

F8Q Engine

14-13




After 15 minutes warm ing up at a voltage of 13.5 volts.

STARTING - CHARGING

Alternator 16

IIIIDDDDEEEENNNNTTTTIIIIFFFFIIIICCCCAAAATTTTIIIIOOOONNNN

EEEENNNNGGGGIIIINNNNEEEE AAAALLLLTTTTEEEERRRRNNNNAAAATTTTOOOORRRR CCCCUUUURRRRRRRREEEENNNNTTTT

D7F DELPHI 104 802 215 80 A

E7J VVVVAAAALLLLEEEEOOOO AAAA 11111111 VVVVIIII 88887777 75 A

F8Q VVVVAAAALLLLEEEEOOOO AAAA 11111111 VVVVIIII 88888888 75 A

Engine rpm 75 amps 80 amps

1000

2000

3000

4000

46

68

71

72

54

75

80

82

16-1



STARTING - CHARGING

Alternator 16

OOOOPPPPEEEERRRRAAAATTTTIIIIOOOONNNN ---- FFFFAAAAUUUULLLLTTTT FFFFIIIINNNNDDDDIIIINNNNGGGG

These vehicles are equipped with alternator s withinternal ventilation and integral regu lator, also

with a w arning light on the instrument pan elwhich has the following functions :- when the ignition is switched on, the light illu-

minates- when the engine is started the light extin-

guishes,- if the light illuminates whilst the engine is

runn ing there is a "charging "fault.

LLLLOOOOOOOOKKKKIIIINNNNGGGG FFFFOOOORRRR FFFFAAAAUUUULLLLTTTTSSSS

The warning light does not illuminate when the

ignition is sw itched on.

Check:- all electrical connections are good.- the bulb has not blown. (Earth the circuit and

the bulb shou ld illuminate).

The warning light illuminates when the engine is

running.

This ind icates a charging fau lt which could becaused by :

- the alternator drive belt being broken or thecharging wiring being cut,

- internal alternator damage (rotor, stator,diodes or bru sh),

- a regula tor fau lt ,

- excess voltage.

The customer complains of a lack of charge and

the warning light is operating correctly.

If the regu lated voltage is less than 13.5 V, check

the alternator. The fau lt could be caused by :- a diode which has been damaged,- a phase which is cut ,- contaminated or worn tracks.

Checking the vol tage

Connect a voltmeter across the battery terminalsand read the battery voltage.

Start the engine an d increase the engine speedun til the need le registers a stable regulatedvoltage.

This voltage should be between 13.5 V an d 14.8 V.

Connect as man y consumers as possible, theregulated voltage should be between 13.5 V an d14.8 V .

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT : if arc welding work is to be carried

out on the vehicle, the battery and regulator

must be disconnected .

16-2



STARTING - CHARGING

Alternator 16

OPTIMA 5800 Diagnostic station

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE CCCCHHHHAAAARRRRGGGGIIIINNNNGGGG CCCCIIIIRRRRCCCCUUUUIIIITTTT UUUUSSSSIIIINNNNGGGG TTTTHHHHEEEE DDDDIIIIAAAAGGGGNNNNOOOOSSSSTTTTIIIICCCC SSSSTTTTAAAATTTTIIIIOOOONNNN

The OPTIMA 5800 diagnostic station allows the alternator to be checked by measu ring the voltage and cur -rent delivered , w ith or w ithout electrical consum ers .

NNNNOOOOTTTTEEEE :::: the Amps clamp used for this station is of the ind uctive type (measurement range: 0 to 1 000 A). Itis fitted withou t disconnecting the battery , which allows the the computer memory and adaptive informa-

tion to be saved.

Fit the Amp s clamp directly at the alternator outpu t, with the arrow pointing towards the alternator (any in-correct positioning is d etected by the station).

The measuremen t is carried out in three stages :- measurement of the battery voltage, ignition off,- measurement of the regulated voltage and of the current supp lied, without consumers,- measurement of the regulated voltage and current supp lied, with a maximum n umber of consumers.

On completion of the test, the values noted w ill lead to the following fault find ing messages :- Battery voltage, no load < 12.3 V = battery uncharged.

Without consum ers :- Regu lated v oltage > 14,8 V = > regu lator faulty ,- (regula ted voltage, no load < 13.2 V) or (charging curren t< 2 A) = >charging fault.

With consum ers :- Regu lated v oltage > 14.8 V = > regulator faulty,- Regu lated v oltage < 12.7 V = > it is necessary to check the alternator su pp ly in relation to its specifica-

tions :

EngineCurrent (amps)

D7F E7J F8Q

Nominal current 70 75 75

Minimu m current wh ich the alternator mustsup ply, all consum ers connected

53 51 55

FFFFAAAAUUUULLLLTTTT FFFFIIIINNNNDDDDIIIINNNNGGGG


16-3



STARTING - CHARGING

Alternator 16

If the electrical sup ply measu red is too low, check:

- the wear of the alternator (brush...),- the bat tery connect ions,- th e en gin e ear th str ap ,- the conformity of the alternator,- the belt ten sion .

If the electrical supply m easured is correct and the regu lated voltage is too low, the alternator is not faulty.

The cause of the problem is to be attributed to one of the following sources :- the vehicle has too many electrical consumers,- the bat tery is d ischarged .

FFFFAAAAUUUULLLLTTTT FFFFIIIINNNNDDDDIIIINNNNGGGG ((((ccccoooonnnnttttiiiinnnnuuuueeeedddd))))

16-4



STARTING-CHARGING

Alternator 16


Place the veh icle on a tw o post lift .

Disconnect the batter y as well as all electricalconnections leading to the alternator .

Remove :- the alternator belt and that of the power as-

sisted steering pu mp for the D7F engine (if

fitted),- the alternator.


Refitting is the reverse of rem oval.

D7F Engine

Tensioning of the a lternator belt is carried ou tusing the locally manufactured tool shown be-low (threaded rod 100 mm in length (X) and threeM6 nuts).

DDDD7777FFFF //// EEEE7777JJJJ

Engines



10617R

E7J Engine

Tension the belt using the bolt at (1) and tightenthe nut at (2) , having measu red the tension.

13363R

See section 07 "Accessories bel t tens ion"for thetension values.

16-5



STARTING - CHARGING

Starter motor 16

EEEENNNNGGGGIIIINNNNEEEE SSSSTTTTAAAARRRRTTTTEEEERRRR MMMMOOOOTTTTOOOORRRR

D7FVVVVAAAALLLLEEEEOOOO DDDD7777 EEEE1111

Bosch 0001116001

E7J DDDD6666 RRRRAAAA 77773333

F8Q Bosch 0001108180

IIIIDDDDEEEENNNNTTTTIIIIFFFFIIIICCCCAAAATTTTIIIIOOOONNNN

16-7



STARTING - CHARGING

Starter motor 16

OPTIMA 5800 Diagnostic station

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE SSSSTTTTAAAARRRRTTTTEEEERRRR MMMMOOOOTTTTOOOORRRR UUUUSSSSIIIINNNNGGGG TTTTHHHHEEEE DDDDIIIIAAAAGGGGNNNNOOOOSSSSTTTTIIIICCCC SSSSTTTTAAAATTTTIIIIOOOONNNN

Checking of the starter motor is carried ou t using the OOOOPPPPTTTTIIIIMMMMAAAA 5555888800000000 , by measuring the battery voltage andthe current absorbed in the engine starting phase. The following operation faults may be highlighted :- a fault in the battery ( the voltage falls du ring the starting phase),- locking of the starter motor (the current absorbed is too high),- a fault in the engine starter gear (the current absorbed is too low).

