Ar Condicionado e Ventilação PDF

Heating and ventilation
HEATING
AIR CONDITIONING
77 11 190 859 NOVEMBER 1996 Edition Anglaise
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes by the manufacturer in the reference numbering system is forbidden without the prior written authority of
production of the various component units and accessories from which his vehicles Renault.
are constructed".
C Renault S.A. 1988

EXPLODED VIEW
PRJ6000
Heating and Ventilation
Contents
Pages
61 HEATING
General 61-1
Operating principle 61-4
Distribution unit 61-7
Fan unit 61-9
Radiator 61-10
Resistance unit 61-11
Control panel 61-12
Control cables 61-13
62 AIR CONDITIONING
General 62-1
Operating principle 62-5
Fault finding 62-9
Operating diagram 62-47
Consumables 62-48
R12 / R134a conversion 62-49
Fan unit 62-53
Evaporator 62-55
Compressor 62-56
Compressor oil level 62-61
Condenser 62-62
Pressure relief valve 62-64
Dehydrating bottle 62-65
Electrical controls 62-66
HEATING
R19
Phase I General 61
AIR DISTRIBUTION AND CIRCULATION
91936-2R
A External air intake a Central ventilator outlets

B Air distribution b Windscreen de-mister outlet
C Air outlet in rear left hand wing c Dashboard ventilator outlet
d Lower ventilator outlets
e Rear seat ventilator outlets (depending on
equipment level)
f Front side windows de-mister outlet
61-1
HEATING
R19
Phase II
General 61
a Central ventilator outlets

b Windscreen de-icer / de-mister outlets
c Dashboard ventilator outlets
d Lower outlets
e Rear seat ventilator outlets (depending on equipment level)
f Front side window de-mister outlet
61-2
HEATING
General 61
EXPLODED VIEW OF THE FAN AND DISTRIBUTION UNIT
92194R2
WATER BOX
PASSENGER COMPARTMENT
1 Heater radiator
2 Heater fan
3 Hot / cold air flap
4 Air distribution flaps
5 Air distribution cable
6 Air mixing cable
a Air intake
b Windscreen de-misting outlet
c Dashboard ventilator outlets
d Lower ventilator outlets
e Rear seat ventilator outlets (depending on
equipment level)
61-3
HEATING
Operating principle 61
TEMPERATURE CONTROL KNOB (A)
Controls the hot / cold air flap (3).
R19 Phase I R19 Phase II
92033-5R 95717R2
92196R
The fan has no heater valve and is permanently fed. Flap (3) controls the fresh air heating system.
61-4
HEATING
AIR DISTRIBUTION KNOB (B)
Controls the air distribution flaps (4).
R19 Phase I R19 Phase II
92033-3R1 95717R3
92196-1R
61-5
HEATING
POSITION POSITION
The air flow is directed only to the dashboard The air flow is directed to the lower ventilators
ventilators (a) and (c). (d), (e) and the dashboard ventilators (a) and (c).
Each ventilator has three settings :

- open or closed,
- up or down,
- left or right.
POSITION POSITION
The air flow is distributed between all the The air flow is directed to the windscreen
ventilators (a), (b), (c), (d), (e), (f). ventilators (b), the side window ventilators (f),
and the dashboard ventilators (a) and (c).
The dashboard ventilators (a) and (c) may be
closed. To improve de-misting and de-icing of the
windscreen, ventilators (a) and (c) may be closed.
FAN CONTROL KNOB (C)
Ventilation is by means of blown air. The amount

of air circulating in the passenger compartment is
determined by the position of knob (C).
NOTE : To improve de-misting and de-icing of the

windscreen, fan control knob (C) should be on the
last but one position (2).
92033-1R1
61-6
HEATING
Distribution unit 61
SPECIAL TOOLING REQUIRED
Mot. 453 -01 Hose clamp

M.S. 583 Hose clamp
REMOVAL Fit hose clamps Mot. 453-01 or Mot. 583.
Disconnect the battery.
Remove:
- the dashboard (refer to relevant section),
- the upper seal on the water box and the
external air intake grilles.
Disconnect the fan feed connector (A).
92202R
Remove:
- the 2 radiator inlet hose clips,
- the fan unit from inside the vehicle together
with its control.
92283R
Remove the 2 fan mounting bolts (B) and remove

the fan from the driver’s side (the water box can
only be removed in one position).
92200R
61-7
HEATING
Distribution unit 61
REFITTING
Fit the fan unit on the bulkhead (ensure that the

seals are in good condition).
Fit the fan with the 2 fan mounting bolts (B). Do

not tighten these two bolts. The fan unit is also
positioned on the dashboard by two bolts (C).
92283R
92203R1
Refit the dashboard.
Check the control cable adjustment and re-adjust

if necessary (see corresponding section).
Connect the radiator hoses.
Tighten the 2 fan mounting bolts (B) and refit the

feed connector (A).
Refit the air intake grilles and the water box seal.
Top up and bleed the engine cooling circuit (see

corresponding section) if necessary.
61-8
HEATING
Fan unit 61
REPLACEMENT
The fan unit is removed after removing the upper

water box seal and the external air intake grille.
Remove the feed connector (A) and the 2

mounting bolts (B).
92223R
When refitting, put the motor back in position so

that the connector is not taut.
Refasten the two half covers using the clips (D)

provided in the kit and hot-crimp them.
Fit the new seal provided in the kit to the

