"The repair methods given by the manufacturer in this document are based on the technical specifications current when it was prepared. The methods may be modified as a result of changes by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed". C RENAULT 1999 77 11 205 759 JULY 1999 Edition Anglaise N.T. 3218A DA03 - EA03 SPECIAL FEATURES OF THE F5R 740 ENGINE (including related assemblies) For all parts not dealt with in this Technical Note refer to Workshop Repair Manual MR 312. Follow the instructions regarding cleanliness when working on this vehicle. All copyrights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.
The methods may be modified as a result of changes by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".
C RENAULT 1999
77 11 205 759 JULY 1999 Edition Anglaise
N.T. 3218A
DA03 - EA03
SPECIAL FEATURES OF THE
F5R 740 ENGINE
(including related assemblies)
For all parts not dealt with in this Technical Note refer to Workshop Repair Manual
MR 312.
Follow the instructions regarding cleanlinesswhen working on this vehicle.
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority ofRenault.
Contents
07-107-307-407-2107-2207-2307-2407-2507-2707-29
Pages
Capacities - GradesAccessories belt tensioningTiming belt tensioning procedureCylinder head tighteningTyres - wheelsBrakesBrake compensatorUnderbody heightFront axle angle checking valuesRear axle angle checking values
* Adjust using a dipstick(1) Following replacement of the oil filter
VALUES AND SETTINGSCapacities - Grades 07
UnitsCapacityin litres
(approx.) *
Petrol engine(oil)
F5R
Grade
Whendraining
5.15.4 (1)
0 °C + 30 °C- 30 °C + 20 °C- 20 °C - 10 °C
- 15 °C
ACEA A2/A3
ACEA A1*/A2/A3
ACEA A1*/A2/A3
ACEA A1*/A2/A3
+ 10 °C
ACEA A1-98 standard* Oil for fuel economy
15W40-15W50
10W30-10W40-10W50
0W30-5W30
0W40-5W40-5W50
European Union countries and Turkey
PETROL
Other CountriesIf the lubricants specified for the European Union countries are notavailable, the following specifications must be taken into account:
PETROL
0 °C + 30 °C- 30 °C + 10 °C + 20 °C- 20 °C - 10 °C
- 15 °C
API SH/SJ
API SH/SJ
API SH/SJ
API SH/SJ
API SH/SJ
Oil for fuel economy:API SJ-IL SAC GF2 standard
15W40-15W50
10W40-10W50
10W30
5W30
5W40-5W50
07-1
VALUES AND SETTINGSCapacities - Grades 07
Units Capacityin litres
JC5gearbox
Grade Special features
3.1 All countries: TRANSELF TRX 75 W 80 W(API GL5 or MIL-L 2105 G or D standards)
F5Rcoolingcircuit
7 Glacéol RX(type D)
Protection to - 20 °C ± 2 °C for hot, temperate andcold climates.Protection to - 37 °C ± 2 °C for very cold climates.
07-2
VALUES AND SETTINGSAccessories belt tensioning 07
A CrankshaftB Air conditioning compressorC AlternatorD Power steering pumpE Coolant pumpF PulleyT Automatic tensioner
When refitting the belt, it is essential to ensurethat the tooth (X) inside the pulleys (timing side)remains "free".
ALTERNATOR, POWER STEERING AND AIRCONDITIONING
To remove the belt, turn the belt’s automatic ten-sioner in the direction indicated below using a 13mm offset ring ended spanner. Clamp the tensio-ner using a 6 mm hexagonal wrench (1).
15579-1R1
15304R
15110R
WARNING: the accessories belt rests on the ridgedpart on the pulley (F).
07-3
VALUES AND SETTINGSTiming belt tensioning procedure 07
ESSENTIAL SPECIAL TOOLS
Mot. 799-01 Tool for immobilising pinions for
toothed timing belt
Mot. 1054 Top Dead Centre pin
Mot. 1368 Tool for tightening camshaft
pulleys
Mot. 1383 Pipe wrench for removing HP
pipes
Mot. 1448 Clip pliers for spring clips
Mot. 1453 Engine support tool
Mot. 1488 Tool for refitting camshaft
covers
Mot. 1512 Tool for fitting the camshaftseals
Mot. 1526 Tool for setting the camshafts
Mot. 1535 Tool for immobilising the
camshaft pulleys
There are two very distinct procedures for settingthe timing.
1st PROCEDURE
The first procedure is applied in the event of re-placement of any components in the timing facewhich do not require slackening of the camshaftpulley(s).
Follow the instructions regarding cleanliness andsafety when working on the fuel circuit.
ESSENTIAL EQUIPMENT
Angular tightening wrench
07-4
VALUES AND SETTINGSTiming belt tensioning procedure 07
Setting the timing
WARNING: it is essential to de-grease the end of the cranks-haft, the crankshaft pinionbore and the crankshaft pulleycontact surfaces to prevent sli-ding between the timing andthe crankshaft which coulddestroy the engine.
Position the camshaft groovesusing Mot. 799-01 as indicatedin the diagram opposite.
It is essential that the groovesare horizontal and offsetdownwards.
15614S
Fit tool Mot. 1526 which is secured at the end ofthe camshafts.
16077R
07-5
VALUES AND SETTINGSTiming belt tensioning procedure 07
Check that the crankshaft is at Top Dead Centreand not in the balancing hole.
Correct position
15163S
15163-1S
Incorrect position
07-6
VALUES AND SETTINGSTiming belt tensioning procedure 07
The crankshaft groove (5) should be between the two marks on the en-gine block.
15577R
The exhaust camshaft pinion mark should be opposite the cylinder posi-tion sensor securing hole.
07-7
VALUES AND SETTINGSTiming belt tensioning procedure 07
Fitting the belt
When the timing belt is changed, it is essential tochange the timing tensioners and pulleys.
Check that the tensioner lug (1) is correctly posi-tioned in the groove (2).
15578R
15201R
Refit:- the timing belt,- the pulleys (3) tightening
the mounting bolts to a tor-que of:• 5 daN.m for the M10 bolts• 2.5 daN.m for the M8 bolts
- the crankshaft accessoriespulley bringing the bolt intoposition without contactwith the pulley (clearancebetween bolt and pulley2 to 3 mm).
NOTE:- the crankshaft accessories
pulley bolt can be re-used ifthe length under the headdoes not exceed 49.1 mm(otherwise change it),
- do not coat a new bolt withoil. However, if the bolt isre-used, it is essential to coatit with oil.
07-8
VALUES AND SETTINGSTiming belt tensioning procedure 07
Align marks (6) and (7) on the tensioner using a6 mm hexagonal wrench at (B).
15256R
Pre-tighten the tensioner nut to a torque of 0.7daN.m.
Tighten the crankshaft pulley bolt to a torque of2 daN.m (Top Dead Centre pin Mot. 1054 still inplace).
NOTE: do not turn the tensioner anti-clockwise.
07-9
VALUES AND SETTINGSTiming belt tensioning procedure 07
15303S
Remove camshaft setting tool Mot. 1526 and TopDead Centre pin Mot. 1054.
Carry out angular tightening of the crankshaftpulley bolt to 115° ± 10°, while immobilising theengine flywheel using a screwdriver.
Make a mark (C) indicating theposition of the camshaft pul-leys in relation to the camshaftbearing cap castings.
15778-1R
07-10
VALUES AND SETTINGSTiming belt tensioning procedure 07
15163-1S
Correct position
15163-2R
Turn the crankshaft two revolutions clockwise (ti-ming end). Before the end of the two revolutions(that is a half-tooth before alignment of themarks on the camshaft pulleys and the camshaftbearing cap castings), insert the Top Dead Centrepin Mot. 1054 to be between the balancing holeand the pinning hole, then bring the timing to itssetting point.
Incorrect position
15163S
Remove the Top Dead Centre pin Mot. 1054.
Check that the tensioner marks are aligned andrepeat the tensioning procedure if they are not.Then tighten the nut to a torque of 2.7 daN.m.
Checking the setting and the tension
Checking the tension
Turn the crankshaft two revolutions clockwise (ti-ming end), then pin the crankshaft just before theend of the two revolutions aligning the camshaftpulley and camshaft bearing cap casting marksmade previously.
Remove the Top Dead Centre pin Mot. 1054.
Check that the tensioner marks are aligned andrepeat the tensioning procedure if they are not.
07-11
VALUES AND SETTINGSTiming belt tensioning procedure 07
15614S
Checking the setting
Ensure that the tensionermarks are positioned correctlybefore checking the timing set-ting.
Fit the Top Dead Centre pinMot. 1054 checking the ali-gnment of the marks madepreviously.
Fit (without using force) cams-haft setting tool Mot. 1526(the camshaft grooves shouldbe horizontal and offset down-wards). If the tool does not en-gage, the timing setting andtensioning procedure must berepeated.
16077R
07-12
VALUES AND SETTINGSTiming belt tensioning procedure 07
The second procedure is applied in the event of replacement of anycomponents which require slackening of the timing camshaft pulley(s).
Setting the timing
WARNING: it is essential to degrease the end of the crankshaft and thecrankshaft pinion bore, the crankshaft pulley contact surfaces and theends of the camshafts (timing end) and the camshaft pulley bores toprevent sliding between the timing, the crankshaft and the camshaftpulleys which could destroy the engine.
15614S
Position the camshaft grooves horizontally, as indicated on the diagramabove, using tool Mot. 799-01.
It is essential that the grooves are directed downwards.
This operation can be made easier by fitting the camshaft pulleys usingthe old nuts, tightening them to a torque of 1.5 daN.m maximum.
07-13
VALUES AND SETTINGSTiming belt tensioning procedure 07
Fit tool Mot. 1526 which is secured to the end ofthe camshafts.
15163S
Remove the old pulley nuts. It is essential to re-place them with new nuts.
Pre-tighten the nuts, without locking them, with aclearance of 0.5 to 1 mm between the nuts andthe pulleys.
Check that the crankshaft is pinned at Top DeadCentre and not in the balancing hole (crankshaftgroove (5) should be between the two marks (1)of the engine block).
Correct position
16077R
15163-1S
Incorrect position
15114-1R
07-14
VALUES AND SETTINGSTiming belt tensioning procedure 07
When a timing belt is changed, it is essential tochange the timing tensioners and pulleys.
Position the exhaust camshaft pulley mark oppo-site the poition sensor thread.
NOTE: incorrect positioning of the exhaust cams-haft pulley prevents starting of the engine.
Ensure that the tensioner lug (1) is correctly posi-tioned in the groove (2).
15201R
Refit:- the timing belt,- the pulleys (3) tightening
the mounting bolts to a tor-que of 5 daN.m in the caseof the ∅ 10 mm bolts and2.5 daN.m in the case of the∅ 8 mm. bolts.
Fit the crankshaft accessories pulley, pre-tightening the bolt (without fully tightening the bolt, clearance of2 to 3 mm between the bolt and the pulley).
NOTE:- the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed
49.1 mm (otherwise change it),- do not coat the new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil.
15578R
07-15
VALUES AND SETTINGSTiming belt tensioning procedure 07
Check that there is still a clearance of 0.5 to 1 mmbetween the camshaft nuts and pulleys.
Align tensioner marks (6) and (7) using a 6 mmhexagonal wrench at (B).
15256R
Pre-tighten the tensioner nut to a torque of 0.7daN.m.
Turn the timing face through six revolutions viathe exhaust camshaft pulley using tool Mot. 799-01.
NOTE: during this operation, ensure that the pul-leys do not come into contact with the nuts. Ifthey do, reposition them from time to time.
07-16
VALUES AND SETTINGSTiming belt tensioning procedure 07
15578-1R
Check that the tensioner marks are aligned and repeat the tensioningprocedure if they are not. Then tighten the nut to a torque of 2.8 daN.m.
Turn the exhaust camshaft pulley to position the mark opposite the pha-sing sensor.
Tighten the crankshaft pulley bolt to a torque of 2 daN.m (Top DeadCentre pin still in place in the crankshaft).
Make a mark (C) to indicate the position of the camshaft pulleys in rela-tion to the camshaft bearing cap castings.
07-17
VALUES AND SETTINGSTiming belt tensioning procedure 07
Remove the Top Dead Centre pin.
Carry out angular tightening of the crankshaftpulley bolt to 115° ± 10°, while immobilising theengine flywheel using a screwdriver.
15163-1S
15303S
Pin the crankshaft aligning the camshaft pulleyand camshaft bearing cap casting marks madepreviously to ensure that the pin is correctly posi-tioned in the pin hole and not in the crankshaftbalancing hole.
Correct position
15163S
Fit camshaft pulley immobilising tool Mot. 1535and secure it using a cover bolt.