In order to carry out the measur emen t, it is necessary to stop the vehicle from starting :- for D7F an d E7J engines : disconnect the engine speed sensor (located on the clutch housing ,- for FFFF8888QQ Q Q engines : disconnect the pu mp electrical solenoid and isolate the termina l.

NNNNOOOOTTTTEEEE :::: - an open circuit on the engine speed sensor or the ignition creates a fault memorised by the injection

comp uter, this fault must then be erased from the memory using the XXXXRRRR22225555 (see " Injection" section),- if the engine is fitted w ith an imm obiliser, it is sufficient to lock the doors using the remote control.

FFFFAAAAUUUULLLLTTTT FFFFIIIINNNNDDDDIIIINNNNGGGG


16-8



STARTING - CHARGING

Starter motor 16


Place the vehicle on a lift, and disconnect the bat-tery.

Disconnect the starter electrical connections.

10076R

Remove the two starter mounting bolts.



D7F Engine

16-9



STARTING - CHARGING

Starter motor 16


Place the vehicle on a tw o p ost lift.

Remove:- the a ir filt er in let p ipe,- the battery,- the computer support mounting bolts as well

as the connectors at (1), then move thecomp uter sup port/ diesel filter assembly toone side.

13088R3

- the starter mounting bolts and the heat shield(A),

- the star ter connections,- the star ter motor itse lf.



Check for the presence of the centring d owel,wh ich should be located at (B).

13087R1

F8Q Engine

16-11



IGNITION

Semi-static ignition 17

PPPPRRRREEEESSSSEEEENNNNTTTTAAAATTTTIIIIOOOONNNN

The system comprises:

- the injection computer (the ignition powerstage is integrated into the comp uter),- two dual output coils, (for the DDDD7777FFFF engine,

these are moulded into one),- fou r sp ark p lu gs,- an anti-interference condenser (4).

DDDDEEEESSSSCCCCRRRRIIIIPPPPTTTTIIIIOOOONNNN ---- OOOOPPPPEEEERRRRAAAATTTTIIIINNNNGGGG PPPPRRRRIIIINNNNCCCCIIIIPPPPLLLLEEEE

CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR

The injection comp uter (120), dep end ing on th einformation received from various sensors, butprincipally depend ing on the engine speed andload, determines:- the number of degrees of advance to be used

and consequently the ignition point,- which cylinders are at TDC and consequently

the ignition coil to be opera ted.

The spark is created at the two cylinders at TDC bycutting the earth to the coil concerned .

CCCCOOOOIIIILLLLSSSS ((((1111))))

There are two coils. They are of the dual outpu ttype (they cannot be separated in the DDDD7777FFFF en -gine ).

They are controlled separa tely by the compu ter.

They create two sparks simultaneou sly.

Both coils are connected to an anti-interferencecondenser.

99931-1R2

D7F Engine

E7J Engine

13242R

Special features of the E7J engine

The coil at (2) has a black electrical conn ector. Itcreates a spark simu ltaneously at cylind ers 1 an d4. It is controlled by track 28 of the injectioncomputer.

The coil at (3) has a grey electrical connector . Itcreates a spa rk simu ltaneously at cylinders 2 an d3. It is controlled by track 29 of the injectioncomputer.

17-1



IGNITION

Semi-static ignition 17

Test to be made

between tracksResistance

1 - 2 1.5 Ω

1 - 3 1 Ω

1 - 4 1 Ω

2 - 3 1 Ω

2 - 4 1 Ω

3 - 4 0.6 Ω

HT - HT 8 kΩ

D7F Engine

Electrical connector

Track Allocation

1coil contro l for cylinders

1-4

2coil contro l for cylinders

3-2

3 +after ignition

4+anti-interference

condenser

Test to be made

between tracksResistance

1 - 2 0.5 Ω

1 - 3 1 Ω

2 - 3 1 Ω

HT - HT 10 kΩ

Track Allocation

1+anti-interference

condenser

2 +after ignition

3coil contro l by

computer

D7F Engine

Electrical connector

17-2



IGNITION

Spark plugs 17

Engine Make Type

D7FEYQUEM

NGK

RFC 50 LZ 2E

BKR 5EK

E7JEYQUEM

CHAMPIONRFC 52 LSRC 10 PYC

Flat skirt w ith seal

Gap: 0.9 mm

Tightening torque : 2.5 to 3 daN.m

D7F Engine

To disconnect the spark plug leads, use the tool (3), wh ich is integrated to the plastic cover (4) on the cylin-der head.

99940R

99894R1

DDDD7777FFFF////EEEE7777JJJJ

Engines

NNNNOOOOTTTTEEEE :::: to remove the spark plugs, use the tool kit, Ele. 1382.

17-3



INJECTION

General 17

SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS FFFFOOOORRRR MMMMUUUULLLLTTTTIIIIPPPPOOOOIIIINNNNTTTT IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN

• 35 track SSSSAAAAGGGGEEEEMMMM or MMMMAAAAGGGGNNNNEEEETTTTIIII MMMMAAAARRRREEEELLLLLLLLIIII compu ter for vehicles without op tions.

• 55 track SAGEM comp uter , SSSSAAAAFFFFIIIIRRRR or MMMMAAAAGGGGNNNNEEEETTTTIIII MMMMAAAARRRREEEELLLLLLLLIIII ttttyyyyppppeeee for versions with air conditioning.

• Semi-sequential multipoint injection. Injectors contr olled two by two (injectors for cylinder s 1 an d 4 fol-lowed by injectors for cylinders 2 an d 3).

• Semi-static ignition with dua l single unit coils.

• Canister bleed solenoid valve controlled by RCO signal.

• Computer configuration depending on gearbox type (manual gearbox or automatic transmission).

• The maximu m engine speed p ermitted is 6 200 rpm.

• Idle speed correction dep ending on :- battery voltage,- air con dition in g- power assisted s teering pressostat .

• Injection warning light on instrum ent panel not operational.

• Use fault find ing fiche n° 27.

D7F Engine

FFFFIIIITTTTTTTTIIIINNNNGGGGAAAA2222NNNNDDDDGGGGEEEENNNNEEEERRRRAAAATTTTIIIIOOOONNNNEEEENNNNGGGGIIIINNNNEEEEIIIIMMMMMMMMOOOOBBBBIIIILLLLIIIISSSSEEEERRRRRRRREEEEQQ Q Q UUUUIIIIRRRREEEESSSSAAAASSSSPPPPEEEECCCCIIIIAAAALLLLPPPPRRRROOOOCCCCEEEEDDDDUUUURRRREEEEFFFFOOOORRRRRRRREEEEPPPPLLLLAAAACCCCIIIINNNNGGGGTTTTHHHHEEEE

CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR....

17-4



INJECTION

General 17

SSSSPPPPEEEECCCCIIIIAAAALLLL NNNNOOOOTTTTEEEESSSS FFFFOOOORRRR MMMMUUUULLLLTTTTIIIIPPPPOOOOIIIINNNNTTTT IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN

• 55555555 ttttrrrraaaacccckkkk SSSSIIIIEEEEMMMMEEEENNNNSSSS FFFFEEEENNNNIIIIXXXX 5555 computer.

• Semi-sequential multipoint injection. Injectors are controlled two by two (injectors for cylinders 1 an d 4followed by cylinders 2 an d 3).

• Semi-static ignition with dual coils.

• Canister bleed solenoid controlled by RCO signal.

• Compu ter configuration d epend ing on gearbox type (manu al gearbox or au tomatic transmission)

• Idle speed correction dep ending on :- air con dition in g,- power assisted s teering pressostat ,- battery voltage.

• Injection warning light on instrum ent panel operational.

• Use fault find ing fiche n° 27.

• Maximu m speed :- 6 200 rpm if 1st , 2nd or 3rd gears- 6 000 rpm if 4th,or 5th gears.