92283R assembly.
IMPORTANT: the seal must be in perfect

condition. If it is damaged, water may enter the
Remove the fan from the left hand side of the passenger compartment.
vehicle (the water box can only be removed in one
position).
92200R 92223R1
Disconnect the motor connector.
Open the two half covers.
Pull the motor out as shown below.
61-9
HEATING
Radiator 61
REPLACEMENT
The radiator is removed after removing the air

distribution unit.
Spread the 4 retaining clips (E) and remove the

radiator by pulling in the direction shown in the
diagram below.
92201R
NOTE: take care not to damage the radiator fins.
When refitting, ensure that the radiator is fitted

into the holder with its foam adjustment strips.
Ensure that the 4 tabs are correctly fastened.
Fit the 2 mounting bolts (F) onto the body of the

fan unit if the clips have broken.
90292R
61-10
HEATING
Resistance unit 61
REPLACEMENT
The resistance unit is reached after removing the

water box upper seal and the external air intake
grille.
Disconnect connector (A) and remove the two

mounting bolts (G).
92283R1
Detach clips (H) and remove the resistance unit.
NOTE: if the resistance unit is being removed due

to damage, ensure that the fan rotates freely,
otherwise change it.
There are no special precautions for refitting the

resistance unit.
92204S
61-11
HEATING
Control panel 61
REPLACEMENT
Remove the two mounting bolts for the lower

dashboard cover (J).
92224R
When refitting, change the cable sleeve stops and

the clips (M).
92289R1
Remove the two mounting bolts securing the

control panel to the dashboard (K).
92288R
Push the control panel in and release it from the

bottom.
The control panel facade may be changed by

removing the 4 retaining clips (L).
61-12
HEATING
Control cables 61
REPLACEMENT Place the air distribution control in
position and the heating control on
The control cables can be removed without maximum cold (blue spot).
removing the air distribution unit.
Refit the control panel to the air distribution unit.
Remove:
- the control panel as described on the previous Align the flap control quadrant markers.
page,
- the 2 mounting bolts for the air deflector (N).
92203R 92207R
Unclip the cable to be changed and turn it 1/4 Refit:

turn to release it from the flap control lever. - the mixing flap return spring (P) (only for air
mixing control),
When refitting, clip the cable to the control panel - the air deflector and the lower dashboard
against the cable sleeve stops (clips M). cover, bolts (N) and (J).
92289R1
92224R1
NOTE: the flap control cables are of a different
length, the longer one is for the mixing flap.
61-13
AIR CONDITIONING
General 62
91096-1R
62-1
AIR CONDITIONING
General 62
A Passenger compartment
B Engine compartment
C External air
D To mixing unit
E Scuttle panel
F External air or recycled air
1 Compressor
2 Condenser
3 Refrigerant reservoir
4 Tri-function pressostat
5 High pressure bleed
6 Pressure relief valve
7 Thermostat control for pressure relief valve
8 Evaporator
9 Low pressure bleed
10 Air conditioning fan
11 Cooling fan
12 Engine radiator
13 High pressure liquid
14 Low pressure vapour
15 High pressure vapour
62-2
AIR CONDITIONING
General 62
RECOMMENDATIONS MAINTENANCE
The quality of heating and ventilation repairs is When a vehicle is fitted with air conditioning, the
highly dependent on the rules below being engine may heat up more than on other vehicles.
followed: It is recommended that the level of coolant is
checked more frequently.
Never leave:
- the pipes open to the air; risk of moisture Every year, it is recommended that:
being absorbed,
- a can of oil open. 1. the quantity of refrigerant in the air
conditioning circuit is checked.
When topping up the oil using filling equipment:
2. the condenser and the engine cooling
• Never use oil left over from a previous radiator are cleaned.
operation. Use the exact quantity of oil
required for each operation. 3. the condition of the air conditioning system
condensation outlet is checked (blockage).
• Work cleanly. The smallest foreign body at the
unions could cause slow leaks or internal For the repair of major leaks, each time a
malfunction. component is changed (compressor, condenser
etc...) or if the presence of moisture in the circuit is
• Do not allow oil to come into contact with the suspected, change the dehydrating bottle and
vehicle’s paintwork or plastic components. create a vacuum. The same applies if the air
conditioning circuit has been left open for more
• Emphasise the importance of operating the than 10 minutes without being plugged.
air conditioning system regularly, both in
summer and in winter.
If the air conditioning system is not operated for
• The system must be filled with the correct and a prolonged period
precise quantity of refrigerant (refer to the
"Consumables" section). Too much or not If the system is not operated for a prolonged
enough refrigerant reduces the performance period, in particular in winter, operate the
of the system and in extreme cases risks compressor periodically in order to prevent
damaging the compressor. destruction of the compressor rotor bearing races.
The needles mark the bearing races when the
• Never fill an air conditioning system which assembly is immobilised in one position and
operates using R134a with R12 refrigerant vibrate under the effect of the engine rotation.
and vice versa.
This destruction is manifested by significant noise
when the compressor is operated again.
62-3
AIR CONDITIONING
General 62
92419G
1 Fan unit A External air intake

2 Fan B Recycled air intake
3 Evaporator C To air distribution unit
4 Fan control unit
5 Evaporator temperature sensor NOTE : the air distribution unit and the dashboard
6 Recycling motor are identical for versions with heating and
7 Pressure relief valve ventilation and versions with air conditioning.
8 Component unit
62-4
AIR CONDITIONING
SPECIFIC OPERATION FOR DIESEL AND TURBO DIESEL VERSIONS (see diagram on following page).
AIR CONDITIONING CUT-OUT
Principle of the system Special notes
In order to improve moving away when on a slope The clutch pedal switch does not require any
and to avoid stalling the engine, the air special adjustment, other than when the clutch
conditioning compressor clutch is cut for 4 pedal is not depressed, the switch plunger should
seconds. be fully depressed.
Conditions Using an ohmmeter:
The clutch pedal must be depressed and the clutch pedal not depressed:
accelerator pedal must be over a certain engine - switch resistance = 0 ohm
load.
clutch pedal depressed:
- switch resistance= infinity
Operation
When the two conditions above are fulfilled