Tighten the inlet camshaft pulley nut to a torqueof 3 daN.m, then turn it through an angle of 90°.
Incorrect position
16078R
07-18
VALUES AND SETTINGSTiming belt tensioning procedure 07
Remove camshaft setting tool Mot. 1526, cams-haft pulley immobilising tool Mot. 1535 and TopDead Centre pin Mot. 1054.
Checking the setting and tension
Checking the tension
Turn the crankshaft two revolutions clockwise (ti-ming side), then pin the crankshaft just before theend of the two revolution aligning the camshaftpulley and camshaft bearing cap casting marks.
Remove the Top Dead Centre pin Mot. 1054.
Check that the tensioner marks are aligned andrepeat the tensioning procedure if they are not.
Tighten the exhaust camshaft pulley nut to a tor-que of 3 daN.m, then turn it through an angle of45° then a second angle of 45° using tool Mot.1368.
16218S
07-19
VALUES AND SETTINGSTiming belt tensioning procedure 07
Checking the setting
Ensure that the tensionermarks are positioned correctlybefore checking the timing set-ting.
Fit the Top Dead Centre pinMot. 1054 checking that themarks made previously are ali-gned.
Fit (without using force) cams-haft setting tool Mot. 1526(the camshaft grooves shouldbe horizontal and offset down-wards). If the tool does not en-gage, the timing setting andtensioning procedure must berepeated.
16077R
15614S
07-20
VALUES AND SETTINGSCylinder head tightening 07
CYLINDER HEAD TIGHTENING PROCEDURE
The bolts can be re-used if the length under the head does not exceed137.7 mm (otherwise change all the bolts).
REMINDER: to obtain correct tightening of the bolts, remove any oilfrom the cylinder head securing holes using a syringe.
Do not coat new bolts with oil. However, if the bolts are re-used, it is es-sential to coat them with oil.
Tighten all the bolts to 2 daN.m in the order indicated below.
15659R
Check that all the bolts are correctly tightened to 2 daN.m then carry outangular tightening (bolt by bolt) of 195° ± 6° in the order of tightening.
The cylinder head bolts are not re-tightened following application ofthis procedure.
07-21
VALUES AND SETTINGSTyres - Wheels 07
Vehicle Rim Tyres
Tyre pressurewhen cold (in bar) (1)
Front Rear
DA0 3 6.5 J 16 195/50 R 16 V 2.4 2.2
EA0 3 6.5 J 16 195/50 R 16 V 2.4 2.3
(1) During motorway use with full load.
Wheel nut tightening torque: 9 daN.m
Rim run-out: 1.2 mm
07-22
VALUES AND SETTINGSBrakes 07
Vehicle
At the front
Disc thickness (in mm)
Maximum Minimum
At the rear
Disc thickness (in mm)
Maximum Minimum
Drum diameter (in mm)
Maximum (1) Minimum
DA0 3EA0 3 24 21.8 8 6.3 - -
(1) Drum: maximum wear diameter (where applicable).
The disc run-out is 0.07 maximum
Vehicle
Lining thickness (in mm)
Front (including support)
New Minimum
Rear
New Minimum
Brake fluid
DA0 3EA0 3 18.3 6 11 5 SAE J1703
DOT 4
07-23
VALUES AND SETTINGSBrake compensator 07
VehicleFuel level status
(driver in vehicle)
Check pressure (1) (in bar)
Front Rear
DA0 3EA0 3 140 49
BRAKING PRESSURE
+ 180
90966S
(1) The check is carried out using two pressure gauges arranged in an X formation.
07-24
VALUES AND SETTINGSUnderbody height 07
VehicleAt the front
H1 - H2 = ... mmAt the rear
H4 - H5 = ... mmDimension X (in mm)
D and G
DA0 3 116 51 471
EA0 3 116 38 488
Tolerance: ± 7.5 mm
The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not ex-ceed 5 mm, the driver’s side always being the highest.
Any alteration to the underbody height also requires adjustment of the brake compensator (if fitted) and ofthe headlights.
07-25
VALUES AND SETTINGSUnderbody height 07
16102R
H1 : radius of tyre under loadH2 : height measured between the lower surface of the sub-frame and the ground in line with the centre-
line of the wheelH4 : radius of rear tyre under loadH5 : height measured between the centreline of the rear axle joint and the ground
MEASURING POINTS
88636-4R
07-26
DA03
H1-H2 = 116 mmH1-H2 = 124 mmH1-H2 = 130 mm
H5-H2 = 71 mmH5-H2 = 51 mmH5-H2 = 31 mm
10°36’10°42’10°49’
Maximum right /left difference= 1°
4°03’4°33’5°03’
Maximum right /left difference= 1°
H1-H2 = 116 mmH1-H2 = 124 mmH1-H2 = 130 mm
81603S1
93011-1S
93014-1S
93013-1S
93012-1S
VALUES AND SETTINGSFront axle angle checking values 07
UNLADEN
CANNOT BEADJUSTED
CAMBER
VALUES
CASTOR
- 0°12’- 0°11’- 0°08’
Maximum right /left difference= 1°
SETTINGPOSITION OF THE
FRONT AXLE
KINGPIN INCLINATION
PARALLELISM
POSITION FOR TIGHTENING RUBBER BUSHES
Adjusted byrotating track
rod sleeves1 turn = 30’
(3 mm)
(For 2 wheels)
toe out
+ 0°10’ ± 10’
+ 1 mm ± 1 mm
ANGLES
UNLADEN- -
±30’
±30’
±30’CANNOT BE
ADJUSTED
CANNOT BEADJUSTED
07-27
EA03
H1-H2 = 116 mmH1-H2 = 125 mmH1-H2 = 133 mm
H5-H2 = 83 mmH5-H2 = 63 mmH5-H2 = 43 mm
10°36’10°44’10°52’
Maximum right /left difference= 1°
3°47’4°17’4°47’
Maximum right /left difference= 1°
H1-H2 = 116 mmH1-H2 = 125 mmH1-H2 = 133 mm
81603S1
93011-1S
93014-1S
93013-1S
93012-1S
VALUES AND SETTINGSFront axle angle checking values 07
UNLADEN
CAMBER
VALUES
CASTOR
- 0°12’- 0°10’- 0°06’
Maximum right /left difference= 1°
SETTINGPOSITION OF THE
FRONT AXLE
KINGPIN INCLINATION
PARALLELISM
POSITION FOR TIGHTENING RUBBER BUSHES
Adjusted byrotating track
rod sleeves1 turn= 30’
(3 mm)
(For 2 wheels)
toe out
+ 0°10’ ± 10’
+ 1 mm ± 1 mm
ANGLES
UNLADEN- -
±30’
±30’
±30’
CANNOT BEADJUSTED
CANNOT BEADJUSTED
CANNOT BEADJUSTED
07-28
(For 2 wheels)
Toe-in
- 0° 30’ ± 20’
- 3 mm ± 2 mm
- 0°50’ ± 15’
93013-2S
93011-2S
81603S1
VALUES AND SETTINGSRear axle angles checking values 07
UNLADEN
CAMBER
VALUES4 BAR AXLE
PARALLELISM
ANGLES
UNLADEN
UNLADEN- -
POSITION FOR TIGHTENINGRUBBER BUSHES
POSITION OF THE
REAR AXLESETTING
CANNOT BEADJUSTED
CANNOT BEADJUSTED
07-29
ENGINE AND PERIPHERALS ASSEMBLYIdentification 10
Type ofvehicle
Engine GearboxCubic
capacity(cm3)
Bore(mm)
Stroke(mm)
Compressionratio
DA03EA03 F5R 740 JC5 1998 82.7 93 11.5/1
Manual to be consulted: Mot. F5R.
10-1
87363R1
ENGINE AND PERIPHERALS ASSEMBLYOil pressure 10
ESSENTIAL SPECIAL TOOLS
Mot. 836 -05 Boxed kit for measuring oil
pressure
Douille longue ou clé à tube de 22 mm
CHECK
The oil pressure check must be carried out whilethe engine is warm (approximately 80 °C).
Contents of boxed kit Mot. 836-05.
USE
B + F
Connect the pressure gauge in place of the oilpressure switch.
Oil pressureIdle 1 bar (minimum)3,000 rpm 3 bars (minimum)
22 mm long socket or tube wrench
ESSENTIAL EQUIPMENT
10-2
ENGINE AND PERIPHERALS ASSEMBLYEngine and transmission assembly 10
Sub-frame front mounting bolt 6.2
Sub-frame rear mounting bolt 10.5
Front right suspended engine mountingcover to engine mounting bolt 6.2
Front right suspended engine mountingcover mounting nut 4.4
Rubber engine mounting to front left sidemember support mounting nut 6.2
Mot. 1159 Tool for retaining the engine onthe sub-frame
Mot. 1233-01 Threaded rods for lowering thesub-frame
Mot. 1448 Clip pliers for spring clips
Mot. 1453 Tool for supporting the engine
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove the engine undertray.
Drain:- the cooling circuit via the lower radiator hose,- the gearbox and the engine (if necessary),- the refrigerant circuit using filling equipment.
Follow the instructions regarding cleanliness andsafety when working on the fuel circuit.
10-3
ENGINE AND PERIPHERALS ASSEMBLYEngine and transmission assembly 10
15961R
- the horns,- the two power steering pipe fasteners on the
sub-frame on the right-hand side,- the steering shaft yoke nut and eccentric bolt
after pushing back the protector.
Remove:- the front wheels and the mud shields,- the sub-frame - body tie-rods,- the steering ball joints,- the brake calipers (and the ABS sensors) and at-
tach them to the suspension springs,- the shock absorber base bolts,- the heat shield (A) and the gearbox control ca-
ble,- the protective plate (1) and unclip the fuel
pipes,- the fuel supply and return pipes. Fit plugs to
maintain cleanness,- the tie-rod (2) mountings,- the catalytic converter clamp (3) and attach it to
the body.
SPECIAL FEATURES OF VEHICLES FITTED WITH ADRIVER’S AIR BAG
WARNING
To prevent any risk of destruction of the rotaryswitch under the steering wheel, follow the in-structions below:• Before the steering column and the rack are
uncoupled, it is ESSENTIAL that the steeringwheel is immobilised with the wheels straightusing a "steering wheel immobiliser" tool forthe entire duration of the operation.
• If there is any doubt about the correct centringof the rotary switch, the steering wheel mustbe removed and the centring procedure descri-bed in the "Air bag" section must be applied.
REMINDER: in this case, only qualified, trainedpersonnel must carry out the procedure.
Remove:- the front bumper,- the air filter unit and its support,- the accelerator and clutch cables,- the brake servo vacuum pipe (manifold end).
Remove the computer fasteners and fold back theassembly on the engine.
10-4
ENGINE AND PERIPHERALS ASSEMBLYEngine and transmission assembly 10
98756R
Remove:- the heating radiator hose using tool Mot. 1448,- the expansion bottle fasteners and move it
aside,- the relay board and the electrical connector of
the engine connection unit,
- the earth strap on the bulkhead,- the air conditioning pipe fasteners on the
pressure relief valve,- the starter supply wire.
NOTE: it is essential to fit plugs on the pipes andthe pressure relief valve to prevent theintroduction of moisture into the circuit and onthe fuel pipes to keep them clean.
Fit engine retaining tool Mot. 1453 ensuring thatthe strap is positioned correctly.
Remove the suspended engine mountings coverand the engine tie-bar.
Place a shim between the gearbox and the sub-frame.
Remove nut (1), then, using a copper hammer, tapto detach the stud from the suspended enginemountings fastener.
98754R
15959R1
10-5
ENGINE AND PERIPHERALS ASSEMBLYEngine and transmission assembly 10
Fit the two tools Mot. 1159 as indicated below.
99024R2
15960R
Secure tool Mot. 1040-01 under the sub-frame.
98755R1
Lower the lift until the tool comes into contactwith the ground.
Remove the sub-frame mounting bolts and re-move the engine and transmission assembly by lif-ting the body.
When starting to lift the body, be sure to removethe catalytic converter and to extract the radiatorfrom its upper fasteners (then place it on the sub-frame again).
NOTE: in the case of an operation which requiresseparation of the engine/gearbox/sub-frame as-sembly, take care to mark the position of the toolsMot. 1159 on the sub-frame.
10-6
ENGINE AND PERIPHERALS ASSEMBLYEngine and transmission assembly 10
REFITTING
The alignment of the sub-frame with the bodywill be made easier by positioning two threadedrods Mot. 1233-01 in the two front fasteners ofthe body sub-frame.
Be sure to reposition the catalytic converter on lo-wering the body onto the engine and transmis-sion assembly.