E7J Engine

FFFFIIIITTTTTTTTIIIINNNNGGGG AAAA 2222NNNNDDDD GGGGEEEENNNNEEEERRRRAAAATTTTIIIIOOOONNNN EEEENNNNGGGGIIIINNNNEEEE IIIIMMMMMMMMOOOOBBBBIIIILLLLIIIISSSSEEEERRRR RRRREEEEQQ Q Q UUUUIIIIRRRREEEESSSS AAAA SSSSPPPPEEEECCCCIIIIAAAALLLL PPPPRRRROOOOCCCCEEEEDDDDUUUURRRREEEE FFFFOOOORRRR RRRREEEEPPPPLLLLAAAACCCCIIIINNNNGGGG TTTTHHHHEEEECCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR....

17-5



INJECTION

General 17

1 Coil2 Air filter3 Oxygen sensor4 Absolu te pressure sensor5 Throttle position potentiometer6 Idle regulation s tepping motor7 Air temperatu re sensor8 In jection compu ter9 In ertia sw itch

10 Lockin g relay11 Fu el p um p relay12 TDC sensor13 Fuel vapour recycling solenoid valve14 Coolant temperature sensor15 Tool for removing spark plug leads16 Pin kin g sen sor17 Power assisted steering pressostat18 Pressu re regula tor19 Anti-interference condenser20 Fuel vapour absorber (canister)

LLLLOOOOCCCCAAAATTTTIIIIOOOONNNN OOOOFFFF CCCCOOOOMMMMPPPPOOOONNNNEEEENNNNTTTTSSSS

13081

D7F Engine

17-6



INJECTION

General 17

1 Fuel vapour recycling solenoid valve2 Air filter3 Pinkin g sensor4 Absolu te pressure sensor5 Idle speed regulation stepping motor6 Throttle position potentiometer7 Air temperatu re sensor8 In jection compu ter9 In ertia sw itch

10 Fu el p um p relay11 TDC sensor12 Coolant temperature sensor13 Oxygen sen sor14 Coil for cylinders 2 - 315 Power assisted steering pressostat16 Coil for cylinders 1 - 417 Fuel vapour absorber (canister)18 Anti-interference condenser

LLLLOOOOCCCCAAAATTTTIIIIOOOONNNN OOOOFFFF CCCCOOOOMMMMPPPPOOOONNNNEEEENNNNTTTTSSSS

13082

E7J Engine

17-7



INJECTION


4 Absolu te pressure sensor5 Throt tle posit ion potent iometer6 Idle speed regulation stepping motor

7 Air temperatu re sensor

13 Fuel vapour recycling solenoid14 Coolant temperature sensor

16 Pinking sensor(tightening torque: 2.5 daN.m)

11313R4

11311R1

99939-1R2

8 In jection compu ter9 Inertia sw itch

13051R1

D7F Engine

17-8



INJECTION


H Lock ing relayK Fu el p um p r elay

3 Oxygen sensor(tightening torque : 5 daN.m)

12993R

1 Coil19 Anti-interference condenser

99931-1R1

12839S

17 Power assisted steering pressostat

13050R

D7F Engine

17-9



INJECTION


12 Coolant temperature sensor8 In jection compu ter9 Inertia sw itch

13240R

3 Pin kin g sen sor(tightening torque: 2.5 daN.m)

13336R

13239R

E7J Engine

17-10



INJECTION


4 Absolu te pressure sensor5 Idle speed regulation stepping motor7 Air temperatu re sensor

6 Throttle position potentiometer11 TDC sensor

13337R

1 Fuel vapour recycling solenoid valve14 Coil for cylinders 2-316 Coil for cylinders 1-418 Anti-interference condenser

13242R1

13339R

13 Oxygen sensor(tightening torque : 4.5 daN.m)

13243R

E7J Engine

17-11



INJECTION


K Fan assembly relay (for versions with airconditioning)

L Fu el p um p relayM Fan assembly relay (for versions without air

conditioning) slow speed fan assembly (with

air conditioning)

15 Power assisted steering pressostat

13241R

12839S

E7J engine

17-12



INJECTION

Coolant temperature management

244 Injection coolant temp eratu re sensor andcoolant temp eratu re indication oninstrum ent panel.3 track sensor, of which two tracks are

allocated to the injection coolanttemperature information, and one to theindication of the coolant tempera ture onthe instrum ent pan el.

259 Warn ing coolant temperature switch forinstrum ent panel.

Operating principle

Sensor 244 allows :- the coolant temperature to be shown on the

instrum ent panel,- the injection computer to receive constant in-

formation on the engine coolant temperature.

The injection compu ter, depending on the co-olant temperature, controls :- the in jection system,- the cooling fan assembly .

The engine cooling fan assembly is controlledat fast speed (both slow and fast speed s are

controlled by the a ir conditioning system) if the temperatu re is greater than 99°C. If thetemp eratu re falls below 96°C, it cuts off au tomatically ( if a check has to be carried ou t,ensu re that the air conditioning is not opera-tional).

17

11634R2

D7F Engine

13239R1

E7J Engine

17-13



INJECTION

Injection fault warning light 17

PPPPRRRRIIIINNNNCCCCIIIIPPPPLLLLEEEE FFFFOOOORRRR IIIILLLLLLLLUUUUMMMMIIIINNNNAAAATTTTIIIIOOOONNNN OOOOFFFF IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN FFFFAAAAUUUULLLLTTTT WWWWAAAARRRRNNNNIIIINNNNGGGG LLLLIIIIGGGGHHHHTTTT OOOONNNN IIIINNNNSSSSTTTTRRRRUUUUMMMMEEEENNNNTTTT PPPPAAAANNNNEEEELLLL

• Vehicles not equipped with the immobiliser function:

When the ignition is switched on, the warning light illum inates constantly for 3 seconds , then extin-guishes.

• Vehicles with immobiliser function deactivated:

When the ignition is switched on , the injection w arning light illuminates constantly for 3 seconds an dthen extinguishes.

When th e doors are u nlocked, the red imm obiliser light, which was p reviously flashing, extin-guishes.When ignition is switched on, it illuminates for 3 seconds , then extinguishes.

• Vehicles with immobiliser function activated:

When the ignition is switched on , the compu ter does not recognise the code, and stops the engine fromstarting. The injection warn ing light rem ains illum inated for 3 seconds and then extinguishes.

Before the ignition is switched on, the red immobiliser light flashes. On switching the ignition on, itflashes more rap idly.

If a fault is detected in the imm obiliser system w hilst the engine is runn ing, the injection w arning lightflashes in the engine speed range between idle speed and 1 500 rpm approximately .

• Fault in a component of the injection system

The warn ing light is illum inated if a fau lt has been detected in:- th e p ressu re sen sor ,- th e veh icle sp eed ,- the throt tle potent iometer ,- the idle speed regulation stepping motor.

17-14



INJECTION

Immobiliser function 17

This vehicle is fitted w ith a 2nd generation immobiliser system.

RRRREEEEPPPPLLLLAAAACCCCIIIINNNNGGGG TTTTHHHHEEEE IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR

All computers are sup plied uncoded , but are capable of being p rogramm ed w ith a code.

When replacing the compu ter, the vehicle code m ust be program med in and then a check must be mad e toensu re that the imm obiliser system is operational.

To do this, it is sufficient to carry ou t the following op erations:- turn the ignition on for a few seconds and turn it off again,- remove the key to guarantee the immobiliser function.

CCCCHHHHEEEECCCCKKKKIIIINNNNGGGG TTTTHHHHEEEE IIIIMMMMMMMMOOOOBBBBIIIILLLLIIIISSSSEEEERRRR FFFFUUUUNNNNCCCCTTTTIIIIOOOONNNN

Remove the key from the ignition switch. After 10 seconds the red immobiliser w arning light w ill flash.