(switch circuit open), relay (661) cuts out and no
longer feeds the timer relay (635).
The AC compressor clutch control relay (584) is
therefore cut for 4 seconds by the timer relay.
Note
The diode stops the AC compressor clutch from

being fed by the pre-heating unit during starting
and engine warming.
62-5
AIR CONDITIONING
PHASE I PHASE II
92034-2R3 95718R2
TEMPERATURE CONTROL KNOB (A) AIR FLOW CONTROL KNOB (C)
This control has the same function as described in This control has the same function as described in
the heating and ventilation section when the air the heating and ventilation section.
conditioning control (D) is in position 0.
There are 6 positions for fan speed in comparison
When the air conditioning control (D) is in the to the 3 positions for the heating and ventilation
position "NORM" or "MAX", air is first cooled and version.
dried by crossing the evaporator, then some of it
is heated by crossing the radiator. POSITION 0: there is no ventilation, the air intake
is closed by the recycling flap.
When the control is turned to the extreme left,
the air is not heated and is therefore at its coolest The air conditioning system cannot be operated.
possible temperature.
This position shuts off the complete system,
Moving the knob to the right allows the air whatever the other control knob settings may be.
temperature to be controlled.
62-6
AIR CONDITIONING
PHASE I PHASE II
92034-1R1 95718R3
AIR CONDITIONING CONTROL KNOB (D) This position allows the passenger compartment
temperature to be lowered quickly and also
This control starts and stops the air conditioning isolates the passenger compartment from the
system. external atmosphere ( driving in polluted areas).
Its use allows: If this position is used for a prolonged period of

- the air temperature in the passenger time, there may be a slight misting up of the air in
compartment to be lowered, the passenger compartment.
- the humidity level in the passenger
compartment to be reduced (improves de- It is therefore advisable to return to the "NORM"
misting). position as soon as the polluted area is left or the
desired passenger compartment temperature is
POSITION 0: air conditioning is not operational, reached.
the vehicle has the same heating and ventilation
system functions as a vehicle without air NOTE: The air conditioning control only starts the
conditioning. system operating if the air flow control (C) is set to
a position other than 0.
POSITION "NORM": air conditioning is
operational. This is the normal position for air
conditioning use. Fresh air is taken from outside
the vehicle and constantly renewed.
POSITION "MAX": air conditioning is operational.

Air is taken from inside the passenger
compartment and recirculated. No air is taken
from outside.
62-7
AIR CONDITIONING
SPECIAL NOTES ABOUT THE SYSTEM
The temperature of the air from the evaporator is

not adjustable. It is automatically controlled by
the electronic thermostat and the sensor (S).
92287R
Moving the mixing flap control knob (A) allows

the desired air temperature to be set.
62-8
AIR CONDITIONING
Fault finding - Customer complaints 62
Air conditioning
Lack of efficiency Chart 1
No cool air Chart 2
Air too cold Chart 3
Air flow problem
Recycling flap does not operate - Model year 1989 and 1990 Chart 4
Recycling flap does not operate - From model year 1991 Chart 5
Passenger compartment fan does not operate

Model year 1989 and 1990 Chart 7A
Passenger compartment fan does not operate

From model year 1991 Chart 7B
Air distribution problem Chart 8
Air distribution problem when distribution control is in position : Chart 9A
Chart 9B
Air setting on hot Chart 9C
Air setting on cold Chart 9D
Engine cooling fan problem
Engine cooling fan only operates slowly Chart 6
Passenger compartment problems
Controls difficult to operate Chart 10
Smells in passenger compartment Chart 11
Water in passenger compartment Chart 12
e53531.1
62-9
AIR CONDITIONING
Fault finding - Fault charts 62
FAULT CHART N° 1 : Lack of efficiency
AC and fan on max,

engine at idle speed. no See Chart 1A
Does the compressor operate ?
yes
Check the compressor belt tension, the

clutch air gap and its condition (slipping).
Change the belt or the compressor no Correct
clutch.
Does the fault persist?
yes
* If the sensor resistance is incorrect :
1) above max. level :
the compressor operates too
Check the evaporator sensor early and reduces its efficiency.
resistance (*). 2) below min. level :
no Correct
Change the sensor if necessary. the compressor operates too
Does the fault persist? late, the evaporator freezes,
reducing its efficiency and the
air flow.
yes
Check that the recycling flap is in the recycling See Chart 4A (from model year 91).
position when AC is at max. no
Is this correct ? Chart 4B (up to model year 90).
yes
Check that the mixing flap moves correctly and

readjust the cable if necessary. no Correct
yes
See Chart 7A or 7B air flow or fan