Tighten the sub-frame mounting bolts to a torqueof:- 6.2 daN.m at the front,- 10.5 daN.m at the rear.
Refit in the reverse order to removal.
Fit the heat shields correctly.
Fit the caliper mounting bolts with LoctiteFRENBLOC and tighten them to the specified tor-que.
Press the brake pedal several times to bring thepistons into contact with the pads.
Carry out the following operations:- fill the engine and gearbox with oil (if necessa-
ry),- fill and bleed the cooling circuit (see section 19
"Filling - Bleeding").
Fill the refrigerant circuit using the filling equip-ment.
10-7
ENGINE AND PERIPHERALS ASSEMBLYSump 10
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove the steering shaft yoke nut.
97390-1R2
ESSENTIAL SPECIAL TOOLS
T.Av. 1233-01 Tool for working on the sub-frame - axle
Pre-tightening of sump bolts 0.8
Tightening of sump bolts 1.35 ± 0.15
TIGHTENING TORQUES (in daN.m)
10-8
ENGINE AND PERIPHERALS ASSEMBLYSump 10
Remove the sub-frame tie-rods mounting bolts and lower the sub-frame by approxi-mately 100 mm.
13507R2
Drain and remove the sump.
10-9
ENGINE AND PERIPHERALS ASSEMBLYSump 10
REFITTING
Apply a spot of RHODORSEAL 5661 at (A) on ei-ther side of bearing n° 1, and at (B) at the intersec-tion of the crankshaft closing plate and the cylin-der block.
15159-2R
Refit the sump with a new seal pre-tightening itto a torque of 0.8 daN.m, then carry out a finaltightening of 1.35 daN.m in the order shown.
15195R
10-10
ENGINE AND PERIPHERALS ASSEMBLYMulti-function support 10
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove:- the alternator (see section 16 "Alternator").- the air conditioning compressor fasteners and
attach it to the upper crossmember,- the multi-function support removing the stud
(A).
REFITTING
Refit the support tightening the bolts and thestud to a torque of 4.4 daN.m.
Refer to section 07 "Accessories belt tensioning"for the tensioning procedure.
Refit in the reverse order to removal.
15576R
Multi-function support bolts and stud 4.4 ± 0.4
TIGHTENING TORQUE (in daN.m)
10-11
Angular tightening wrench
TOP AND FRONT OF ENGINETiming belt 11
ESSENTIAL SPECIAL TOOLS
Wheel bolt 10
Pulley bolt:
- M10: 5
- M8: 2.5
Tensioner nut 2.8
Crankshaft pulley bolt 2 + 115° ± 10°
Mounting bolt on suspended mounting 6.2
Intermediate timing cover bolt 2
High pressure pump mounting bolt 1
High pressure pipe union 2.5
Mot. 799-01 Tool for immobilising pinionsfor toothed timing belt
Mot. 1054 Top dead centre pin
Mot. 1368 Tool for tightening camshaftpulleys
Mot. 1383 Pipe wrench for removing HPpipes
Mot. 1453 Engine support
Mot. 1488 Tool for refitting camshaft co-vers
Mot. 1512 Tool for fitting the camshaftseals
Mot. 1526 Tool for setting the camshafts
Mot. 1535 Tool for immobilising camshaftpulleys
TIGHTENING TORQUES (in daN.m or/and °) REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove:- the front right wheel,- the front right wheel arch and the engine un-
dertray.
Fit the engine support Mot. 1453.
98750R2
ESSENTIAL EQUIPMENT
Follow the instructions regarding cleanliness andsafety when working on the fuel circuit.
11-1
TOP AND FRONT OF ENGINETiming belt 11
Remove:- the Top Dead Centre pin plug,
15102-1S
Remove :- the suspended engine mountings cover and
movement limiter assembly,- the bolt (A) and slacken engine tie-bar bolt (B).
Raise the engine.
15424R3
Lock the accessories belt tensioner. To do this,turn the tensioner towards the right and immobi-lise it using a 6 mm hexagonal wrench (see section07 "Accessories belt tensioning").
15579-1S
- the air resonator (1),- the ignition coil and harness (2),
15617R
- the inlet manifold (3) (see section 12 "Inlet ma-nifold"),
11-2
TOP AND FRONT OF ENGINETiming belt 11
- the exhaust camshaft sealing plug (4),- the high pressure fuel pipe using tool Mot.
1383 (5). For this operation, support the unionsusing open wrenches.
Fit blanking pieces to maintain cleanness.
Remove:- the high pressure fuel pump (6),- the timing cover mounting bolts then remove
the covers (7).
15578-3R
15615R2
11-3
TOP AND FRONT OF ENGINETiming belt 11
Setting the timing
Position the exhaust camshaft pulley mark (1) onetooth before the phase sensor fastener (2). Thecamshaft grooves must be towards the bottomand almost horizontal as indicated below.
15614-1S
15740-1R
11-4
TOP AND FRONT OF ENGINETiming belt 11
Insert pin Mot. 1054 to be between the balancinghole and the setting groove of the crankshaft.
15163-2S
Turn the engine slightly, in the same direction, en-gaging pin Mot. 1054 at the setting point.
Incorrect position
15163S
Correct position
15163-1S
11-5
TOP AND FRONT OF ENGINETiming belt 11
Remove the timing pulley immobilising the en-gine flywheel using a screwdriver.
15303S
Slacken the timing belt usingthe tensioner.
Remove the belt and the pul-ley.
Take care not to let the cranks-haft pinion fall as it does nothave a key.
WARNING: it is essential to de-grease the end of the cranks-haft, the crankshaft pinionbore and the contact surfacesof the crankshaft pulley to pre-vent sliding between the ti-ming and the crankshaft whichcould destroy the engine.
15578S
11-6
TOP AND FRONT OF ENGINETiming belt 11
REFITTING
When the timing belt is changed, it is essential tochange the timing tensioners and pulleys.
Refit:- the timing belt (it is essential to follow the pro-
cedure described in section 07 "Timing belt ten-sioning procedure"),
- the accessories belt (see section 07 "Accessoriesbelt tensioning procedure"),
- the Top Dead Centre pin plug applying a spotof RHODORSEAL 5661 to the thread,
- the new exhaust camshaft sealing plug usingtool Mot. 1488,
- the high pressure fuel pump and pipe (refer tothe procedure described in section 13 "Highpressure pump"),
Replace the shim (1),
16127R
Refit the inlet manifold (refer to the proceduredescribed in section 12 "Inlet manifold"),
15617S
15615S
- the air resonator and air intake pipe,- the right-hand suspended engine mounting
tightening the bolts to the specified torque.
11-7
Cylinder head testing equipmentAngular tightening wrench
TOP AND FRONT OF ENGINECylinder head gasket 11
ESSENTIAL SPECIAL EQUIPMENT
Mot. 1054 Top Dead Centre pin
Mot. 1159 Engine support tool
Mot. 1368 Tool for tightening camshaftpulleys
Mot. 1383 Pipe wrench for removing HPpipes
Mot. 1448 Clip pliers for spring clips
Mot. 1453 Engine support tool
Mot. 1488 Tool for refitting camshaft co-vers
Mot. 1512 Tool for fitting the camshaftseals
Mot. 1526 Tool for setting the camshafts
Mot. 1530 Tool for removing injectors
Mot. 1532 Tool for removing the highpressure rail
Mot. 1533 Tool for fitting injector seals
Mot. 1535 Tool for immobilising camshaftpulleys
ESSENTIAL EQUIPMENT
TIGHTENING TORQUES (in daN.m or/and °)
Wheel bolt 10
Pulley bolt:
- M10: 5
- M8: 2.5
Tensioner nut 2.8
Crankshaft pulley bolt 2 + 115° ± 10°
Mounting bolt on suspended mounting 6.2
Intermediate timing cover bolt 2
Camshaft bearing cap casting bolt 1.2
Oil separator bolt 1.3
Injection rail mounting bolt 1.5
High pressure pump mounting bolt 1
High pressure pipe union 2.5
Follow the instructions regarding cleanliness andsafety when working on the fuel circuit.
11-8
TOP AND FRONT OF ENGINECylinder head gasket 11
Remove:- the air intake pipe and resonator,- the ignition coil and harness,- the inlet manifold (see section 12 "Inlet mani-
fold"),- the high pressure fuel pipe using tool Mot.
1383 supporting the unions using openwrenches.
Fit blanking pieces to maintain cleanness.
Remove:- the high pressure fuel pipe (see section 13
"High pressure pump"),- the suspended engine mountings,- the exhaust camshaft sealing plug,- the accessories belt (see section 11 "Accessories
belt").
Position the engine at Top Dead Centre using thepin Mot. 1054.
Remove the timing belt (see section 11 "Timingbelt").
Fit tool Mot. 1535 positioning the timing coverbolt in hole (1), and remove the camshaft pulleys.
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove:- the front right wheel,- the front right wheel arch and the engine un-
dertray.
Drain the cooling circuit (via the lower radiatorhose).
Fit the engine support tool Mot. 1159.
99024R2
16078R2
15960R
11-9
TOP AND FRONT OF ENGINECylinder head gasket 11
Remove:- the clips between the injectors and the rail,- the injectors using tool Mot. 1530. To do this,
turn the injector slightly to break the carbondeposit.
Extract the injector and position the plugs tomaintain cleanness.
16635R
Remove the injection rail mounting bolts (fit thesealing plugs).
Fit the injection rail extraction tool Mot. 1532 (thedowels and the threaded rods).
16126R
Extract the injection rail. The injector retainingclips remain in place and may allow the injectionrail to escape on removal.
Fit blanking pieces to maintain cleanness.
11-10
TOP AND FRONT OF ENGINECylinder head gasket 11
Remove:- the oil separator,
15612S
- the EGR valve/manifoldconnecting pipe,
- the EGR valve support,- the camshaft bearing cap
bolts.
15612-3S
11-11
TOP AND FRONT OF ENGINECylinder head gasket 11
Vertically detach the camshaft bearing cap castingby tapping on the lugs (2) using a mallet and atthe same time, slide a screwdriver under the lug.
15660-1R
Remove:- the camshafts,
15656S
11-12
TOP AND FRONT OF ENGINECylinder head gasket 11
- the earth strap,- the catalytic converter/ ma-
nifold connecting bolts,- the exhaust manifold strut,- the harness supports,- the coolant pipes on the ple-
num chamber,- the tabs and the hydraulic
stops,
15657S
- the aluminium timing cover (1).
15574R
11-13
TOP AND FRONT OF ENGINECylinder head gasket 11
Remove the cylinder head.
15659S
CHECKING THE MATING SURFACE
Check whether the mating surface is deformedusing a ruler and a set of feeler gauges.
Maximum deformation 0.05 mm
Grinding of the cylinder head is prohibited.
Test the cylinder head to detect any cracks.
Cleaning
It is very important that the mating surfaces ofthe aluminium parts are not scratched.
Use the product Décapjoint to dissolve the part ofthe gasket which remains attached.
Apply the product to the section to be cleaned;wait approximately ten minutes, then remove itusing a wooden spatula.
It is advisable to wear gloves during this opera-tion.
Do not allow the product to fall onto the paint-work.
Your attention is drawn to the care which mustbe taken when carrying out this operation to pre-vent the introduction of foreign bodies into thepressurised oil feed pipes leading to the cams-hafts (pipes located both in the cylinder block andin the cylinder head).
11-14
TOP AND FRONT OF ENGINECylinder head gasket 11
REFITTING
When removing-refitting the cylinder head,observe the following points:
- It is essential to reprime the hydraulic stops asthey risk becoming empty after a veryprolonged time.To check whether it is necessary to reprimethem, press the top of the stop at (A) with thethumb. If the stop piston lowers, immerse it ina container full of diesel.
15658R
Refit:- the tabs,- the camshaft lubricating the bearings.
WARNING: do not apply oil to the cylinder headcover mating surface.
NOTE: the camshafts are identified by a mark (A).
Details of mark (A) :- mark B is only used by the supplier,- mark C identifies the camshafts:
A = Inlet,E = Exhaust,
- mark D indicates the type of engineFor example:
F5RE616 330 11 38
BCD
15653-2R
11-15
15614S
TOP AND FRONT OF ENGINECylinder head gasket 11
Position the camshaft grooves as indicated on the diagram below (thegrooves must be horizontal and offset downwards).
NOTE: the mating surfaces must be clean, dry andnot greasy (avoid finger prints).
Using a roller (uneven) apply Loctite 518 to thecamshaft bearing cap casting mating surface untilit is reddish.