For special notes on testing an injection computer (test part), refer to section 82: "Immobili ser".

17-15



INJECTION

Computer configuration depending on gearbox type 17

The screen will display :

CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR CCCCOOOONNNNFFFFIIIIGGGGUUUURRRRAAAATTTTIIIIOOOONNNN DDDDEEEEPPPPEEEENNNNDDDDIIIINNNNGGGG OOOONNNN GGGGEEEEAAAARRRRBBBBOOOOXXXX TTTTYYYYPPPPEEEE ((((MMMMAAAANNNNUUUUAAAALLLL GGGGEEEEAAAARRRRBBBBOOOOXXXX OOOORRRR AAAAUUUUTTTTOOOOMMMMAAAATTTTIIIICCCC

TTTTRRRRAAAANNNNSSSSMMMMIIIISSSSSSSSIIIIOOOONNNN))))

Each time the injection compu ter is replaced, it must be program med w ith the type of gearbox (manu al or

au tomatic) wh ich is fitted in the vehicle. The comp uters are d esigned to function with either typ e of gearbox.

Method for configuring the computer

Connect the XXXXRRRR22225555

Select S8

Switch on the ignition

Enter D13 then

For vehicles fitted with manual gearbox :

Enter G50* 2*

For vehicles fitted with automatic transmission :

Enter G50* 1*

if the configur ation has not been made

To ensure that the compu ter has memor ised the da ta correctly, switch the ignition back on , using fault fin-ding fiche n° 27; the fault bargraph 22220000 LLLLHHHH should be extingu ished, wh ilst the 19 LH or RH status bargraph

should be illuminated.

then if the configuration is complete

17-16



INJECTION

Injection/air conditioning programming 17

TTTTHHHHIIIISSSS VVVVEEEEHHHHIIIICCCCLLLLEEEE IIIISSSS FFFFIIIITTTTTTTTEEEEDDDD WWWWIIIITTTTHHHH AAAA VVVVAAAARRRRIIIIAAAABBBBLLLLEEEE OOOOUUUUTTTTPPPPUUUUTTTT CCCCOOOOMMMMPPPPRRRREEEESSSSSSSSOOOORRRR

AAAAIIIIRRRR CCCCOOOONNNNDDDDIIIITTTTIIIIOOOONNNNIIIINNNNGGGG////IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR CCCCOOOONNNNNNNNEEEECCCCTTTTIIIIOOOONNNN

The electrical conn ection :

- between the air conditioning computer and the injection computer consists of a single wire (track 5).This track carries two types of information :- the fast idle speed request information . For this information to be transm itted to the injection

compu ter , two cond itions mu st be fulfilled :• the air conditioning function must have been selected on the control panel ,• the pressure in the air conditioning circuit must be greater than a certain threshold.If this information is transmitted, the fast idle speed is obtained (it is therefore normal thatsometimes, when the air conditioning is switched on , engine idling, there is no fast idle speed ).

- the Absorbed Power information. This information has no influence on the idle speed . It simp lyinforms the injection comp uter of the torque value taken up by the compressor; the comp uter, inturn, acts on the idle speed regulation solenoid. The absorbed power may be visualised using theXXXXRRRR22225555. When the air cond itioning is switched on , #44 should be between 300 and 5 000 watts.IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT:::: the value at #44 or idle speed is never equ al to 0, whatever the status of thecompressor, off or on . The minimu m value w hich m ay be read using #44 is app roximately 300

watts.- between the the injection computer and the air conditioning computer consists of a single wire (track

51). This track carries the information regard ing the auth orisation or pr evention of compr essoroperation.

CCCCOOOOMMMMPPPPRRRREEEESSSSSSSSOOOORRRR OOOOPPPPEEEERRRRAAAATTTTIIIIOOOONNNN PPPPRRRROOOOGGGGRRRRAAAAMMMMMMMMIIIINNNNGGGG

Dur ing certain operating phases, the injection compu ter preven ts the comp ressor from op erating.

Programming when starting engine

The comp ressor is prevented from functioning for 10 seconds after starting the engine .

Recovery of performance ( D7F engine)

Depending on the torque required by the driver and on the pow er absorbed by the air cond itioningcompr essor, the injection compu ter stops or allows the operation of the comp ressor .

Anti-stalling function (D7F engine)

If the no load p osition is recognised , and the engine speed is lower th an 600 rpm, and if the pow er absorbedby the compressor is greater than 300 watts, the compressor disengages .

It engages again if:- the no load position is recognised w hen the engine speed reaches 850 rpm.,- if the no load position is not recognised w hen the engine speed reaches 1 800 rpm.

Thermal protection programming ( E7J engine )

The compressor does not engage in cases where the coolant temperatu re is greater than or equal to +

115°C.

Over-revving protection (E7J engine )

The comp ressor is prevented from operating if the engine speed is greater than 5 900 rpm.

17-17



INJECTION

Idle speed correction 17

CCCCOOOONNNNNNNNEEEECCCCTTTTIIIIOOOONNNN BBBBEEEETTTTWWWWEEEEEEEENNNN TTTTHHHHEEEE PPPPOOOOWWWWEEEERRRR AAAASSSSSSSSIIIISSSSTTTTEEEEDDDD SSSSTTTTEEEEEEEERRRRIIIINNNNGGGG PPPPRRRREEEESSSSSSSSOOOOSSSSTTTTAAAATTTT AAAANNNNDDDD TTTTHHHHEEEE IIIINNNNJJJJEEEECCCCTTTTIIIIOOOONNNN CCCCOOOOMMMMPPPPUUUUTTTTEEEERRRR

The injection compu ter receives information from the pow er assisted steering pressostat . This variesdep end ing on the pressure present in the hydrau lic circuit. The higher the p ressure, , the more energy is

absorbed by the pow er assisted steering pu mp .

To comp ensate for this energy absorp tion, the injection comp uter increases the open ing ratio of the idlespeed regu lation stepping m otor.

The information is received on track 13 of the injection comp uter. If the p ressostat is closed , the computerreceives an earth . The idle speed is ad justed to 800 rpm for the D7F engine an d 850 rpm for the E7J

engine .

IIIIDDDDLLLLEEEE SSSSPPPPEEEEEEEEDDDD CCCCOOOORRRRRRRREEEECCCCTTTTIIIIOOOONNNN DDDDEEEEPPPPEEEENNNNDDDDIIIINNNNGGGG OOOONNNN TTTTHHHHEEEE BBBBAAAATTTTTTTTEEEERRRRYYYY VVVVOOOOLLLLTTTTAAAAGGGGEEEE

The objective of this correction is to compen sate for the drop in voltage, du e to consumer operation whenthe battery is poorly charged To correct this, the idle speed is increased, allowing the alternator to rotatefaster and consequ ently increase the charging voltage.

The lower th e voltage, the greater the degree of correction. Correction of the engine sp eed is thereforevariable. It begins w hen the voltage drop s to below 12.7 Volts. Correction begins at the nom inal enginespeed and m ay reach a maximum of 880 rpm for the D7F engine and 930 rpm for the EEEE7777JJJJ engine .

IIIIDDDDLLLLEEEE SSSSPPPPEEEEEEEEDDDD CCCCOOOORRRRRRRREEEECCCCTTTTIIIIOOOONNNN DDDDEEEEPPPPEEEENNNNDDDDIIIINNNNGGGG OOOONNNN AAAAIIIIRRRR CCCCOOOONNNNDDDDIIIITTTTIIIIOOOONNNNIIIINNNNGGGG OOOOPPPPEEEERRRRAAAATTTTIIIIOOOONNNN

The injection comp uter increases the idle speed to 850 rpm. for the DDDD7777FFFF engine and 880 rpm . for the E7J

engine , prov ided it receives the fast idle speed information from the air cond itioning compu ter.