Is there an air flow problem ? yes
problem
no
A (See next page)

e53531.1
62-10
AIR CONDITIONING
FAULT CHART N° 1 : Lack of efficiency (cont)
Connect the HP/LP pressure gauges and check the

pressures. Vehicle stationary, engine at idle speed
and A/C MAX. Using the HP pressure gauge check the engine
If the HP>25 bars : cooling fan control pressostat pressure
- there is too much refrigerant in the circuit, settings.
- the engine cooling fan is not operating Pressures 16/19 bars ± 1.5 bar.
correctly, NOTE: If the setting is too high the
- the engine is getting too hot, yes
fan switches on and off too late and
- the condenser is dirty. The compressor thus reduces the efficiency of the AC
operates via the HP pressostat under these system.
precise conditions. Change the pressostat if necessary.
Is HP < 25 bars ? Does the fault persist?
no
no
yes
Check that the sensor harness is clean.
Clean or change the condenser. no Correct Correct
yes
The humidity in the circuit may have
formed a plug of ice in the pressure
relief valve or the valve may be faulty
(slight lack of gas in the bulb).
Change the dehydrating bottle and the
pressure relief valve and top up the
Check the operation of the engine cooling fan at refrigerant level.
top speed (passenger compartment fan and AC on
max.).
Fan operates if HP ≥19 bars.
no See Chart 6
Fan stops if HP ≤ 16 bars.
Fan operates for engine coolant temperature ≥
92°C.
Is the fan operation correct?
yes
Adjust the refrigerant level in the circuit. There

may have been too much refrigerant.
e53531.1
62-11
AIR CONDITIONING
FAULT CHART N° 1A : Lack of efficiency
AC and passenger compartment fan on max,

engine idling. yes See Chart 1.
Does the compressor operate?
no
Engine running at idle speed, AC and fan still on

max., check for bubbles in the dehydrating bottle
inspection glass.
no Correct
If bubbles are seen, there is not enough
refrigerant in the circuit. Adjust the level.
yes
Connect the HP and LP pressure gauges.

Check the operation of the engine cooling fan at
top speed ( AC on max.). If the fan control pressostat pressure settings
- Fan operates if HP ≥ 19 bars are too high, the fan starts and stops too late
no
- Fan stops if HP ≤ 16 bars. and reduces the AC efficiency.
- Fan also operates for engine coolant If this is the case, change the pressostat.
temperature ≥ 92°C.
Is the fan operation correct?
yes
With the windows and doors closed, the vehicle in

a shady location, temperature ≤ 25 °C, engine
idling, passenger compartment fan and AC on Check the evaporator sensor resistance.
max., measure the temperature of the air in the no Change the sensor if necessary.
central ventilator and check that the compressor Does the fault persist?
operates for a temperature < 4°C.
Is this correct? yes no
yes
Correct
Check the pressures (passenger compartment fan
and AC on max).
If LP > 4 bars or HP=LP the pressure relief valve is Change the pressure relief
fully open. yes
valve and adjust the
If LP ≤ 0 bar the pressure relief valve is refrigerant level.
closed.
Do you read these values ?
no
If various operations have been carried out on * Attention: type 709 compressors
the cooling equipment and oil has been circulate more oil in the circuit
no Correct
added, there may be too much oil in the circuit than 508 type compressors.
(*).
If this is the case, remove the compressor
and check its oil level (see method in the A/C
workshop repair manual), drain the oil in the
pipes and the condenser, change the dehydrating
yes Change the AC compressor.
bottle and adjust the refrigerant level.
e53531.1
62-12
AIR CONDITIONING
FAULT CHART N° 2.1 : No cool air
Is the compressor operating ? yes See Chart 2.2.
no
Check the fuse or fuses, change if necessary.

no Correct
yes
Fan and AC on max., check the 12 volt compressor Check the clutch resistance
feed. ye (3.2 ± 0.5 ohms).
Is there+ 12 Volts ? Change the clutch if necessary.
no
For X53A (E7J 700 Bosch injection) ;X539; X53Y ; X53D ; X53F
: see Chart 2A
For X53C, X538 and X53V : see Chart 2B
X533 ; X536 ; X537 ; X53H ; X53G For X53A (AC DELCO injection) : see Chart 2C
X53I;X53J ; X534 ; X53K ; X53Z For X53A (E7J 745 Bosch injection) : see Chart 2K
For X535 (E7J 742 Bosch injection) : see Chart 2K
Check for + 12 volts on tri- Shunt the tri-function pressostat

function pressostat connector between tracks A1 and C1 and See Chart 2H for
yes no
track A1. check if the compressor operates. F8Q engine.
Is this correct? Does it operate ?
no yes no
Press on a filling valve to see if there is E6J ; C2J ; F2N

refrigerant in the circuit.
NOTE: with the engine stopped and cold,
the pressure gauges should read Check the wiring between :
between 5 and 7 bars HP and LP for - track C1 on pressostat and the
a workshop temperature of compressor connector.(1)
20/25°C.
Is this correct ?
(1) for F2N 727
Check relay 720
yes no
and its wiring
Change the pressostat. Adjust the refrigerant

level.
A (See next page)
e53531.1
62-13
AIR CONDITIONING
FAULT CHART N° 2.1 : No cool air (cont)
A/C and passenger compartment fan

on max.
Shunt the evaporator sensor and yes Change the evaporator sensor.
check if the compressor operates.
Does it operate?
no
A/C and passenger compartment fan

on max. A/C and passenger compartment fan
Check for + 12 volts on output from on max.
electronic thermostat unit track 5 or Check for + 12 Volts at electronic
no no Chart 2D
track B1 of black connection R99 of thermostat unit input, track 7.
component unit. Is there + 12 Volts ?
Is there + 12 Volts ?
yes Year of manufacture 1989 ; 1990