15641S
11-16
15656S
TOP AND FRONT OF ENGINECylinder head gasket 11
Refit:- the camshafts.
15612-2R
- the camshaft bearing capcastings. Tighten them to atorque of 1.2 daN.m follo-wing the order and the pro-cedure indicated.
11-17
15612R
TOP AND FRONT OF ENGINECylinder head gasket 11
Tighten the oil separator to atorque of 1.3 daN.m in the or-der indicated.
- the EGR valve support,- the oil separator.
Using a roller (uneven) apply Loctite 518 to themating surfaces until they are reddish.
15643S
11-18
TOP AND FRONT OF ENGINECylinder head gasket 11
Refit:- the camshaft seals using tool Mot. 1512.
15644R
- the coolant pipes on the plenum chamber,- the harness supports,- the earth strap,- the catalytic converter/manifold connecting
bolts,- the exhaust manifold strut,- the EGR valve/manifold connecting pipes,- the EGR valve support.
11-19
TOP AND FRONT OF ENGINECylinder head gasket 11
Refit the injector seals using tool Mot. 1533 (refer to the procedure described in section 13 "Injectionrail/injectors").
Refit the injectors and the clips on the rail observing their positions.
16125S
Refit the injection rail (see section 13 "Injection rail/injectors").
11-20
TOP AND FRONT OF ENGINECylinder head gasket 11
Setting the timing
WARNING: it is essential to degrease the end ofthe crankshaft, the crankshaft pinion bore andthe contact surfaces of the crankshaft pulley toprevent sliding between the timing and thecrankshaft which could destroy the engine.
Refit:- the timing belt (it is essential to follow the
procedure described in section 07 "Timing belttensioning procedure",
- the high pressure pump refitting the shim (1)(see section 13 "High pressure pump"),
16127R
- the exhaust camshaft sealing plug using toolMot. 1488,
- the inlet manifold (see section 12 "Inletmanifold"),
- the accessories belt (refer to the proceduredescribed in section 07 "Accessories belt"),
- the right-hand suspended engine mountingand the engine tie-bar.
Before starting the engine, switch on the ignitionseveral times to run the petrol pump and primethe fuel circuit.
IMPORTANT: if the exhaust manifold fasteningstuds have been removed, change them and sealusing "LOCTITE FRENBLOC BLEUE".
11-21
FUEL MIXTURESpecifications 12
VehicleGear-box
Engine
Type IndexBore(mm)
Stroke(mm)
Cubiccapacity
(cm3)
Compressionratio
Catalyticconverter
Emissioncontrol
standard
Type ofinjection
DA0 3EA0 3 JC5 F5R 740 82.7 93 1998 11.5/1 ◊ C110
◊ C77 EU 96
Multipointdirect
Staticignition
Temperature in °C - 10 25 50 80 110
Air sensorNTC type resistance in Ohms
8525 to10450 1880 to 2120 760 to 860 - -
Coolant sensorNTC type resistance in Ohms - 2140 to 2360 770 to 850 275 to 290 112 to 117
CO (%) (1) C02 (%) HC (ppm) Lambda (λ)
750 ± 50 0.5 maximum 14.5 minimum 100 maximum 0.97 < λ < 1.03 Super unleaded(IO 95)
Checks carried out at idle *
Emissions of pollutants**Idle speed (rpm)
Fuel ***(minimum
octane rating)
(1) at 2,500 rpm the CO should be 0.3 maximum.* At a coolant temperature greater than 80 °C and after a constant engine speed of 2,500 rpm for
approximately 30 seconds.** For the legislative values, refer to the specifications for the country concerned.*** Compatible IO 91 unleaded.
12-1
FUEL MIXTURESpecifications 12
DESCRIPTION BRAND/TYPE SPECIAL NOTES
Injection and ignition computerInjectors control computer
SIEMENS "SIRIUS 3H"SIEMENS "Driver"
90 tracks55 tracks
Injection - Direct multipoint sequential
Ignition - Static with monobloc coil
Idle stepper motor PHILIPS Resistance : 53 ± 5 Ω at 25 °C
Throttle potentiometer CTS - MAGNETIMARELLI
Incorporated in the throttle housingResistance of track : 1,200 ± 240 ΩResistance of cursor < 1,050 Ω
Magnetic sensor(TDC and engine speed) ELECTRIFIL
Variable reluctance typeResistance = 200 to 270 Ω
Camshaft position sensor SAGEM Hall Effect sensor
Canister solenoid valve SAGEM Incorporated in the canisterResistance : 26 ± 4 Ω to 23 °C
Remove:- the air intake pipe,- the air resonator (1),
15618R
15616R1
- the pressure sensor (2) and air temperature sen-sor (3) connectors,
- the ignition coil,- the ignition harness,
- the manifold side bolt (4),- the inlet manifold mounting bolts and nuts.
12-4
FUEL MIXTUREInlet manifold 12
REFITTING
Replace the manifold seal and the EGR valve.
Refit:- the inlet manifold replacing the seals and ob-
serving the tightening torque of the ∅ 6 mmand ∅ 8 mm bolts and nuts.
15617R1
- the manifold side bolt,- the coil (3) and the ignition harness (4),- the air resonator and air intake pipe.
In the case of removal of the throttle housing, re-fer to the procedure described in section 12"Throttle housing").
12-5
FUEL MIXTUREExhaust manifold 12
Catalytic converter/manifold connecting nuts 1.2
Exhaust manifold mounting nuts 1.8
Engine tie-bar 6.2
Oxygen sensor 4.5
Shock absorber lower bolts 17
Lower ball joint 6
TIGHTENING TORQUES (in daN.m)
- the front right wheel,- the front right mud shield,- the ABS sensor connector,- the front right brake caliper,- the right lower ball joint mounting bolt,- the lower shock absorber mounting bolts,- the front right driveshaft,- the oxygen sensor (3) using tool Mot. 1495,
ESSENTIAL SPECIAL TOOLS
Mot. 1495 Tool for removing the oxygen
sensor
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove:- the idle regulation solenoid valve (1),- the EGR pipe (2),
16080R
12-6
FUEL MIXTUREExhaust manifold 12
15619R
- the exhaust strut (1),- the manifold heat shields,- the engine tie-bar,- the manifold to catalytic
converter connection moun-ting bolts.
Slacken the catalytic converter/ exhaust line connectionclamp to move the catalyticconverter back a few centime-tres.
Remove the exhaust manifoldnuts.
Tilt the engine and detach themanifold from underneath.
REFITTING
Replace all the seals removed and the EGR pipeclamps.
It is essential to tighten all the bolts to the speci-fied torque.
Refit the heat shield.
IMPORTANT: in the case of removal of the ex-haust manifold mounting studs, replace them andseal using "LOCTITE FRENETANCH BLEUE".
16079S
12-7
FUEL SUPPLYSpecifications 13
The fuel supply circuit is composed of:- the low pressure supply pump (placed in the gauge/pump assembly in the tank (1),- a fuel filter located at the front of the tank (2),- a high pressure mechanical pump located at the end of the camshaft (3),- an injection rail (high pressure) fitted with the pressure sensor and regulator (which cannot be remo-
ved) (4),- four electromagnetic injectors opening directly into the combustion chamber (5).
Removal of the interior of the high pressure pump and the injectors is prohibited. The pressure regulatorcannot be separated from the injection rail, it is essential to replace the assembly.
OBSERVE THE RULES REGARDING CLEANLINESS DESCRIBED IN THIS DOCUMENT (SECTION 17) STRICTLYWHEN WORKING ON THE FUEL SUPPLY SYSTEM.
16310R
13-1
FUEL SUPPLYSupply pump 13
The low pressure supply pump is immersed in thefuel tank.
It is installed on the pump/gauge assembly andhas a low pressure regulator (4).
15754R
For the removal of the low pressure supply pump,refer to the procedure described in section 19"Pump - gauge" of Workshop Repair ManualMR 312.
13-2
FUEL SUPPLYSupply pressure / Pump output 13
SUPPLY PRESSURE CHECK
Disconnect the fuel supply union (1) on the highpressure pump and fit in its place a "T" union fit-ted with the checking pressure gauge Mot. 1311.
Start the engine to run the low pressure fuelpump.
Disconnect the supply union (R) located after thefuel filter and place it in the graduated receptacle.
Run the supply pump shunting the control relay orusing the diagnostic equipment.
Minimum output measured: 165 litres/hour.
ESSENTIAL SPECIAL TOOLS
Mot. 1311 Fuel pressure checking kit withpressure gauge and adapters
ESSENTIAL EQUIPMENT
2,000 ml graduated receptacle
15615R
WARNING: THE PRESSURE READ UNDER THE"FUEL PRESSURE" PARAMETER ON THEDIAGNOSTIC EQUIPMENT CANNOT BE MEASUREDUSING A PRESSURE GAUGE. NO ATTEMPT MUST BE MADE TO READ IT IN ANYCIRCUMSTANCES.
15755R1
13-3
FUEL SUPPLYHigh pressure pump 13
The high pressure pump is a mechanical pump lo-cated at the end of the inlet camshaft.Removal of the interior of the high pressure pumpis prohibited, it is sold complete.
WARNING: when removing the injectors, the railor the high or low pressure pumps, be aware ofthe quantity of the fuel in the unions. Protectareas susceptible to damage.
REMOVAL
Disconnect the low pressure fuel supply and re-turn unions (1). Fit appropriate plugs to maintaincleanness.
Remove:- the inlet manifold (refer to the procedure des-
cribed in section 12 "Inlet manifold"),
ESSENTIAL SPECIAL EQUIPMENT
Mot. 1383 Tool for removing high pressureunions
WARNING:Before carrying out any work, connect the aftersales service diagnostic equipment, enter into dia-logue with the injection computer and check thatthe pressure in the rail is below 5 bars. Be awareof the fuel temperature.
High pressure pump mounting bolt 1
High pressure pipe union 2.5
TIGHTENING TORQUES (in daN.m)
Place the vehicle on a two post lift.
Disconnect the battery.
THE RULES REGARDING CLEANLINESS MUST BEOBSERVED STRICTLY.
- the high pressure pipe (2) using tool Mot. 1383.To do this, support the pump’s intermediatesteel union during slackening (3) and the railunion (4),
- the pump mounting bolts (5),- the intermediate shim between the pump and
the cylinder head and clean its mating surface.
15615R3
13-4
FUEL SUPPLYHigh pressure pump 13
Fit:- the pump on its support and tighten the bolts
to the specified torque,- the pipe and tighten the unions to the specified
torque using tool Mot. 1383. To do this, sup-port the intermediate steel unions of the pumpand the rail.
REFITTING
Replace the intermediate shim between the pumpand the cylinder head.
16127S
WARNING:After all work, check that there are no leaks onthe fuel circuit. Run the engine at idle until the co-oling fan assembly cuts in, then accelerate severaltimes while stationary. Check that there are noleaks.
13-5
FUEL SUPPLYInjection rail / Injectors 13
NOTE: removal of the intermediate union locatedbetween the rail and the high pressure pipe andremoval of the pressure regulator is prohibited. Inthis case, replace the injection rail.
The injectors are secured to the injection rail bymeans of clips. They open directly into the cylin-der head combustion chamber.
ESSENTIAL SPECIAL TOOLS
Mot. 1383 Tool for removing high pressureunions
Mot. 1530 Tool for extracting injectors
Mot. 1532 Tool for removing the injectionrail
Mot. 1533 Tool for replacing injector seals
Rail mounting bolt 1.5 ± 0.2
High pressure pipe union 2.5 ± 0.3
Pressure sensor 2 ± 0.2
TIGHTENING TORQUES (in daN.m)
13-6
FUEL SUPPLYInjection rail / Injectors 13
Disconnect the injection railand injector connectors.
Remove the inlet manifold (seesection 12 "Inlet manifold").
WARNING: when removingthe injectors, the rail or thehigh or low pressure pumps,be aware of the quantity ofthe fuel in the unions.Protect areas susceptible todamage.
15613S
REMOVAL
WARNING:Before carrying out any work, connect the aftersales service diagnostic equipment, enter into dia-logue with the injection computer and check thatthe pressure in the rail is below 5 bars. Beware ofthe fuel temperature.
Disconnect the battery.
THE RULES REGARDING CLEANLINESS MUST BEOBSERVED STRICTLY.
13-7
FUEL SUPPLYInjection rail / Injectors 13
Remove the high pressure union using tool Mot.1383 supporting the unions on the rail and on thepump (1).
Fit blanking pieces to maintain cleanness.
Remove the fuel return pipe (low pressure).
Fit blanking pieces to maintain cleanness.
Remove the rail mounting bolts.
Extract the rail using tool Mot. 1532.