17-18



INJECTION

Adaptive idle speed correction 17

PPPPRRRRIIIINNNNCCCCIIIIPPPPLLLLEEEE

Und er normal warm engine operating conditions , the RRRR....CCCC....OOOO.... idle speed value at #12 varies between ahigh value and a low value, until the nominal idle speed is obtained .

It is possible that du ring variations in the operation of the vehicle (runn ing in, engine wear..), that theRRRR....CCCC....OOOO.... idle speed va lue could become close to the highest or lowest values.

The adaptive correction (#21) of the RRRR....CCCC....OOOO.... idle speed (#12) allows th e slow variations in the eng ine air re-qu irement to be corrected, so that the RRRR....CCCC....OOOO.... ( #12) is recentred to an average nom inal value.

This correction only becomes effective if the coolant temp eratu re is higher than 75°C, 20 seconds afterstarting the engine and if the nominal idle speed regu lation phase has been reached.

VVVVAAAALLLLUUUUEEEESSSS FFFFOOOORRRR TTTTHHHHEEEE RRRR....CCCC....OOOO.... IIIIDDDDLLLLEEEE SSSSPPPPEEEEEEEEDDDD AAAANNNNDDDD IIIITTTTSSSS AAAADDDDAAAAPPPPTTTTIIIIVVVVEEEE CCCCOOOORRRRRRRREEEECCCCTTTTIIIIOOOONNNN

D7F 710

engine

E7J 780

engine

Nominal id le speed (#06) X = 740 rpm X = 750 rpm

R.C.O. id le speed (#12) 4 %≤X≤14 % 2 %≤X≤15 %

Adaptive idle speed (#21) Limit value:- minimu m : - 4.3 %- maximum :+3.9 %

Limit value:- minim um : - 2.4 %- maximum :+6.2 %

IIIINNNNTTTTEEEERRRRPPPPRRRREEEETTTTAAAATTTTIIIIOOOONNNN OOOOFFFF TTTTHHHHEEEE GGGGAAAATTTTEEEE VVVVAAAALLLLUUUUEEEESSSS

In the case of excess air (air leak or throttle stop incorrectly ad justed ..) the idle speed increases, and theRRRR....CCCC....OOOO....idle speed value at #12 decreases , in order to return to the nominal idle speed; the value of theRRRR....CCCC....OOOO....idle speed ad aptive correction at #21 decreases to re-centre th e RRRR....CCCC....OOOO.... idle speed at #12.

In the case of a lack of air (contamination, etc.), the p rocess is inver ted : the RRRR....CCCC....OOOO.... idle speed at #12 in-creases and the adap tive correction at #21 also increases, in order to re-centre the #12 to an average nomi-nal value.

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: It is vital, after erasing the memory from the comp uter (disconnecting the battery ), to let theengine ru n at idle speed before returning th e vehicle to the customer, so that the adaptive correction can becorrectly reset.

17-19



OOOOXXXXYYYYGGGGEEEENNNN SSSSEEEENNNNSSSSOOOORRRR VVVVOOOOLLLLTTTTAAAAGGGGEEEE ((((####00005555))))

Reading #05 on the XXXXRRRR22225555 : the value read is the voltage sent to the computer by the oxygen sensor; it is ex-pressed in volts (the value actually varies between 0 an d 1 000 millivolts).

When th e engine is in the loop phase, the voltage value shou ld oscillate rapid ly and shou ld be between50±50 mV (lean m ixture) and 850 ± 50 mV (rich mixture) and vice versa.

The smaller the gap between the u pp er and lower values, the poorer the information from the sensor (thegap is usually at least 500 mV).

RRRRIIIICCCCHHHHNNNNEEEESSSSSSSS CCCCOOOORRRRRRRREEEECCCCTTTTIIIIOOOONNNN ((((####33335555))))

The value given un der # 35 on the XXXXRRRR22225555 repr esents the average value of richness corrections made by thecompu ter dep end ing on the richness of the bur nt mixture as seen by the oxygen sensor (the oxygen sensor ac-tually analyses the oxygen content of the exhau st gases directly from the richness of the bu rnt m ixture).

The richness correction has a centre point of 128 with thresholds of 0 an d 255 (experience has shown that un -der normal operating conditions # 35 is located close to 128 with only a small amou nt of var iation).

- Value less than 128 : request for mixture to be made leaner.

- Value greater than 128 : request for mixture to be made richer.

EEEENNNNTTTTRRRRYYYY IIIINNNNTTTTOOOO RRRRIIIICCCCHHHHNNNNEEEESSSSSSSS RRRREEEEGGGGUUUULLLLAAAATTTTIIIIOOOONNNN MMMMOOOODDDDEEEE

Loop phase

Richness regulation begins after the timed starting period :

- for no load, if the coolant temperature has reached :• 46°C for the EEEE7777JJJJ engine ,• 30°C for the D7F engine.

- outside no load conditions if the coolant temperature is greater than :• + 20°C for the E7J, engine• + 20°C for the D7F engine.

The timed starting p eriod is d ependent on the coolant temp erature :

- at 20°C it is a maximum of :• 3 minutes for the EEEE7777JJJJ engine,• 1 minute 20 seconds for the DDDD7777FFFF engine,

- at 80°C it is a maximum of :• 1 minute 30 seconds for the EEEE7777JJJJ engine,• 35 seconds for the D7F engine,

If richness regulation has not yet started, #35 = 128

INJECTION

Richness regulation 17

17-20



INJECTION

Richness regulation 17

Non-loop mode

When r ichness regulation is occurring, the operating p hases wh en the computer ignores the voltage informa-tion from the oxygen sensor are:

- Full load: #35 = variable and greater than 128- Sharp acceleration : #35 = variable and greater than 128

- Deceleration with no load information (injection cut) : #35 = 128

- Oxygen sen sor fau lt: #35 = 128

DDDDEEEEFFFFEEEECCCCTTTT MMMMOOOODDDDEEEE IIIINNNN TTTTHHHHEEEE EEEEVVVVEEEENNNNTTTT OOOOFFFF AAAANNNN OOOOXXXXYYYYGGGGEEEENNNN SSSSEEEENNNNSSSSOOOORRRR FFFFAAAAUUUULLLLTTTT

If the voltage from the oxygen sensor is incorrect (# 05 varies only slightly or not a t all) du ring richness regu-lation, the computer w ill only enter defect mod e (# 35 = 128 ) if the fault has been p resent for 3 to 5 minutes .The fault will be mem orised in th is case only.

If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system entersthe open loop mod e directly (# 35 = 128 )

17-21



INJECTION

Adaptive richness correction 17

DDDD7777FFFF

Engine

EEEE7777JJJJ

Engine

106 ≤ #30 ≤ 150 40 ≤ #30 ≤ 192

106 ≤ #31 ≤ 150 40 ≤ #31 ≤ 192

PPPPRRRRIIIINNNNCCCCIIIIPPPPLLLLEEEE

In the loop mod e (see section 17 "Richness regulation"), richness regulation (# 35 ), corrects the in jection ti-ming to give fuel metering w hich is as close as possible to richness 1. The correction value is close to 128, withlimit va lues of 0 an d 255.

Variations may affect the comp onents of the injection system an d th e correction may d rift toward s 0 or 255,to ensure richness 1 is obtained .

Adaptive correction allows the injection m app ing to be adjusted to recentre the richness regulation to 128

and to ensure a constant au thority of correction to make the mixture leaner or richer.

Adaptive correction to richness regulation has two pa rts:- Adaptive correction for average and high engine loads (#30)- Adaptive correction for idle speed and low engine loads (#31).