yes X533 ; X536 ; X537
yes Chart 2J
Check the wiring continuity
between :
- 5 on electronic thermostat and B1
of black connection R99.
Other model years
- B1 of black connection R99 and and other vehicles.
A5 of brown connection R34.
- A5 of brown connection R34 and
A1 of the tri-function pressostat.
Check the earth on track 6 of the

electronic thermostat unit and shunt
it between tracks 3 and 4. no Correct
Repair if necessary.
Is this correct?
yes
Change the electronic thermostat

unit.
e53531.1
62-14
AIR CONDITIONING
FAULT CHART N° 2.2 : No cool air (cont)
Does the compressor operate? no See Chart 2.1
yes
Check for bubbles in the inspection glass of the

dehydrating bottle, engine idling, A/C on max. yes Adjust the refrigerant level.
Are there bubbles ?
no
Check that the mixing flap moves when the

control is moved. See Chart 8
no
Is there movement? Air distribution problem.
yes
Visually check on the assembly that the flap travel

is correct.
no Correct
Adjust if necessary.
yes
Connect the HP and LP pressure gauges and check

the pressures, engine idling, AC on max.
If HP=LP the pressure relief valve is fully open or
if LP ≤ 0 bar the pressure relief valve is closed. no Correct
If you read these values change the pressure relief
valve and adjust the refrigerant level.
yes
Change the compressor.
e53531.1
62-15
AIR CONDITIONING
FAULT CHART N° 2A : No cool air- X53A vehicles (E7J 700), X53Y Bosch monopoint injection, X539, X53D,
X53F Siemens multipoint injection
Connect the XR 25 (injection fiche 3).

Enter code D03, ISO selector on S8. (1) except for X53A, X53F
Put the passenger compartment fan and the AC no See Chart 2F. move on to the next point
on max.
Does right hand bargraph 14 illuminate? (1)
yes
Does left hand bargraph 14 illuminate? no See Chart 2G.
X53D, X53Y, X539 yes yes X53A - X53F see Chart 2I
Check for + 12 Volts on track 3 of relay 474. Check the wiring between track 3
Is there + 12 Volts ? yes of relay 474 and the AC compressor
Repair.
no Check for + 12 Volts on

Check for +12 Volts on track B3 of the grey
track A1 of the tri-function connector R34.
Is there + 12 Volts on track 5 pressostat connector
no no Fan and AC on max.
of relay 474 ? Is this correct? Is this correct?
yes
yes no yes
Shunt the tri-function pressostat Repair the wiring

between tracks A1 and C1 and check between track B3
that the compressor operates. Does of connection R34
Check for + 12 Volts between tracks 1 the compressor operate? and track A1 of the
and 2 of relay 474. pressostat.
yes no
no yes Repair the wiring Repair the wiring between

between track 5 of relay track B3 of connection R34
474 and track C1 of the and the fuse box.
Change relay 474.
pressostat.
Check the wiring between : Press on a filling valve to see if

- track 2 of relay 474 and track 22 on there is refrigerant in the circuit.
the computer NOTE: with the engine stopped,
- the shunt between track 1 and the pressure gauges should read Adjust the
track 5 of relay 474 (X53D) between 5 and 7 bars HP and LP for no
refrigerant level.
Repair if necessary. a workshop temperature of
Does the fault persist? 20/25°C.
Is this correct ?
yes no
yes
Correct
The injection is preventing the AC Change the tri-function pressostat

from operating - look for a possible
cause or change the injection
e53531.1
computer.
62-16
AIR CONDITIONING
FAULT CHART N° 2B : No cool air - X53C ; X538 ; X53V vehicles

Enter code D03, ISO selector on S8.
Put the passenger compartment fan and the AC no See Chart 2F.
on max.
Does right hand bargraph 14 illuminate?
yes
Does left hand bargraph 14 illuminate? no See Chart 2G.
yes
Repair.
no
Check for +12 Volts on Check for + 12 Volts on
track A1 of the tri- track A5 of the brown
Is there + 12 Volts on track 5 of function pressostat connector R34.
no no
relay 474 ? connector. (Fan and AC on max).
Is this correct? Is this correct?
yes
yes
no yes
Check for + 12 Volts between tracks 1
and 2 of relay 474. Shunt the tri-function pressostat
Is there + 12 Volts ? between tracks A1 and C1 and check Repair the electrical
that the compressor operates. Does wiring between track
no yes A5 of connection R34
the compressor operate?
and track A1 of the
pressostat.
Change relay 474. no
yes
Check the wiring between :
- track 2 of relay 474 and track 22 on Repair the electrical
the computer (or track 23 for F3P; wiring between track 5 Check on track B1 of the
X538) of relay 474 and track C1 black connector R99 of the
- the shunt between track 1 and track 5 of the pressostat. component unit for + 12
of relay 474. Volts (fan and AC on max).
Repair if necessary. Press on a filling valve to see if Is there 12 Volts ?
Does the fault persist? there is refrigerant in the circuit.
NOTE: with the engine stopped,
the pressure gauges should read no yes
yes no between 5 and 7 bars HP and LP
for a workshop temperature of
20/25°C. C D
Correct
Is this correct ?
Injection is preventing the AC from (See next page)

operating - look for a possible cause or yes no
change the injection computer.
A B
(See next page) e53531.1
62-17
AIR CONDITIONING
FAULT CHART N° 2B (cont) : No cool air - X53C ; X538 ; X53V vehicles
A B C D
Adjust the refrigerant

level. Repair the wiring
between track B1 of
component unit and
Change the tri-function pressostat. track A5 of brown
connector R34.
yes
Check for + 12 Volts on track

5 of the electronic
no
thermostat (fan and AC on
max).
Is there 12 Volts ?
Check for + 12 Volts on

track 7 of electronic Repair the wiring between
thermostat (fan and AC track 5 on the electronic
on max) thermostat and track B1 on
Is there 12 Volts ? the black connector R99.
no
yes
See Chart 2D.
Before changing the electronic

thermostat, check the earth on
track 6 and the shunt between
tracks 3 and 4.
e53531.1
62-18
AIR CONDITIONING
FAULT CHART N° 2C : No cool air - X53A AC Delco injection vehicles
Connect the XR 25 (injection fiche).