NOTE: the injectors are secured to the rail by re-taining clips. It is not necessary to remove them toextract the injection rail.
Remove the injector clips
Fit blanking pieces to maintain cleanness.
Fit extraction tool Mot. 1530.
Rotate to break the carbon deposit on the injectornozzle.
16126R
16635R
Remove the injectors.
Fit blanking pieces to maintain cleanness.
15615R4
13-8
- place:• the cone of tool Mot. 1533 on the injector,
FUEL SUPPLYInjection rail / Injectors 13
REPLACEMENT OF THE INJECTOR NOZZLE SEAL
It is essential to replace the Teflon injector seals.
To do this:- clean the injector soaking it in a suitable, clean
thinner. The use of a metal brush, sandpaper,or an ultrasound cleaner is prohibited,
- wipe the injector nozzle using a lint-free wipe,- cut the seal carefully using circlip pliers taking
care not to mark the injector, clean the injectoragain.
• the seal on the cone and fit it slowly by hand,
16373S
16375S
- remove the cone and retract the seal from theinjector using the body of tool Mot. 1533 pus-hing it to its limit.
16376R
16374R
13-9
FUEL SUPPLYInjection rail / Injectors 13
Fit:- the injection rail,- the pipe and tighten it to the specified torque using tool Mot. 1383 taking care not to place it under stress.
Refit the connectors.
REFITTING
Change:- the O-rings,- the clips,- the injector Teflon seals.
Position the injectors on the injection rail.
Fit the injector retaining clips taking care to position them correctly.
16125S
WARNING:After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan as-sembly cuts in, then accelerate several times while stationary. Check that there are no leaks.
13-10
FUEL SUPPLYPressure sensor 13ESSENTIAL SPECIAL TOOLS
Mot. 997 -01 Socket for removing thepressure sensor
Injection rail pressure sensor 2 ± 0.2
TIGHTENING TORQUES (in daN.m)
REMOVAL
WARNING:Before carrying out any work, connect the aftersales service diagnostic equipment, enter into dia-logue with the injection computer and check thatthe pressure in the rail is below 5 bars. Be awareof the fuel temperature.
Disconnect the battery.
THE RULES REGARDING CLEANLINESS MUST BEOBSERVED STRICTLY.
Disconnect the injection rail connectors.
WARNING: when removing the injectors, the railor the high or low pressure pumps, be aware ofthe quantity of the fuel in the unions. Protectareas susceptible to damage.
13-11
FUEL SUPPLYPressure sensor 13
Disconnect the pressure sensor(1) and unscrew it.
Fit a blanking piece to main-tain cleanness.
15613R
REFITTING
Change the seal.
Fit the sensor then tighten it to the specified tor-que.
Refit the connector.
WARNING:After all work, check that there are no leaks onthe fuel circuit. Run the engine at idle until the co-oling fan assembly cuts in, then accelerate severaltimes while stationary. Check that there are noleaks.
WARNING: removal of the fuel pressure regulatoris strictly prohibited.
13-12
FUEL SUPPLYAnti-percolation system 13
PRINCIPLE OF OPERATION
The anti-percolation system is controlled directlyby the injection computer.
The coolant temperature information is takenfrom the injection coolant temperature sensor(see section 17 "CCTM").
When the ignition is switched off, the injectioncomputer changes to monitoring mode. If the en-gine coolant temperature exceeds the thresholdof 100 °C during the two minutes which followswitching off of the engine, the fan low speed re-lay is supplied.
If the temperature again falls below 96 °C, the fanassembly relay is cut off (operation of the fan as-sembly cannot exceed a duration of 10 minutes).
13-13
ANTI-POLLUTIONOil vapours rebreathing 14
BASIC DIAGRAM OF THE CIRCUIT
13042R
1 Engine2 Oil separator3 Air filter housing4 Inlet manifold
15612S
CHECK
To ensure correct operation ofthe anti-pollution system, theoil vapours rebreathing circuitmust be kept clean and ingood condition.
14-1
ANTI-POLLUTIONExhaust gas recirculation E.G.R. 14
PRESENTATION OF CIRCUIT
16080R1
3 Inlet manifold4 Exhaust manifold5 EGR valve
14-2
ANTI-POLLUTIONExhaust gas recirculation E.G.R. 14
REFITTING
It is essential to change the valve seal.
PURPOSE OF THE EGR SYSTEM
The recirculation of the exhaust gas is used to re-duce the nitrogen oxide (NOx) content of the ex-haust gas.
Passage of the gas is authorised by the control ofan electromagnetic valve by the injection compu-ter.
Programming conditions:- engine speed 2,800 ± 100 rpm,- manifold pressure of 630 ± 150 mbars,- for a duration of approximately 30 seconds.
REMOVAL OF THE VALVE
Remove:- the lower gas recirculation clip (pipe/valve),- the mounting bolts,- if necessary, the valve support (1).
EGR valve mounting bolt 2.7
EGR valve support 1
TIGHTENING TORQUES (in daN.m) PRINCIPLE OF OPERATION
The valve is controlled by an RCO signal emittedby the injection computer. The RCO signal permitsmodulation of the opening of the valve, andconsequently, the quantity of exhaust gas direc-ted back towards the inlet manifold.
The computer continuously carries out a test todetect the position of the EGR valve flap.
OPERATING CONDITIONS
The parameters which determine the activation ofthe EGR solenoid valve are as follows:- air temperature,- coolant temperature,- atmospheric pressure,- accelerator pedal position,- engine speed,- vehicle speed,- battery voltage.
EGR is authorised if:- the air temperature is greater than 10 °C,- the coolant temperature is greater than 70 °C,- the manifold pressure is between 300 and 650
mbars,- the engine speed is between 1,700 and 3,800
rpm,- a map (torque/engine speed/load potentiome-
ter) is above a given threshold.
The computer controls the EGR except in the follo-wing cases:- in the case of a fault on one of the following:
• coolant temperature sensor,• air temperature sensor,• pressure sensor,• vehicle speed information,• EGR valve.
15615R5
14-3
ANTI-POLLUTIONFuel vapours rebreathing 14
CANISTER PURGE CONDITION
The canister purge solenoid valve is controlled bytrack 4 of the computer when:- the coolant temperature is greater than 70 °C,- the air temperature is greater than 10 °C,- the throttle position potentiometer is not at
no-load and is outside idle regulation.
It is possible to display the canister purge solenoidvalve opening cyclic ratio using the diagnosticequipment by consulting the parameter "Canisterpurge solenoid valve RCO".
The solenoid valve is closed if the value is below1.5 % (minimum value).
CANISTER PURGE OPERATION CHECK
A system malfunction may result in an unstableidle or stalling of the engine.
Check the conformity of the circuit (refer to thebasic diagram) and the condition of the pipes tothe tank (refer to Workshop Repair ManualMR 312).
After 15 minutes of warming up under a voltage of 13.5 volts.
RPM 100 Amperes
2,000 63 A
3,000 86 A
4,000 95 A
16-1
STARTING - CHARGINGAlternator 16
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove:- the wiring and computer fasteners and fold it
back onto the engine,- the front right wheel,- the front right wheel arch.
98710S
Lock the accessories belt tensioner using a ∅ 8mm pin, then remove the belt (see section 07"Accessories belt tensioning").
15579-1S
15576-2S
Remove the power steering reservoir support fas-teners and unclip the power steering reservoir.
Move aside the power steering reservoir and sup-port assembly to allow access to the alternator.
Remove:- the power steering pump pulley,
16-2
STARTING - CHARGINGAlternator 16
- the power steering pump. REFITTING
Refit in the reverse order to removal.
NOTE: on refitting, use the upper alternator andpower steering support mounting bolt to positionthe alternator.
Take care not to crush the wiring between thecompressor and the power steering support.
Refer to section 07 "Accessories belt tensioning"for the tensioning procedure.
15576-4S
Disconnect the alternator.
Remove the alternator mounting bolts.
15576-3S
Remove the alternator from above.
16-3
STARTING - CHARGINGStarter 16
IDENTIFICATION
Vehicle Engine Starter
DA0 3EA0 3 F5R BOSCH 0001 106 012
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
From below
Remove:- the manifold/catalytic converter connecting
rod,- the pre-catalytic converter lower heat shield,- the right-hand lower wishbone ball joint
mounting bolt,- the shock absorber strut upper bolt,- the starter supply wire.
Detach the ball joint and tilt the shock absorberstrut to uncouple the right-hand driveshaft.
Remove the air intake pipe and the resonator.
From above
Disconnect the starter energising connector.
Remove the starter mounting bolts.
16316S
Remove the starter.To do this:- tilt the starter downwards,- free the fastener on the engine block side.
REFITTING
Refit in the reverse order to removal.
15618S
16-4
IGNITIONStatic ignition 17
DESCRIPTION
The ignition system is of the static type supplied with signals from the engine speed and exhaust camshaft po-sition sensors.
The power module is incorporated in the injection computer.
TIGHTENING TORQUES (in daN.m)
Ignition coil bolts 1 to 1.5Spark plugs 2.5 to 3
16124S
WARNING: the spark plugs fitted to the F5R engine are specific and have a long thread.
17-1
INJECTIONGeneral 17
SPECIAL FEATURES OF THE MULTIPOINT DIRECT INJECTION FITTED TO THE F5R ENGINE
• SIEMENS "SIRIUS 3H" 90-way computer controlling the injection and the ignition. 55-way computercontrolling the opening of the injectors.
• Multipoint direct injection operating in sequential mode from the time the engine is started.
• Injection warning light on the instrument panel.
• Use of the engine overheating warning light in the event a major fault on the high pressure circuit.
• Special precautions relating to the engine immobiliser.Adoption of a 2nd generation type engine immobiliser making a special computer replacement procedurenecessary.
• High pressure fuel circuit with an electric scavenge pump (low pressure) and a mechanical high pressurepump.
X Engine flywheel targetY Camshaft targetZ Voltage supplied by the cylinder position sensor
NOTE: all values are expressed in degrees top dead centre.
17-5
INJECTIONCleanliness / Safety 17
INSTRUCTIONS REGARDING CLEANLINESS WHICH IT IS ESSENTIAL TO FOLLOW WHEN WORKING ON THEHIGH PRESSURE DIRECT INJECTION SYSTEM
RISKS RELATING TO CONTAMINATION
The petrol direct injection system is very sensitive to contamination. The risks incurred by the introduction ofcontamination are:- damage to or destruction of the high pressure injection system,- seizing of a component or a component which is not sealed,- destruction of the engine (by continuous injection into the cylinder).
All after sales service operations must be carried out under extremely clean conditions. This means that no im-purities (particles a few microns in size) have penetrated into the high pressure injection system during remo-val or into the circuits via the fuel unions.
The principles of cleanness must be applied from the filter to the injectors.
WHICH ELEMENTS CAUSE CONTAMINATION?
The elements which cause contamination are:- metal or plastic splinters,- paint,- fibres:
• cardboard,• brush,• paper,• clothing,• cloth.
- foreign bodies such as hair,- ambient air,- etc...
WARNING: it is possible to clean the engine using a high pressure washer at the risk of damaging the connec-tions. Also, the moisture may stagnate in the connectors and cause electrical connection problems. The water may also be stored in the recesses of injectors and spark plugs opening directly into the cylinder.
17-6
INJECTIONCleanliness / Safety 17
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
• Ensure that the plugs for the unions which you wish to open are available (bag of plugs sold by the PartsDepartment).The plugs can be used only once. After use, they must be thrown away. (Cleaning is not sufficient to makethem reusable).
• Ensure that plastic bags which will hermetically seal several times are available for storing removed parts.There is less risk of parts stored in this way being subjected to impurities. The bags can be used only once.After use, they must be thrown away.
• Ensure that lint-free cleaning wipes are available (wipes with SODICAM part numbers). The use of conven-tional cloth or paper is prohibited. In fact, these create lint and may contaminate the system’s fuel circuit.Each wipe can be used only once.
CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE THE FUEL CIRCUIT IS OPENED
• Use new thinner for each operation (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinner to clean the parts to be removed, the tools which will be used and the part of theworkbench used.
• Wash your hands before and during the operation if necessary.
• When using protective gloves, cover leather gloves with latex gloves (available from SODICAM).
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is opened, it is essential to plug the openings which could allow contamination to en-ter. The plugs to be used are available from the Parts Department. They must not be reused in any circum-stances.
• Reseal the bag hermetically, even if it has to be re-opened only a short time later. The ambient air carriescontaminants.
• All components of the injection system which are removed must, after being plugged, be stored in a her-metically sealed plastic bag.