Adaptive corrections take 128 as the average va lue after initialisation (erasing the mem ory) and have thefollowing threshold v alues:

Adaptive correction only takes place when the engine is warm , in the loop phase (#35 variable) and for aspecified man ifold pressu re range.

The engine mu st have operated in the loop mod e for several pressure zones in order that ad aptive correc-tion begins to change to compensate for the var iations in engine operating richness.

Following reinitialisation of the computer (return to 128 for # 30 an d # 31 ) a special road test mu st thereforebe carried ou t.

17-22



INJECTION

Adaptive richness correction 17

IIIINNNNTTTTEEEERRRRPPPPRRRREEEETTTTAAAATTTTIIIIOOOONNNN OOOOFFFF IIIINNNNFFFFOOOORRRRMMMMAAAATTTTIIIIOOOONNNN GGGGAAAATTTTHHHHEEEERRRREEEEDDDD DDDDUUUURRRRIIIINNNNGGGG AAAA RRRROOOOAAAADDDD TTTTEEEESSSSTTTT

If there is a lack of fuel (injectors d irty, fuel pressu re and flow too low...), richn ess regu lation # 35 increases toobtain the richness as close as possible to richness 1 and adaptive correction # 30 an d # 31 increases until the

richness correction retu rns to oscillate aroun d 128.

If there is an excess of fuel, the situation is rever sed : Richness regu lation # 35 redu ces and adap tivecorrection # 30 an d # 31 also redu ces to recentre the r ichness correction (# 35) around 128.

NNNNOOOOTTTTEEEE :::: the analysis which may be made u sing # 31 remains difficult since this correction mainly opera tes foridle speed and low load s and is also very sensitive.

Hasty conclusions should not therefore be draw n from this gate value, rather the position of # 30 should beexamined.

The information from th ese two gates gives an idea abou t the engine operation richness, and may be u sed asa guide for fault find ing. In order for these to be pu t to good u se dur ing fault find ing, no conclusion may bedraw n from their value u nless they are at the m inimu m or maximum correction limit, and if both gate valueswere offset in the same d irection.

IMPORTANT : # 30 and # 31 should only be examined and analysed after a customer complaint, an opera-

ting fault and if they are at the threshold w ith the value for # 35 also offset (# 35 varies above 175 or be-

low 80).

17-24



COOLING

Filling and bleeding 19

There is no heater m atrix water control valve.

Water flow is continuou s in the heater matrix,wh ich contributes to the cooling of the engine.

FFFFIIIILLLLLLLLIIIINNNNGGGG

Check the tightening of the drain p lug(s).

Open the tw o bleed screws.

Fill the circuit throu gh the op ening in the expan -sion bottle.

Tighten th e bleed screws as soon as the liqu idflows in a continuou s jet.

Start the engine (2 500 rpm).

Adjust the level by overflow for a p eriod of about4 minutes .

Close the bottle.

BBBBLLLLEEEEEEEEDDDDIIIINNNNGGGG

Allow the engine to run for about 10 minutes at

2 500 rpm, until the fan(s) operate (time necessaryfor autom atic degassing).

Check the liquid level is at the "Maximum" mar -ker.

DDDDOOOO NNNNOOOOTTTT OOOOPPPPEEEENNNN TTTTHHHHEEEE BBBBLLLLEEEEEEEEDDDD SSSSCCCCRRRREEEEWWWWSSSS WWWWHHHHIIIILLLLSSSSTTTT TTTTHHHHEEEE

EEEENNNNGGGGIIIINNNNEEEE IIIISSSS TTTTUUUURRRRNNNNIIIINNNNGGGG....

RRRREEEE----TTTTIIIIGGGGHHHHTTTTEEEENNNN TTTTHHHHEEEE EEEEXXXXPPPPAAAANNNNSSSSIIIIOOOONNNN BBBBOOOOTTTTTTTTLLLLEEEE CCCCAAAAPPPP WWWWHHHHIIIILLLLSSSSTTTT

TTTTHHHHEEEE EEEENNNNGGGGIIIINNNNEEEE IIIISSSS WWWWAAAARRRRMMMM....

19-2



COOLING

Testing 19


MMMM....SSSS.... 554-01 Adapter for M.S. 554-05

MMMM....SSSS.... 554-06 Adapter for M.S. 554-05

MMMM....SSSS.... 554-07 Kit for testing cooling circuit

sealing

97871R

Engine Colour of valveValve rating (in

bars)

D7F-E7J-F8Q Brown 1.2

1 - Testing the sealing of the circuit

Replace the expansion bottle valve with ad ap terM.S. 554-01.

Connect this to tool M.S. 554-07.

Let the engine warm up then turn it off.

Pump to put the circuit und er pressure.

Stop pu mp ing at 0.1 bar less than the valve israted.

The pressure shou ld not drop, otherwise look forthe leak.

Slowly unscrew the union of tool M.S. 554-07 to

decomp ress the cooling circuit, then r emove toolM.S. 554-01 and refit the expansion bottle valvewith a new seal.

2 - Checking the rating of the valve.

If liqu id passes through the expansion bottlevalve,the valve mu st be replaced.

On pump M.S. 554-07 fit tool M.S. 554-06 and fit

the assembly on the va lve to be checked.

Increase the pressure w hich should stabilise at thevalve rating pr essure w ith a test tolerance of ±0.1 bar.

Valve rating :

19-3



COOLING

Diagram 19

1 Engine2 Radiator3 ”Hot” bot tle with permanent degassing4 H eater m atrix5 3 mm diameter rest rict ion

The fan assembly is controlled at high speed by

the injection compu ter if the coolant temp era-ture is greater than 99°C.

If the coolant tempera ture is lower than 96°C, thefan assembly stops opera ting.

Water pum p

Thermostat

Bleed screw

The expansion bottle valve is brow n, and its ratingis 1.2 bar.

10070-2R

D7F Engine

19-4



COOLING

Diagram 19

1 Heater2 Radiator3 ”Hot” bot tle with permanent degassing4 H eater m atrix5 Thermosta t moun ting6 3 mm diameter rest rict ion

The fan assembly is controlled at high speed bythe injection compu ter if the coolant temp era-ture is greater than 99°C.

If the coolant tempera ture is lower than 96°C, thefan assembly stops opera ting.

Water pum p

Thermostat

Bleed screw

Temp erature switch

The expansion bottle valve rating is 1.2 bar

(colour:brown).

13508R

E7J Engine

19-5



COOLING

Diagram 19

Water pum p

Thermostat

Bleed screw

Temp erature switch

13504R

F8Q Engine

1 Heater2 Radiator3 ”Hot” bot tle with permanent degassing4 H eater m atrix5 Thermosta t moun ting6 3 mm diameter rest rict ion

The expansion bottle valve rating is 1.2 bar

(colour:brown).

19-6



COOLING

Water pump



of all aluminium components.

Use the product Décapjoint to dissolve the par tof the gasket wh ich rem ains attached.

App ly the produ ct to the part to be cleaned, waitapp roximately 10 minu tes, then rem ove it using awooden spatula.

The wearing of gloves is recomm ended du ringthis operation.

19





Mot. 1289-03 Tool for centring the suspended en-

gine movement limiter

Mot. 1379 Tool for retaining engine on sub-

frame

10478S

D7F Engine

Crankshaft output mounting bolts 2 + 90°

Bolt for mounting front right suspended


Bolt for mounting front right suspended

engine mounting on vehicle body 6.2


Water pump mounting bol t 0.9






section 11 "Timing belt),- the power assisted steering pump pulley (if fit-

ted),- the upper alternator mounting bolt and

slacken the lower bolt,- the bolts for mounting the power assis ted

steering pipe on the cylind er block,- the bolts for mounting the power assis ted

steering pu mp on its supp ort (move the po-wer assisted steering p um p-pipe assembly toone side),

- the power assis ted steering pump support,- the w ater pu mp hose,- the tension wheel along with the water pump

itself.