Put the passenger compartment fan and the AC no See Chart 2F
on max.
Does left hand bargraph 17 illuminate?
yes
Does left hand bargraph 18 illuminate? no See Chart 2G
yes
The injection computer is preventing

Does right hand bargraph 18 illuminate? no operation of the air conditioning. Look for a
possible cause (strategy) or change the
yes injection computer.
Repair.
no
Check for + 12 Volts between Is there + 12 Volts on track 5 of Change

tracks 1 and 2 of relay 474. yes relay 474 ? yes
relay 474.
no no
Check for +12 Volts on
track B3 of the grey
Check the wiring between : Check for +12 Volts on connector R34.
- track 2 of relay 474 and track 22 on the track A1 of the tri-function no (Passenger compartment
injection computer pressostat connector. Is this fan and AC on max.).
- track 1 of relay 474 and track 5 of the correct? Is this correct?
fuel pump relay 236.
Repair if necessary. yes no yes
Shunt the tri-function pressostat Repair the electrical

between tracks A1 and C1 and check wiring between track
Press on a filling valve to see if that the compressor operates. Does
there is refrigerant in the circuit. B3 of connector R34
the compressor operate? and track A1 on the
NOTE: with the engine stopped,
the pressure gauges should read pressostat.
yes no
between 5 and 7 bars HP and LP
for a workshop temperature of Repair the electrical wiring
20/25°C. Repair the electrical wiring
between track 5 of relay 474 between track B3 of
Is this correct ? connector R34 and the fuse
and track C1 of the
pressostat. box.
yes no
Change the tri-

function pressostat.
Adjust the refrigerant level. e53531.1
62-19
AIR CONDITIONING
FAULT CHART N° 2D : No cool air
Test conditions :
- Passenger compartment fan operating
- AC on MAX.
Is the vehicle
X533
X536 model year 1989 or 1990 ? yes Refer to Chart 2E on the next page.
X537
no
Check for + 12 Volts on track 3 of the AC relay Repair the wiring between track 7 of the
(ref 690) . yes electronic thermostat unit and track 3 on the
Is this correct? AC relay.
no
Check the wiring between tracks :
Check for + 12 Volts on track 5 of the AC relay - 5 on relay 690 and A2 on black connector
Is this correct? no R99.
- A2 on black connector R99 and + 12 Volts
at the fuse box.
yes
Check + 12 Volts feed between tracks 1 and 2 of

relay 690. yes Change the relay.
Is this correct?
no
Repair the wiring between track 2 on relay 690
Check + 12 Volts on track 1 of relay 690. and track B4 on connector R99.
Is this correct? yes Track B4 on connector R99 and vehicle earth
M11.
no
Check + 12 volts on track A1 of connector R99. Repair the wiring between track A1 of
Is there + 12 Volts ? yes connector R99 and track 1 on relay 690.
no
Check for + 12 Volts on track B3 of control panel

connector 319 (On/Off info).
Passenger compartment fan operating and AC on Repair the wiring between track A1 on black
yes connector R99 and track B3 on the control
NORM.
Is this correct? panel.
no
Disconnect control panel connector 319 and check no Change the control panel.
the continuity between tracks B1 and B3 and
between tracks B1 and B4.
Passenger compartment fan operating and AC on Repair the earth on track A5 and + 12 Volts
NORM. yes on track B1 of control panel 319.
Is this correct?
e53531.1
62-20
AIR CONDITIONING
FAULT CHART N° 2E : No cool air - Only for vehicles X533 ; X536 ; X537 ; Model Year 1989 or 1990.
Check for + 12 Volts on track A2 of black Repair the wiring between track 7 of the
connector R99. yes electronic thermostat and track A2 of
Is there + 12 Volts ? connector R99.
no
Repair the wiring between track A2 of black

connector R99 and + 12 Volts on the fuse box.
e53531.1
62-21
AIR CONDITIONING
FAULT CHART N° 2F : No cool air
Test conditions :
- Passenger compartment fan operating
- AC on MAX.
Repair the wiring between track 30 on the

On brown connector R34, check for + 12 Volts on injection computer (track 13 for X53A AC
track D5. DELCO injection) and track D5 of brown
yes
Is this correct? connector R34.
If the fault persists, the injection computer is
at fault, preventing the AC system from
operating.
no
Check for + 12 Volts on track B4 of control panel Check the continuity between track B4 of
connector 319 (On/Off info). black control panel connector 319 and track
no
Is this correct? D5 on brown connector R34.
Repair the wiring.
yes
With the black control panel connector

disconnected, check the continuity between
no Change the control panel.
tracks : B1 and B4 - B1 and B3.
Is this correct?
yes
Repair the wiring between tracks :

- A5 of the control panel and earth M10.
- B1 of the control panel and the fuse box
(+after ignition).
62-22
AIR CONDITIONING
FAULT CHART N° 2G : No cool air
Test conditions :
- Passenger compartment fan operating at maximum speed
- AC on MAX.