• After opening the circuit, the use of a brush, thinner , a blower, a scraper, or a conventional cloth is strictlyprohibited. In fact, these elements are liable cause the entry of impurities into the system.
• If a component is replaced with a new one, do not remove this from its packaging until it is to be fitted onthe vehicle.
• When cleaning a mating surface, use lint-free absorbent paper. Start from the centre of the part and cleangradually towards the outside to push away any impurities.
17-7
INJECTIONCleanliness / Safety 17
DI1325
17-8
INJECTIONOperation 17
OPERATION OF THE DIRECT INJECTION
The low pressure pump (also called the scavenge pump) supplies the HP pump, via the filter, under a pressureof 4.5 bars.
The sole purpose of the HP pump is to supply the output which it directs towards the rail. The pressure regula-tor located on the rail modulates the high pressure values in line with the requirements of the computer andthe pressure sensor data. The fuel circulates in the rail to supply each injector.
The computers:- determine the pressure value necessary for correct operation of the engine, then control the pressure re-
gulator. They check that the pressure value is correct by analysing the value transmitted by the HP sensorlocated on the rail.
- determine the injection time necessary to supply the correct quantity of fuel, and the start of the injection.After determining these two values, they control each injector individually. The system can inject fuel intothe engine at a pressure between 50 to 100 bars,
- control the ignition.
The system consists of:- a low pressure pump (1) located in the intake assembly,- a fuel filter (2),- a high pressure pump (3) located at the end of the camshaft,- a pressure regulator and a pressure sensor (4) installed on the rail,- an injection rail (5),- four electromagnetic injectors (6),- various sensors (coolant and air temperature, pressure sensor, ...),- a 90-way injection computer and a 55-way injector control computer.
16310R1
17-9
INJECTIONInjection fault warning light 17
Vehicles which operate with the multipoint direct injection system use two injection warning lights illumina-ted for a few seconds every time the ignition is switched on:- the injection warning light used in the event of a minor fault,- the coolant temperature warning light:
• illuminated if the coolant temperature is above 118 °C,• flashing in the event of a major injection fault making it necessary to stop the engine as soon as possi-
ble.
PRINCIPLE OF ILLUMINATION OF THE MINOR INJECTION FAULT WARNING LIGHT
In the event of a minor high pressure injection system fault, the warning light illuminates. These faults are:- injector failure,- low pressure operation fault,- inter-computer connection problem,- fuel pressure sensor fault,- excessive pressure.
If a fault is present when the ignition is switched on, the warning light illuminates for a few seconds, extin-guishes briefly then illuminates again depending on the fault.
PRINCIPLE OF ILLUMINATION OF THE COOLANT TEMPERATURE WARNING LIGHT
In the event of a major high pressure injection system fault, the engine overheating warning light flashes. Inthis case, it is essential to switch the engine off as soon as possible. These faults are:- fuel pressure regulator fault (pressure above 125 bars),- pressure sensor fault (pressure above 125 bars),- jamming of the EGR valve.
In this situation, the scavenge pump (low pressure), the ignition and the injection are cut off after a few se-conds.
17-10
INJECTIONEngine immobiliser function 17
This vehicle is fitted with an engine immobiliser system which is controlled by a random rolling code key reco-gnition system.
REPLACEMENT OF AN INJECTION COMPUTER
The injection computers are supplied without a code but they can all be programmed with one.
When a computer is replaced, it must be programmed with the code of the vehicle and the correct operationof the engine immobiliser function must be checked.
To do this, simply switch on the ignition for a few seconds without starting the engine then switch it off. Withthe ignition off, the engine immobiliser function comes into operation after approximately 10 seconds (thered engine immobiliser warning light flashes).
WARNING:
In the case of this engine immobiliser system, the computer retains the engine immobiliser code for life.
Furthermore, this system does not have a security code.
Consequently, it is prohibited to carry out tests using computers borrowed from the warehouse or anothervehicle which must then be returned.
It will not be possible to erase the code.
17-11
INJECTIONInjection / AC strategy 17
THE COMPRESSOR IS OF THE VARIABLE CUBIC CAPACITY TYPE
INJECTION COMPUTER/AC COMPUTER CONNECTION
The injection computer is connected to the AC computer by two wires:- one wire from the injection computer to track 10 of the AC computer. The compressor operation authori-
sation or prohibition information is sent along this wire. - one wire from the AC computer to track 23 of the injection computer. This is for a power absorbed infor-
mation signal.
When the AC switch is pressed, the AC computer requests operation of the compressor. The injection computer authorises or prohibits engagement of the compressor and imposes a modified idlespeed. In this case, the engine speed may reach 200 rpm.
COMPRESSOR OPERATION STRATEGY
During certain phases of operation, the injection computer prohibits operation of the compressor.
Engine starting strategy
Compressor operation is prohibited for 10 seconds after the engine is started.
Overheating protection strategy
The compressor is not engaged if the coolant temperature is above 110 °C.
17-12
INJECTIONIdle speed correction 17
IDLE SPEED CORRECTION IN LINE WITH THE TEMPERATURE
COOLANT (°C) Idle speed reference (rpm)
- 40 1,360
- 30 1,264
- 20 1,200
- 10 1,200
0 1,200
10 1,152
20 1,104
30 1,056
40 992
50 880
60 800
70 752
80 752
90 752
100 752
110 800
120 848
IDLE SPEED CORRECTION IN LINE WITH THE INLET MANIFOLD PRESSURE
In the event of failure of the manifold pressure sensor, the idle sped is increased to 1,020 rpm.
17-13
INJECTIONIdle speed correction 17
POWER STEERING PRESSURE SWITCH - INJECTION COMPUTER CONNECTION
The injection computer receives information from the power steering pressure switch (which can be dis-played on the diagnostic equipment). This depends on the pressure in the hydraulic circuit and on the fluidityof the power steering fluid. The higher the pressure, the more energy is used by the power steering pump.
The injection computer alters the engine idle speed to a speed of 815 rpm.
ELECTRICAL CORRECTION IN LINE WITH THE BATTERY VOLTAGE AND THE ELECTRICAL BALANCE
The purpose of this correction is to compensate for the drop in voltage due to operation of a power consu-ming component while the battery is at low charge. To do this, the idle speed is increased, thus permittingthe rotation of the alternator to be increased and, consequently, the battery voltage.
The lower the voltage, the more significant the correction. Therefore the engine speed correction is variable.It begins when the voltage falls below 12.7 Volts. The idle speed may reach a maximum 910 rpm.
ADAPTIVE IDLE SPEED CORRECTION
The adaptive idle speed correction only takes effect if the coolant temperature is above 70 °C, 30 seconds af-ter starting the engine and if the idle regulation phase is active (no-load and vehicle stationary).The idle adaptation value makes it possible to reset the regulation in line with the age and variations of theengine.
PARAMETER F5R 740 engines
Nominal idle speed X = 750 rpm
Idle RCO 9 % ≤ X ≤ 15 %
Idle RCO adaptation value Limit:- minimum : - 6 %- maximum : +6 %
Every time the engine is switched off, the computer resets the stepper motor to its lower limit.
IMPORTANT: it is essential, after erasing the computer memory, to start the engine and then switch it off topermit resetting of the potentiometer. Start the engine again and let it run at idle so that the adaptive cor-rection can take place.
17-14
INJECTIONFuel pressure regulation 17
The fuel pressure is regulated by the computer by supplying a regulator (1) located on the injection rail. Thisregulator is controlled by a reference value which takes into account the variations and the age of the en-gine. This control reference value can be displayed by the diagnostic equipment in "parameters" mode.
The fuel pressure regulation takes into account the following components:- the injection rail pressure sensor,- the coolant temperature sensor (for the starting phase),- the engine speed sensor,- the throttle position potentiometer.
15613R2
The pressure read under the "fuel pressure" parameter should be between 45 and 100 bars (engine running)when the pressure regulation is active (Status: "Pressure regulation: CONFIRMED").The "Fuel regulation solenoid valve RCO" parameter should fluctuate between 20 and 30 %.
NOTE: a regulation error (Parameter: "Fuel pressure regulation error") results in illumination of the faultwarning light.
17-15
INJECTIONMixture regulation 17
OXYGEN SENSOR HEATING
The upstream oxygen sensor is heated by the in-jection computer from the time the engine is swit-ched on.
The downstream oxygen sensor is heated after agiven period determined in line with the coolanttemperature and the engine speed.
Heating of the upstream oxygen sensor is stop-ped:- if the vehicle speed is above 70 mph (140 km/h)
(value given for information),- in the event of high engine loads,- in the case of a significant engine speed.
The downstream sensor is heated continuously.
UPSTREAM SENSOR VOLTAGE
The value read on the diagnostic equipment un-der the parameter: "upstream sensor voltage" re-presents the voltage (expressed in millivolts) sup-plied to the computer by the oxygen sensor.When the engine is looped, the voltage shouldfluctuate rapidly between two values:- 150 ± 100 mV for a lean mixture,- 750 ± 100 mV for a rich value.
The smaller the gap between the maximum andminimum values, the less reliable is the informa-tion from the sensor (this gap is usually at least500 mV).
NOTE: in the case of a small gap, check the hea-ting of the sensor.
MIXTURE CORRECTION
The value read on the diagnostic equipment un-der the parameter: "mixture correction" repre-sents the average of the mixture corrections madeby the computer in line with the richness of thecarbonised mixture seen by the oxygen sensor.
The correction value has a mid-point of 128 and li-mits of 0 and 255 :- value below 128: leaner mixture required,- value above 128: richer mixture required.
ENTRY INTO THE MIXTURE REGULATION PHASE
Entry into the mixture regulation phase takes ef-fect after a given starting delay if the coolant tem-perature is above 20 °C and if the upstream sensoris ready (sufficiently warm).
The starting delay depends on the coolant tempe-rature (between 20 °C and 80 °C) and is between20 and 320 seconds.
Before entry into the mixture regulation phase,the value of the parameter is 128.
Unlooping phase
In the mixture regulation phase, the phases ofoperation during which the computer does nottake into account the value of the voltage sup-plied by the upstream sensor are:- at full-load if the engine speed is above 3,200
rpm,- during heavy acceleration,- during deceleration with the no-load informa-
tion,- in the event of failure of the oxygen sensor,- in the event of limitation of the engine speed
(excessive pressure, failure...).
DOWNGRADED MODE IN THE EVENT OF FAILUREOF THE OXYGEN SENSOR SENSOR
If the voltage supplied by the oxygen sensor is in-correct during the mixture regulation phase for aminimum duration of 10 seconds, the computerswitches to downgraded mode.
If a failure is detected and if the failure has alrea-dy been stored, the system goes straight into anopen loop (mixture correction value 128).
17-16
INJECTIONAdaptive mixture correction 17
PRINCIPLE
In the looping phase the mixture regulation corrects the injection time to obtain a dosage as close as possibleto mixture 1. The correction value is close to 128, with limits of 0 and 255.
The adaptive correction makes it possible to offset the injection map to realign the mixture regulationaround 128.
Therefore, it is necessary, following reinitialisation of the computer (return to 128 of the adaptive correc-tions), to carry out a special road test.
ROAD TEST
Conditions:- engine warm(coolant temperature > 75 °C),- do not exceed an engine speed of 3650 rpm.
Pressure zones which must be passed through during the test
Range n° 5(mbars)
Range n° 4(mbars)
Range n° 3(mbars)
Range n° 2(mbars)
Range n° 1(mbars)
221 321 421 521 621 780
Average 271 Average 371 Average 471 Average 571 Average 700F5R 740
Following this test, the corrections are operational.
The test must be followed by normal, smooth and varied driving for a distance of 3 to 6 miles (2 to 10 kilome-tres).
After the test, read the mixture adaptation values. Initially 128, they should have changed. If they have not,repeat the test taking care to observe the conditions strictly.
INTERPRETATION OF THE VALUES GATHERED FOLLOWING A ROAD TEST
In the case of a lack of fuel (injectors clogged, pressure and flow of fuel too low, ...), the mixture regulationincreases to obtain a mixture as close as possible to 1. The adaptive mixture correction increases until the mix-ture correction again fluctuates around 128.
In the event of an excessive amount of fuel the reasoning is reversed: the mixture regulation decreases andthe adaptive correction decreases as well to realign the mixture correction around 128.
PARAMETER F5R 740 engines
Operating mixture adaptationvalue
96 ≤ X ≤ 192
Idle mixture adaptive value 32 ≤ X ≤ 224
17-17
INJECTIONCentralised coolant temperature management 17
CCTM
244 Coolant temperature sensor (injection andcoolant temperature indication on the ins-trument panel).
Three-way sensor, two for the coolant tem-perature information and 1 for the indica-tion on the instrument panel.