19-7



COOLING

Water pump


Refit the timing belt (see method described insection 11 "Timing belt").

Remember to remove the TDC pin.

19

10272R

D7F Engine


Special notes

Sealing of the water pum p is carried ou t using

RRRRHHHHOOOODDDDOOOORRRRSSSSEEEEAAAALLLL 5555666666661111, the bead (J) mu st be app liedfollowing th e illustration below.

App ly a bead of LLLLOOOOCCCCTTTTIIIITTTTEEEE 555511118888 on the sealing sur -face (L) between the inlet pipe elbow and th e wa-ter pum p.

19-8



COOLING

Water pump

Refit the timing belt (see method described inchapter 11 "Timing belt").

Fill and bleed the cooling circuit (see section 19

"Filling - Bleeding").

19


Mot. 591-02 Index

Mot. 591-04 Angle tightening wrench

Mot. 1135-01 Tool for tensioning the timing belt



92068R

E7J Engine

Tension wheel nut 5

Crankshaft pulley bolt 2 + 68° + 6°

Bolt for suspended engine mounting cover 6,2

Nut for suspended engine mounting cover 4,4

Water pump bolt 2,2

Water pump nut 1

Wheel bolts 9



Engine support tool


The sealing of the w ater pu mp is carried out u singthe product LLLLOOOOCCCCTTTTIIIITTTTEEEE 555511118888; the bead (H) mu st beapplied following the diagram below.




Drain the cooling circuit from the lower rad iatorhose.


section 11 "Timing belt),- the timing tension wheel,- the water pu mp , and extract this from above.



of all aluminium components.

Use the produ ct Décapjoint to dissolve the par tof the gasket wh ich remains attached.

App ly the produ ct to the part to be cleaned, waitapproximately 10 minu tes, then rem ove it using awooden spatula.

The wearing of gloves is recomm ended du ringthis operation.

19-9



COOLING

Water pump 19



13090R

F8Q Engine

Water pump bolt 1.6

Bolt for water pump pulley 2

Bolt for crankshaft pulley 2 + 115° ± 15°





Drain the cooling circuit through the lower rad ia-tor hose.

Fit the engine sup port tool.

Remove :- the plastic protector for the suspended engine

mou nting cover,- the suspended engine mounting cover ,


Engine support tool

- the front r ight wheel arch ,- the accessories belt ,- the crankshaft pulley (A),- the water pump pulley (B) , lowering the en-

gine as far as possible,- the inject ion pump housing (C),

- the bolt at (1) and move the alternator to theright.

13086R1

19-10



EXHAUST

General 19

FFFFIIIITTTTTTTTIIIINNNNGGGG TTTTHHHHEEEE AAAAFFFFTTTTEEEERRRR SSSSAAAALLLLEEEESSSS SSSSLLLLEEEEEEEEVVVVEEEE

95478R1

Once a collar has been used once, renew it.

The nu t on the collar has a groove (A) to ensure itis tightened to the correct torqu e. When th e nu t istightened and the groove d isapp ears, it causes adistinct clicking sound and the nu t is then tighte-

ned to the correct torque (2.5 daN.m).

NNNNOOOOTTTTEEEE :::: there are two different d iameters of sleeve available:- ∅ 50 mm,- ∅ 45 mm .

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT::::

- check that there is no point of contact bet-ween the exhaust p ipe and the vehicle body,

- check for the presence and correct positioning

of all heat shields for the exhau st pipe,- check that the two cutting marks are correctlyaligned.

99227S

To avoid any leaks in the exhaust p ipe, the sleevemu st be correctly positioned over the tw o exhaustpipe sections. The pipe must be against the stops

inside the sleeve.

Begin by p ositioning th e sleeve over the u sed sec-tion of the p ipe, adjust the collar by tighteninggently.

Check the position of the pipe in r elation to thestops.

Fit the new section of the pipe.

Before fitting the sleeve on the pipe, apply a littlemastic to the inner ring on the sleeve to preventleaks.

(Exhaust mastic, Part Number. 77 01 421 161

SODICAM).

IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: the bolt and nut u sed for tighte-ning the sleeve must be aligned vertically toavoid an y risks of touching the u nd erside of thebody.

19-14



EXHAUST

Pipe assembly 19

DDDDIIIIAAAAGGGGRRRRAAAAMMMM OOOOFFFF EEEEXXXXHHHHAAAAUUUUSSSSTTTT PPPPIIIIPPPPEEEESSSS AAAANNNNDDDD LLLLOOOOCCCCAAAATTTTIIIIOOOONNNN OOOOFFFF CCCCUUUUTTTTTTTTIIIINNNNGGGG AAAARRRREEEEAAAASSSS

13125R

1 Catalytic con ver ter2 SilencerZC Pipe cutt ing area

F8Q Engine

19-16



FUEL TANK

Fuel tank 19

In the engine compar tmen t, d isconnect the fuelpu mp relay at (K) , which is located in the engineconnection u nit.

12839S

DDDDRRRRAAAAIIIINNNNIIIINNNNGGGG TTTTHHHHEEEE FFFFUUUUEEEELLLL TTTTAAAANNNNKKKK (((( DDDDiiiieeeesssseeeellll vvvveeeerrrrssssiiiioooonnnn))))

Since Diesel versions are not fitted with an electri-cal fuel pu mp , a manu al pum p m ust be used to

drain the tank.

For example, the IIIINNNNTTTTAAAAIIIIRRRRCCCCOOOO pneu matic siphoningpu mp is suitable for this opera tion (seeEEEEQQ Q Q UUUUIIIIPPPPMMMMEEEENNNNTTTT catalogue),

Shunt tracks 3 an d 5 and let the fuel flow u ntil itruns out in interm ittent jets.

Disconnect the shunt.

Reconnect the relay.


Remove the pu mp -send er un it steel access cover.

Remove the clip which shows if the assembly hasbeen pushed in (if fitted).

Disconnect the quick release un ion at (1), toolMot. 1265.

99641S

97163R2

Connect the pneum atic pu mp rubber tube to theoutlet un ion at (A).

Drain the tank.

19-18



TANK

Fuel Tank 19

RRRREEEEMMMMOOOOVVVVAAAALLLL OOOOFFFF TTTTHHHHEEEE TTTTAAAANNNNKKKK ((((ppppeeeettttrrrroooollll oooorrrr ddddiiiieeeesssseeeellll vvvveeeerrrr----

sions)



Disconnect the electrical connector (2) and thequ ick release un ions, tool Mot. 1265 or Mot.

1265-01.

97163R4

Disconnect the petrol filter.

Remove the heat shields at (3) and (4) , which aresituated below the tank and beneath the hand -

brake cables.

Remove the exhaust mou nting bracket (5).

Lift the veh icle.

Separate the exhaust pipe from the exhaustdown p ipe.

Remove the exhaust mounting bracket from themid dle of the vehicle.

12866R

Tilt the exhaust toward s the right hand side of thevehicle.

19-19



FUEL TANK

Fuel tank 19

Before the han dbrake ad juster is disengaged , di-mension X mu st be noted.

Disengage the adjuster in such a way tha t boththe left and r ight hand cables can be easily relea-sed (carefully release the plastic cable stop (6)).

Disconnect the two u nions at (7) and (8) usingtool Mot. 1265.

Disconnect the pipe at (9).

Separate the tank from the filler neck (10).

Unclip the handbrake cables from u nder the tank(11).

Unclip the hydrau lic brake pipes on the fuel tankside.

Unclip th e fuel pipes from th e tank.

Position a compon ent jack und er the fuel tank.

Remove the four bolts mou nting the tank.