Under these test conditions shunt the evaporator
sensor and check if the compressor operates and yes Change the evaporator sensor.
left hand bargraph 14 illuminates (right hand
bargraph 18 for X53A AC DELCO injection).
Does the compressor operate ?
no
Under these test conditions, check for

+ 12Volts on the brown connector
yes X53F, X53V, X538, X53C
R34 on track A5. Repair the wiring between
Is there + 12 Volts ? tracks :
Shunt the tri-function - A1 on pressostat and A5
no yes pressostat between tracks of brown connector R34.
A1 and C1 and check if the - C1 on pressostat and 30
no
All types X53F, X53C, compressor operates. Does on injection computer.
X53V, X538 the compressor operate ? If the fault persists, the
injection computer is at
yes fault, preventing AC
operation.
Repair the wiring between Press on a filling valve to see if
track A5 of the brown there is refrigerant in the
connector R34 and track 34 circuit. no Adjust the refrigerant level.
on the injection computer NOTE: with the engine
(track 14 for AC Delco). stopped, the pressure gauges
If the fault persists, the should read between 5 and 7
injection computer is at bars HP and LP for a workshop Change the tri-
yes
fault. temperature of 20/25°C. function pressostat.
Is this correct ?
Under these test conditions, check for + 12 Volts

on track B1 of the black connector R99 for the Repair the wiring between track B1 on the
yes component unit and track A5 on brown
component unit.
no
Check for + 12 Volts (still under these test

conditions) on track 5 of the electronic Repair the wiring between track 5 of the
yes electronic thermostat and track B1 of the black
thermostat.
no
Before changing the electronic thermostat,
Check for + 12 Volts (still under these test yes check the earth on track 6 and the shunt
conditions) on track 7 of the electronic between tracks 3 and 4.
thermostat.
Is there + 12 Volts ? no See Chart 2D.
e53531.1
62-23
AIR CONDITIONING
FAULT CHART N° 2H : No cool air
Test conditions :
- Passenger compartment fan operating at maximum speed.
- AC on MAX.
- Shunt the tri-function pressostat between A1 and C1.
- Ignition on.
Check the coolant temperature switch, it

Pressostat shunt still in place, shunt the coolant should be closed for an engine coolant
temperature switch between tracks 1 and 3 of the temperature < 105°C.
yes
black connector. Before changing the temperature switch,
Does the compressor operate? check that the engine is not overheating,
check the cooling system.
no
Check for + 12 Volts on track 1 of the coolant Repair the wiring between track C1 of the
temperature switch 248. no pressostat and track 1 of the coolant
Is there + 12 Volts ? temperature switch.
yes
Reconnect the coolant temperature switch. Repair the wiring between track 3 of the
Check for + 12 Volts on track 3 of relay 584 or 474 coolant temperature switch and track 3 of
no
on the compressor. relay 584 or 474.
yes
Check for + 12 Volts on track 4 of relay 584 or 474 Repair the wiring between track 4 of relay
on the compressor. yes
584 or 474 and the compressor.
no
Check for + 12 Volts between tracks 1 and 2 of Change relay 584 or 474 (it is stuck on track 5).
relay 584 or 474. no
yes
Check for+ 12 Volts on track 3 of the timer 635. Up to year of manufacture 93

Is there + 12 Volts ? no The PAS pressostat should be closed, check if
this is normal (strategy) or change the
pressostat.
yes After year of manufacture 93
There is a short circuit to +12volts between
track 1 of relay 474 and track 4 of timer 635.
A (See next page)
e53531.1
62-24
AIR CONDITIONING
FAULT CHART N° 2H (cont) : No cool air
Test conditions :
- AC on MAX.
- Ignition on.
Check for + 12 Volts on track 1 of timer 635.

Is there + 12 Volts ? yes Change timer 635.
no
Check for + 12 Volts between tracks 1 and 2 of

relay 661. no Change relay 661 (it is stuck on track 5).
yes
Check the adjustment and condition of the load

switch on the diesel injection pump and the
wiring continuity between :
- track 2 of relay 661 and B2 on the pump Repair the wiring or re-adjust the load switch
no
connector 589 or change the switch.
- track 2 of relay 661 and C2 on the pump
connector 589 (for X534, X53I and X53J).
Is this correct?
yes
Check the clutch switch 634 adjustment and the

insulation of the wiring from earth for tracks :
- 2 on the clutch connector and A2 on connector
R35.
- A2 of connector R35 and A2 of connector R34.
- A2 of connector R34 and track 2 of relay 661.
Repair the wiring if necessary.
e53531.1
62-25
AIR CONDITIONING
FAULT CHART N° 2I : No cool air
Test conditions :
- AC on MAX.
- Ignition on.
Shunt relay connector 474 Check for + 12 Volts on track:

between tracks 3 and 5. no - 3 for X53F,
Does the compressor operate? - 5 for X53A,
of relay 474. Is there + 12 Volts ?
yes
yes no no
X53F X53A
Repair the wiring Repair the wiring Repair the wiring

between: between track 3 of relay between track 5 of relay
- track 5 for X53F 474 and splice A in the 474 and + 12 Volts (fuse
- track 3 for X53A wiring of+ 12 Volts 20A) via the tri-function
of relay 474 and the after ignition for the pressostat (tracks
compressor. alternator. C1/A1).
Check for + 12 Volts between tracks 1 and 2 of