This system is fitted with a single coolant tempera-ture sensor which is used by the injection, the fanassembly and the temperature warning light onthe instrument panel.
Operation
Sensor 244 enables:- the coolant temperature to be indicated on the
instrument panel,- the injection computer to be informed of the
engine coolant temperature.
Depending on the coolant temperature, the injec-tion computer controls:- the injection system,- the fan assembly relays:
• the fan assembly is controlled at low speed ifthe coolant temperature exceeds 99 °C andstops when the temperature falls below96 °C,
• the fan assembly is controlled at high speedif the coolant temperature exceeds 102 °Cand stops when the temperature falls below99 °C,
• the fan assembly may be controlled for theAC and in the event of a temperature sensorfailure.
- the coolant temperature warning light.
In the event of failure of the coolant temperaturesensor, the fan assembly is controlled continuous-ly at low speed.
COOLANT TEMPERATURE WARNING LIGHT
The coolant temperature warning light is control-led by the injection computer if the coolant tem-perature exceeds 118 °C.When the ignition is switched on, the warninglight illuminates for a few seconds.
The engine overheating warning light flashes inthe event of a major HP injection system fault.
15615S
17-18
INJECTIONComputer 17
ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS
1 → IGNITION COIL 2-3 CONTROL
3 --- POWER EARTH
4 → CANISTER PURGE CONTROL
6 → FUEL PRESSURE REGULATOR CONTROL
8 → FAN ASSEMBLY 1 RELAY CONTROL
9 → COOLANT TEMPERATURE WARNING LIGHT
10 → AC COMPRESSOR CONTROL
11 → FUEL CONSUMPTION OUTPUT INFORMATION
12 → IDLE REGULATOR CONTROL (TRACK B)
13 ← COOLANT TEMPERATURE SENSOR INPUT
15 --- PRESSURE SENSOR EARTH
32 → IGNITION COIL 1-4 CONTROL
33 --- POWER EARTH
34 → OBD WARNING LIGHT CONTROL
37 → FAULT WARNING LIGHT CONTROL
38 → FAN ASSEMBLY 2 RELAY CONTROL
39 → ACTUATOR RELAY CONTROL
41 → IDLE REGULATOR CONTROL (TRACK A)
42 → IDLE REGULATOR CONTROL (TRACK C)
43 ← THROTTLE POTENTIOMETER SIGNAL
44 ← DOWNSTREAM OXYGEN SENSOR SIGNAL
45 ← UPSTREAM OXYGEN SENSOR SIGNAL
62 → EGR VALVE CONTROL
63 → UPSTREAM OXYGEN SENSOR HEATING CONTROL
65 → DOWNSTREAM OXYGEN SENSOR HEATING CONTROL
66 --- +AFTER IGNITION
68 → FUEL PUMP RELAY CONTROL
70 → TDC ENGINE SPEED INFORMATION
72 → IDLE REGULATOR CONTROL (TRACK D)
73 --- COOLANT TEMPERATURE SENSOR EARTH
74 --- THROTTLE POTENTIOMETER AND FUEL PRESSURESENSOR SUPPLY
75 --- THROTTLE POTENTIOMETER AND FUEL PRESSURESENSOR EARTH
PRO15097
17-19
INJECTIONComputer 17
ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS (cont)
16 ← MANIFOLD PRESSURE SENSOR SIGNAL INPUT
18 ← EGR VALVE POSITION SIGNAL
19 --- KNOCK SENSOR SHIELDING
20 ← KNOCK SENSOR SIGNAL INPUT
23 ← AC COMPRESSOR POWER ABSORBED INFORMATION
24 ← ENGINE SPEED SENSOR SIGNAL INPUT
26 --- DIAGNOSTICS
27 --- INTER-COMPUTER CONNECTION
28 --- POWER EARTH
29 --- +AFTER IGNITION
30 --- +BEFORE IGNITION
46 ← CAMSHAFT SENSOR SIGNAL
49 ← AIR TEMPERATURE SENSOR INPUT
53 ← VEHICLE SPEED INPUT
54 ← ENGINE SPEED SENSOR SIGNAL INPUT
56 --- DIAGNOSTICS
57 --- INTER-COMPUTER CONNECTION
58 ← ENGINE IMMOBILISER SYSTEM
59 → INJECTOR 1 CONTROL (TO CONTROL COMPUTER)
60 → INJECTOR 3 CONTROL (TO CONTROL COMPUTER)
76 ← DOWNSTREAM OXYGEN SENSOR SIGNAL
77 --- AIR TEMPERATURE SENSOR EARTH
78 --- PRESSURE SENSOR SUPPLY
79 --- KNOCK SENSOR EARTH
80 --- UPSTREAM OXYGEN SENSOR EARTH
82 --- EGR VALVE EARTH
83 --- EGR VALVE SUPPLY
85 → POWER STEERING PRESSURE SWITCH INFORMATION
87 --- INTER-COMPUTER CONNECTION
88 ← ELECTRIC HEATED WINDSCREEN SIGNAL
89 → INJECTOR 4 CONTROL (TO CONTROL COMPUTER)
90 → INJECTOR 2 CONTROL (TO CONTROL COMPUTER)
PRO15097
17-20
INJECTIONComputer 17
ALLOCATION OF INJECTOR CONTROL COMPUTER INPUTS AND OUTPUTS
1 --- INTER-COMPUTER CONNECTION
2 ← INJECTOR 3 CONTROL INFORMATION (COMPUTER)
3 ← INJECTOR 1 CONTROL INFORMATION (COMPUTER)
4 → TDC INFORMATION
5 --- INTER-COMPUTER CONNECTION
22 --- POWER EARTH
23 --- POWER EARTH
25 --- + AFTER IGNITION
26 --- + AFTER IGNITION
27 --- + AFTER IGNITION
28 --- INTER-COMPUTER CONNECTION
29 ← INJECTOR 4 CONTROL INFORMATION (COMPUTER)
30 ← INJECTOR 2 CONTROL INFORMATION (COMPUTER)
33 --- + AFTER IGNITION
34 --- + BEFORE IGNITION
35 → INJECTOR 1 CONTROL
36 → INJECTOR 1 CONTROL
37 → INJECTOR 4 CONTROL
38 → INJECTOR 4 CONTROL
40 → INJECTOR 3 CONTROL
41 → INJECTOR 3 CONTROL
42 → INJECTOR 2 CONTROL
43 → INJECTOR 2 CONTROL
51 --- POWER EARTH
PRN15557
17-21
INJECTIONWiring diagram 17
16414G
17-22
INJECTIONWiring diagram 17
16414D
17-23
INJECTIONWiring diagram 17
PARTS LIST
104 Engine immobiliser system107 Battery120 Injection computer146 Knock sensor147 Air temperature sensor193, 194195, 196 Injectors199 Fuel gauge222 Throttle potentiometer224 Power steering pressure switch225 Diagnostic socket242 Oxygen sensor244 Coolant temperature sensor247 Instrument panel250 Speed sensor272 Air temperature sensor273 Speed threshold sensor371 Canister solenoid valve419 AC control unit565 Throttle housing597 Engine compartment fuse box and relays645 Passenger compartment ECU transponder777 Power fuse board778 Ignition coil927 Impact sensor
17-24
COOLINGFilling - Bleeding 19
The circulation in the heater matrix is continuous,thus contributing to the cooling of the engine.
FILLING
Open the bleed screw located on the plenumchamber.
Fill the circuit via the expansion bottle opening.
Close the bleed screw when the liquid starts toflow in a continuous stream.
Start the engine (2,500 rpm).
Adjust the level by overflow for approximately4 minutes.
Close the reservoir.
BLEEDING
Run the engine for 20 minutes at 2,500 rpm, untilthe fan(s) cut in (time required for automatic de-gassing).
Check that the fluid level is close to the"Maximum" mark.
DO NOT OPEN THE BLEED SCREW WHILE THEENGINE IS RUNNING.
RETIGHTEN THE EXPANSION BOTTLE PLUG WHILETHE ENGINE IS WARM.
Location of the bleed screw (1) on the plenumchamber
15615R6
19-1
COOLINGDiagram 19
1 Engine2 Radiator3 "Warm" reservoir with degassing in line with
thermostat4 Heater matrix5 Thermostat support6 ∅ 3 mm nozzle7 ∅ 8 mm nozzle
Coolant pump
Thermostat
Bleed screw
The expansion bottle valve calibration value is 1.6bar (brown).
14887-2R1
19-2
COOLINGCoolant pump 19
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Drain the cooling circuit via the lower engine ra-diator hose.
Remove:- the right-hand mud shield and the two engine
undertrays,- the accessories belt (see section 07 "Accessories
belt tensioning"),- the lower timing cover mounting bolt and
move it aside,- the coolant pump pulley,- the coolant pump.
ESSENTIAL SPECIAL TOOLS
Mot. 1202 Circlip pliers
TIGHTENING TORQUE (in daN.m)
Coolant pump bolt 1.7
Cleaning
It is very important that the mating surfaces arenot scratched.
Use the Décapjoint product to dissolve the part ofthe seal which remains attached.
Apply the product to the section to be cleaned,wait approximately ten minutes, then remove itusing a wooden spatula.
It is advisable to wear gloves during the opera-tion.
Do not allow any of the product to fall onto thepaintwork.
REFITTING
Refit:- the coolant pump (fitted with a new seal) tigh-
tening the bolts to a torque of 1.7 daN.m,- the accessories belt an tension it (see section 07
"Accessories belt tensioning").
Fill and bleed the cooling circuit (see section 19"Filling - Bleeding").
19-3
COOLINGCatalytic converter 19
REMOVAL
Place the vehicle on a two post lift.
Disconnect the battery.
Remove the mounting nuts of the connection ofthe manifold and the catalytic converter.
Slacken the catalytic converter / exhaust lineconnecting clamp to move the catalytic converterback a few centimetres.
Remove:- the steering shaft yoke bolt,
ESSENTIAL SPECIAL TOOLS
T.Av. 1233 -01 Tools for working on the sub-frame - axle
- the sub-frame tie-rod mounting bolts and lo-wer the sub-frame by 40 mm at the front and90 mm at the rear,
97390-1S1
15870R
- the catalytic converter.
REFITTING
Change the catalytic converter/exhaust manifoldconnection seal and the exhaust clamp.
IMPORTANT: ensure that the steering shaft yokebolt is positioned correctly.
19-4
CLUTCHCover - Disc 20
VEHICLETYPE
ENGINETYPE
COVER DISC
DA0 3EA0 3
F5R 740
215 CPON 4400
26 splines VM : Moss GreenD = 215 mm V : GreenE = 6.8 mm BC : Capri Blue
BL : Light Blue
85873S
90693-2R1694990R1
Monodisc clutch operating dry, cable controlled.
Clutch stop in constant contact.
20-1
CLUTCHCover - Disc 20
REMOVAL
Fit immobilising tool Mot. 582-01.
Remove the cover mounting bolts and remove theclutch disc.
Check and change any faulty parts.
ESSENTIAL SPECIAL TOOLS
Mot. 582 -01 Immobilising tool
TIGHTENING TORQUE (en daN.m)
Cover mounting bolt 2
REFITTING
Clean the clutch shaft splines and refit the assem-bly without any lubricant.
Fit the disc (hub offset gearbox side).
Align it.
REPLACEMENT (following removal of the gearbox)
95414S
Gradually screw in the bolts in a star formation,then tighten the cover mounting bolts to the spe-cified torque.
Remove immobilising tool Mot. 582-01.
Coat with MOLYKOTE BR2 grease:- the tube guide,- the fork pads.
99055R1
20-2
CLUTCHCover - Disc 20
After refitting the gearbox, place the cable on theclutch fork and check the operation of the playcompensation system.
Check the clutch release travel.
The fork travel should be:
X = 25.4 to 25.9 mm
97758-1R
NOTE: in the event of an operation which doesnot require removal of the gearbox, or after fit-ting the gearbox, DO NOT LIFT the fork as it maycome free of the notch (A) of the stop.
99054R
20-3
CLUTCHFlywheel 20
REMOVAL
After removing the clutch disc, remove the engineflywheel mounting bolts (the bolts cannot be reu-sed).
Reworking of the clutch face is prohibited.
REFITTING
Clean the flywheel mounting bolt threads on thecrankshaft.
Degrease the contact surface of the flywheel withthe crankshaft.
Refit the flywheel immobilising it using toolMot. 582-01.
COMMENT: the flywheel mounting bolts must al-ways be replaced.