Tilt the tank slightly forward s, then r emove it.



Take care not to p inch any p ipes (risk of leaks).

Fit the quick release un ions by hand and ensure

they connect correctly.

Take care to ensu re the heat shields are correctlyrefitted.

12873R

99091R1

19-20



FUEL TANK

Fuel tank 19

13039R

1st generation Petrol version

19-21



FUEL TANK

Fuel tank 19

1st generation Petrol fuel tank

13037R

19-22



FUEL TANK

Fuel tank 19

2nd generation petrol fuel tank

13036R

19-24



FUEL TANK

Fuel tank 19

Diesel version

13040R

19-25



FUEL TANK

Fuel tank 19

Diesel fuel tank

13035R

The tank breathes through the top opening of the fuel breather/ sender un it assembly.

19-26



FUEL TANK

Fuel tank 19

Components

1 Tank2 Bolt

3 Filler neck4 Filler neck bow l5 Rivet6 Sleeve mounting clip7 Fuel cap8 Fu el su pp ly p ip e9 Fu el retu rn p ip e

10 Clip13 Cup14 Can ister p ip e15 Can ister p ip e18 Canister19 Bolt20 Clip21 Clip22 Damper pad23 Cap tive nut24 Connection between filler neck outlet and

fuel passage pipe25 Degassing - filling27 Canister connection (fuel vapours)28 Over-filling prevention valve29 Excess pressure-und er-pressure safety valve

30 Rest rict ion valve31 Leak prevention valve in case vehicle turnsover

32 Over-filling prevention valve and leak pre-vention valve in case vehicle turn s over.

A Quick-release unionB Snap-fit un ion

C Quick release unionD Sleeve (not snap-fit )E Opening for air outlet during fillingF Air volume allowing the fuel to expandR Fuel inlet for fillingV Maximum fuel volume allowed.

19-27



FUEL TANK

Fuel tank 19

PPPPUUUURRRRPPPPOOOOSSSSEEEE OOOOFFFF TTTTHHHHEEEE VVVVAAAALLLLVVVVEEEESSSS

28 Overfill prevention valve

When the filler cap is removed the valve isclosed, trapp ing a volume of air within thebreather volum e. This preven ts fuel from fil-ling this volum e.

When the filler cap is replaced, the valveopens allowing the tank to breathe throughthe canister

29 Excess - vacuum safety valve

If the fuel vapour recirculation circuit isblocked, this valve prevents the fuel tankbeing subject to excess pressu re (the tan kwou ld inflate) or vacuum (as fuel is used, thetank wou ld be crushed ).

30 Restriction valve

This valve prevents the introdu ction of leadedfuel into the tan k.

31 Leak prevention valve in case vehicle turns

over

If the veh icle turns over , this valve pr eventsthe tank from emp tying, either through thepipe leading to the canister, or throu gh thebreather pipe (in Diesel versions).

32 Overfill prevention valve and leak prevention

valve in case the vehicle turns over

The overfill prevention valve opera tes usingthe ball at (33).

When the veh icle is stationary, du ring filling,the ball rests in its seat, retaining a certainvolum e of air in the r eservoir .

When the vehicle is moving , the ball (33)moves ou t of its seat, thu s allowing th e tankto be connected to the canister.

When the tan k is full, it is vital that asufficient volume of air to allow th e fuel

contained w ithin it to expand is retainedinside the tank, but not too mu ch, otherw isethere is a risk of the tank exploding .

This valve has the sam e operating p rinciple asthe valve (31) .

The tank has a sealed cap.

The filler neck for unleaded petrol has the follo-wing special features :

- a filling opening with a smaller diameter andnot compatible with a conventional fillingnozzle (the lead w ould have th e effect of pol-luting the depollution system: oxygen sensorand catalytic converter),

- a valve blocking the filing opening (30) (toavoid fuel evaporating or the reverse passageof fuel).

Fitting the cap releases the overfill preventionvalve (A) allowing the tank to breathe (this fea-ture is present on ly in first generation petrol ver-

sions).

99212R2

19-28



FUEL TANK

Sender unit 19

In petrol versions, the pu mp and sender un it can-not be separated.

In diesel versions, there is no pum p imm ersed in

the tank, and there is only a send er un it.

For the remova l of the sender u nit, please refer tosubsections "Tank", "Pump-sender unit".

Checking the sender unit

Check for a va riation in resistance by mov ing thefloat.

NNNNOOOOTTTTEEEE :::: all the above values are given merely asan ind ication.

IndicationValue between terminals

A1 and B1 (in Ω)

4/ 4 7 maximum

3/ 4 54.5 ± 7

1/ 2 98 ± 10

1/ 4 155 ± 16

Low fuel level 300 ± 20

19-29



Mot. 1264 Wrench for removing

Mot. 1264-01 pump-sender unit assembly nut

Mot. 1265 Pliers for removing

Mot. 1265-01 quick release unions

FUEL TANK

Pump- sender unit 19


IIIIMMMMPPPPOOOORRRRTTTTAAAANNNNTTTT :::: During all operations on the fuel tank or on the

fuel supply circuit , it is vital :

- to refrain from smoking and handling incan-

descent objects in the vicinity of the w orking

area,

- to avoid fuel projections, due to the residual

pressure present in the pipes during removal .


To remove the pu mp -sender unit assembly, it is

not necessary to remove the tank, as it is accessi-ble through th e inside of the vehicle. To do this :- d isconnect the battery,- lift the rear bench seat ,- remove the s teel access cover,- remove the electrical connection at (1),- rem ove the clips at (2).

97163R5

Nut for pump - sender unit assembly 7

TTTTIIIIGGGGHHHHTTTTEEEENNNNIIIINNNNGGGG TTTTOOOORRRRQQ Q Q UUUUEEEESSSS ((((iiiinnnn ddddaaaaNNNN....mmmm)))) Disconnect, using tool Mot. 1265 or Mot. 1265-

01:

- the fuel supply pipe (3) (which is marked by agreen qu ick release union),

- the fuel return pipe (4) (marked by a red quickrelease union and by an ar row (B)).

96420R1

19-30



FUEL TANK

Pump- sender unit 19


Check that the seal is not deformed, and replace itif necessary.

Position the pu mp -sender unit assembly(ensuring that the arrow a t (F) is placed in thelongitud inal axis of the vehicle pointing to therear).

Position the nu t and tighten it to the torque of 3.5 daN.m.

Fit the fuel p ipes (it is not necessary to u se thepliers Mot. 1265 or Mot. 1265-01).

Refit the safety clips at (2).

Reconn ect the electrical connection.

Refit the steel cover .

AAAALLLLLLLLOOOOCCCCAAAATTTTIIIIOOOONNNN OOOOFFFF CCCCOOOONNNNNNNNEEEECCCCTTTTOOOORRRR TTTTRRRRAAAACCCCKKKKSSSS

TTTTRRRRAAAACCCCKKKK AAAALLLLLLLLOOOOCCCCAAAATTTTIIIIOOOONNNN

A1 Earth

A2 Fuel min imum level warning ligh t

B1 Sender unit in formation to inst rumentpanel

B2 Not used

C1 pump

C2 pump

Remove the mou nting nu t at (5) using toolMot. 1264 or 1264-01 (release the nu t, remov ethe tool, han d slacken the nut, then remove it).

Extract the fuel pu mp -send er unit assembly.

99367S

NNNNOOOOTTTTEEEE :::: if several hours have to pass between theremoval and refitting of the fuel pum p-senderun it assembly, refit the nut on the tank, to avoiddeforming it.

19-31



ENGINE MOUNTING

Suspended engine mountings 19

13359R3

D7F Engine


19-33



ENGINE MOUNTING

Suspended engine mountings 19F8Q Engine


engine and peripherals

Documents