ESSENTIAL SPECIAL TOOLS
Mot. 582-01 Immobilising tool
Flywheel bolt 5.5
TIGHTENING TORQUE (in daN.m)
REPLACEMENT OF THE FLYWHEEL
20-4
MANUAL GEARBOXIdentification 21
"MEGANE" vehicles with F5R engines are fitted with JC5 manual gearboxes.
Workshop Repair Manual "B.V. JB/JC" deals with the complete repair of this component.
14834-1R
A mark (1), located on the gearbox casing, indi-cates:
A Type of gearboxB Gearbox indexC Manufacturing numberD Factory of manufacture
90775R
0 0 0JCX
X 0 0 0 0 0 0
B
C
A
D
Gears
JC5
Index VehicleStep down
ratio
Speedo-meter drive
gear1st 2nd 3rd 4th 5th Reverse
gear
106 DA0 3EA0 3
16--57
Withoutspeedo-meter
11-- 41
21--43
28--39
31--34
42-- 31
11--39
21-1
MANUAL GEARBOXCapacity - Lubricants
CAPACITY (in litres)
21
LEVEL CHECK
Fill to the level of the opening.
5-speed gearbox
JC5 3.1
Grade - Viscosity
TRX 75W 80W
92081S
21-2
Parts which must always be changed
MANUAL GEARBOXConsumables 21
TYPE PACKAGING
LOCTITE 518
LOCTITE FRENBLOC(locking and sealingresin)
24 ml syringe
100 g tube
24 cc vial
PART NUMBER
77 01 404 452
77 01 394 071
UNIT
77 01 421 162 Casing assembly surfaces
Threaded plugs and switchesBearing plugsEnds of the roll pins on the driveshafts
Input and output shaft nutsFixed gear and hub of 5th
Differential lock drive stud
Right-hand sun wheel splines
Fork pivotStop guideFork pads
MOLYKOTE BR2 77 01 421 1451 kg box Clutch
When they have been removed:- lip seals,- O-rings,- stop guide tubes,- output shaft and differential nuts,- bushes under the gears.
RHODORSEAL 5661
21-3
MANUAL GEARBOXSpecial features 21
The removal and refitting of the gearbox remainsidentical and does not present any difficulties inrelation to MEGANE vehicles fitted with a "JB"gearbox and "K4M and K4J" petrol engines.
NOTE: when refitting the gearbox, it is preferableto support the clutch control fork using string (1)to prevent it from coming free from its ball joint(located on the clutch housing).
TIGHTENING TORQUES (in daN.m)
Drain plug 2.2Brake caliper bolt 3.5Driveshaft gaiter bolt 2.5Lower ball joint nut 6.5Shock absorber base bolt 17Gearbox surround and starter bolt 3Suspended engine mounting to gearbox bolt 6Wheel bolt 10
14834R
21-4
REAR BEARING ELEMENTSHub / Brake disc 33
99582S
The brake discs cannot be ground. The disc mustbe changed if it significantly worn or scratched.
Remove:- the brake/hub disc; to do this refer to the pro-
cedure described on the previous page,- the circlip.
By means of a press, remove the bearing usingtubes (A) and (B).
16215R
NOTE: ensure that the disc is positioned correctlyfor the removal of the bearing. The ABS crownwheel should be facing upwards.
REFITTING
By means of a press, refit the bearing usingtubes (C) and (D).
IMPORTANT: ensure that the bearing is positio-ned correctly: the dust cover should be at the rear.
NOTE: the bearing dust cover plastic protectorshould be removed at the last moment.
Refit:- the circlip,- the hub/disc.
33-2
STEERING ASSEMBLYMechanical power steering pump
ESSENTIAL SPECIAL TOOLS
Mot. 453 -01 Hose clamps
Place the vehicle on a two post lift.
REMOVAL
Disconnect the battery.
Remove the accessories belt (see section 07"Accessories belt tensioning procedure").
Fit a clamp Mot. 453-01 on the supply pipe.
Disconnect the high and low pressure pipes, beprepared for the flow of power steering fluid.
Remove:- the pulley (3 bolts),- the power steering pump (4 bolts).
36
REFITTING
Refit in the reverse order to removal.
Fill and bleed the circuit turning from lock to lockwith the engine running.
NOTE: the power steering pump cannot be repai-red. In the event of a fault, change it.
The power steering pump pressure should be bet-ween 86 and 93 bars.
16213S
36-1
STEERING ASSEMBLYMechanical power steering pump
ESSENTIAL SPECIAL TOOLS
Dir. 1083 -01 Tool for refitting the pulley
T.Ar. 1094 Tool for extracting differential
bearing
REPLACEMENT OF THE HUB
Place the pump on the workbench, in a vice.
Fit tool T.Ar. 1094 and extract the hub.
36
14837R
14836R
NOTE: insert a bolt (1) between the pump shaftand the push rod of tool T.Ar. 1094.
Position the hub (new) and fit it using tool Dir.1083-01. Coat it with multipurpose grease first tomake refitting easier.
NOTE: insert a shim (2) of approximately 25 mmbetween tool Dir. 1083-01 and the hub.
Observe the fitting dimension:X = 41.5 mm
2
1
X
1 Power steering pump2 Hub
36-2
STEERING ASSEMBLYPower steering unit
ESSENTIAL SPECIAL TOOLS
T.Av. 476 Tool for extracting ball joints
Mot. 453 -01 Hose clamps
36
16209S
Wheel bolt 10
Universal joint bolt 2.5
Engine tie-bar nut:- on gearbox 6.5- on sub-frame 7.5
Steering unit to sub-frame mounting nut 5
Steering ball joint nuts 3.5
TIGHTENING TORQUES (in daN.m)
Place the vehicle on a two post lift.
REMOVAL
Disconnect the battery.
Remove:- the two wheels,- the engine undertray.
Disconnect the steering ball joints using tool T.Av.476.
In the engine compartment:
Fit hose clamps Mot. 453-01 onto the power stee-ring reservoir hoses.
Remove the air filter unit.
Disconnect the high and low pressure pipes on thesteering unit. Plug the pipes to prevent the entryof impurities.
Remove the universal joint bolt. To do this, directthe nut upwards and fit a steering wheel immobi-lising tool to retain the same position for refitting.
36-3
STEERING ASSEMBLYPower steering unit 36
16210S
Underneath the vehicle:
Remove the front engine tie-bar bolt.
Uncouple:- the exhaust downpipe from the exhaust assem-
bly,- the gearbox control lever.
Fit a shim to move the engine forwards.
Remove:- the heat shield on the steering unit (2 bolts),
16212S
16211S
- the steering unit mounting nuts,- the left-hand sub-frame/body tie-rod (2 bolts).
Removal of the tie-rod makes it possible to re-move the steering unit easily.
Remove the steering unit from the left-handscuttle panel side by means of successive rotationsto detach the steering with its valve/ram pipes.
Never unscrew the steering rack axial ball jointsunless they are to be changed.
If a steering unit is to be changed, the steeringball joints must be retained.
36-4
STEERING ASSEMBLYPower steering unit 36
REFITTING
In the case of a new steering assembly
Fit the steering ball joints.
Refit in the reverse order to removal observingthe tightening torques.
Bleed the power steering circuit, turning fromlock to lock with the engine running.
NOTE: it is ESSENTIAL to observe the marking ofthe steering ball joints (one mark for the right-hand ball joint, two marks for the left-hand balljoint).
Adjust the parallelism if necessary.
36-5
MECHANICAL COMPONENT CONTROLSMaster cylinder 37
Pipes on master cylinder 1.7Mounting nuts on brake servo 2.3
Place the vehicle on a two post lift.
REMOVAL
Disconnect the battery.
Remove the air filter unit.
91101R
NOTE: these vehicles are fitted with a master cy-linder incorporated in the brake servo. The sealingof the brake servo is directly connected to themaster cylinder. When carrying out any work, anew seal (A) must be fitted.
Position the master cylinder in alignment with thebrake servo so that the push rod (P) correctly en-ters the master cylinder location.
TIGHTENING TORQUES (in daN.m)
DI3718
REFITTING
Refit in the reverse order to removal.
Check the length of the push rod.
Dimension X = 22.3 mm.
Adjustment according to model using rod (P).
16209S
Move aside the expansion bottle.
Disconnect the accelerator cable.
Drain the brake fluid reservoir and remove it.
Disconnect the pipes on the master cylinder mar-king their position.
Remove the two master cylinder mounting boltsand remove it.
37-1
MECHANICAL COMPONENT CONTROLSMaster cylinder 37
Fill the brake fluid reservoir and bleed the brakecircuit.
MASTER CYLINDER (REPLACEMENT)
The kit sold by the Parts Department consists of:- a master cylinder (four outlets or two outlets in
the case of ABS),- two plugs (A),- two mounting nuts (B).
DI3719
37-2
MECHANICAL COMPONENT CONTROLSBrake servo
TIGHTENING TORQUES (en daN.m)
Pipes on master cylinder 1.7Mounting nuts on brake servo 2.3Brake servo nuts on bulkhead 2
- the acoustic mass on the left-hand side member(2 nuts), this will make removal of the brakeservo easier.
The brake servo cannot be repaired. Work is onlypermitted on the:- air filter,- check valve.
REMOVAL
Disconnect the battery.
Remove the air filter unit.
37
Move aside the expansion bottle.
Disconnect the accelerator cable.
Remove:- the master cylinder (see previous page),
16209S
Unhook the clutch fork cable.
89204S
Disconnect the vacuum hose on the brake servo.
16208R
37-3
MECHANICAL COMPONENT CONTROLSBrake servo
REFITTING
Before refitting, check:- dimension L = 104.8 mm,- dimension X = 22.3 mm.
In the passenger compartment
Remove the pin (A) of the yoke connecting thebrake pedal to the push rod by acting on the clip,
37
91101R2
97860R
Refit in the reverse order to removal.
Before refitting the clutch pedal, coat the pin andthe grooved sector with grease.
Ensure that the clutch cable is positioned correctlyon the grooved sector.
Remove:- the stiffener,- the pedal assembly pin nut,
PRG37.9
Remove the pin to detach the clutch and brakepedals.
NOTE: it is not necessary to unhook the cablefrom the clutch pedal grooved sector.
It is necessary to remove the pedals to gain accessto the mounting nuts securing the brake servo tothe bulkhead.
Remove:- the four brake servo mounting nuts,- the brake servo.
37-4
MECHANICAL COMPONENT CONTROLSBrake servo 37
Refit the cable on the clutch fork.
Check that the assembly operates correctly.
With the pedal at rest, in the clutch engagedposition, pull the cable at the clutch fork on thegearbox.
The cable should have at least 2 cm "slack".
Check the fork travel.
It should be: X = 27.4 to 30.7 mm.
89204S
91830R1
Bleed the brake circuit.
37-5
The sealing of the brake servo must be checked onthe vehicle.
Fit Mot. 1311-01 between the brake servo and thevacuum source (inlet manifold).
MECHANICAL COMPONENT CONTROLSBrake servo
SEALING CHECK
When checking the sealing of the brake servo, ensure that the sealing between the brake servo and the mas-ter cylinder is perfect. If there is a leak, change seal (A) (refer to the procedure described on page 37-1).
37
14287R
- assemble the pipes with the connecting "T",the vacuum pressure gauge and the assembly(1) (use union B from kit Mot. 1311-01 and aclamp with a worm screw (2)).
To do this:- remove the vacuum pipe completely,- retain the check valve/hose assembly (1), remo-
ving the clamp,
ESSENTIAL SPECIAL TOOLS
Mot. 1311-01 Pressure gauge and unions for
measuring pressure
14216R
14213R
- position the assembly connecting the valve onthe brake servo on one side and the manifoldoutlet pipe on the other.
NOTE: ensure that the closing valve is on the ma-nifold side.
Run the engine at idle for one minute.
Close the valve and switch off the engine.
The vacuum in the circuit is approximately613 mbar, if the vacuum falls to 33 mbar in 15 se-conds, there is a leak which may be located either:- at the check valve (change it),- at the push rod diaphragm (in this case, change
the brake servo).
37-6
AIR CONDITIONINGGeneral 62
CONSUMABLES
- DELPHI HARRISON V5 compressor oil:PLANETELF PAG 488 : 220 cm3 ± 15(to be ordered from ELF)
- Refrigerant:R134a : 750 g ± 30
- Compressor:DELPHI HARRISON V5
62-1
AIR CONDITIONINGCompressor 62
Pressure relief valve on evaporator bolt 0.6
Connecting pipes on pressure relief valvenut 0.8
Connecting pipes on dehydration canister
retaining bolt 0.8
Connecting pipes on condenserretaining bolt 0.8
Condenser connecting pipe on compressorretaining bolt 0.8