relay 474. yes Change relay 474.
no

- 1 on relay 474 and C7 on the brown connector
Check for + 12 Volts on track 1 of relay 474. R34.
Is there+ 12 Volts ? no - C7 of the brown connector R34 and the
+ 12 Volts after ignition of the ignition switch.
yes
Check the wiring continuity between track 2 of

relay 474 and track:
- 7 for X53F
- 22 for X53A (E7J 700)
of the injection computer.
If the fault persists, the injection computer is at
fault as it is preventing the AC system from
operating.
e53531.1
62-26
AIR CONDITIONING
FAULT CHART N° 2J : No cool air - X533 ; X536 ; X537 ; Model Year 1989 and 1990
Connection to component unit R99 disconnected, Disconnect the control panel connector and
ignition off, passenger compartment fan check the control panel continuity between
operating and AC on MAX. tracks B2 and B4 (passenger compartment fan
no
Check the wiring continuity between tracks A1 operating and AC on MAX).
and C4. Is this correct?
Is this correct?
no
yes yes
Check the wiring continuity between tracks : Repair the wiring between
the control panel and
R99 component connector R99.
unit C4 3 electronic
connection A1 4 thermostat B2 A1
Is this correct? B4 C4
yes no
Repair the wiring. Change the control

panel.

- 6 on the electronic thermostat and B4 on
Check the earth on track 6 of the component unit connector R99.
the electronic thermostat. no - B4 on connector R99 and the vehicle earth
Is this correct? M11.
yes
Change the computer.
e53531.1
62-27
AIR CONDITIONING
FAULT CHART N° 2K : No cool air - X53A (E7J 745) - X535 (E7J 742) vehicles

Put the passenger compartment fan and the AC no See Chart 2G
on max.
Do left hand bargraphs 17 and 18 illuminate?
yes
The injection computer is preventing

Does right hand bargraph 18 illuminate? no operation of the air conditioning. Look for a
possible cause (strategy) or change the
yes injection computer.
Is there + 12 Volts ? yes of relay 474 and the AC
compressor. Repair.
no Check for + 12 Volts on

Check for +12 Volts on track B3 of the grey
track A1 of tri-function connector R34.
Is there + 12 Volts on track 5 pressostat connector.
no no Fan and AC on max.
of relay 474 ? Is this correct? Is this correct?
yes
yes no yes
Shunt the tri-function pressostat Repair the wiring

between tracks A1 and C1 and check between track B3
that the compressor operates. of connection R34
Does the compressor operate?
Check for + 12 Volts between tracks 1 and track A1 of the
and 2 of relay 474. pressostat.
yes no
no yes Repair the wiring Repair the wiring between

between track 5 of relay track B3 of connection R34
474 and track C1 of the and the fuse box.
Change relay 474.
pressostat.
Check the wiring between : Press on a filling valve to see if

- track 2 of relay 474 and track 22 on there is refrigerant in the circuit.
the computer NOTE: with the engine stopped,
- the shunt between track 1 and the pressure gauges should read
track 5 of relay 474 (X53D) between 5 and 7 bars HP and LP for no Adjust the
Repair if necessary. a workshop temperature of refrigerant level.
20/25°C.
Is this correct ?
yes
Change the tri-function pressostat.
e53531.1
62-28
AIR CONDITIONING
FAULT CHART N° 3 : Air too cold
Is the compressor Disconnect the Before changing the electronic

no no
operating? evaporator sensor. thermostat, check there is no short
Is the compressor - circuit :
yes
stopped? - For X53Z ; X533 ; X534 ; X536 ;
X537 ; X53G ; X53H ; X53J ;
yes X53K between track 5 on
Is the compressor still
engaged? (normal if HP ≥ 19 thermostat and the compressor.
bars or engine coolant Check the evaporator - For X538 ; X53A ; X53C ; X53D ;
temperature >92°C sensor resistance. X53F ; X53V ; X53Y ; X535
Is this correct? between track 5 on thermostat
no yes and track 34 on injection
yes no computer (track 14 for 53A AC
DELCO injection).
Connect the pressure Change the evaporator Also check that the computer is
gauge and check the sensor. not permanently earthing track :
pressostat pressures (411). - 22 for X539 ; X53A ; X53C ;
HP 16/19 bars ± 1.5 bar. X53D ; X53Y BOSCH injection.
Change the pressostat if - 9 for X53A AC DELCO injection
necessary. Change the electronic
- 23 for X538 and X53V
thermostat unit. - 7 for X53F
- 20 for X535
Check the evaporator sensor
resistance.
NOTE: If the setting is below the
min. threshold, the compressor no Correct
will operate late.
Change the sensor if necessary.
Does the fault persist ?
yes
Check that the recycling flap is not

stuck in the recycling position.
Move the control switch with AC - Model Year 1989 and 1990 : see chart 4A
no - Model Year 1991 onwards : see chart 4B
on MAX and check if the flap
moves.
Does the flap move?
yes
Check that moving the heating

control moves the mixing flap. no See Chart 8.
Does the flap move?
yes
Visually check on the assembly

that the flap moves correctly.
Re-adjust if necessary.
e53531.1
62-29
AIR CONDITIONING
FAULT CHART N° 4 : Recycling flap does not operate
Year of manufacture 1989 and 1990
Check that the connectors are connected

no Repair.
correctly. Is this correct ?
yes
Remove the recycling relay 475 and check if the

yes recycling flap is stuck.
Is it stuck?
yes no
92034R1
With the passenger compartment fan operating,

Repair. Change the motor
check on the terminals of the recycling motor that;
- Knob A on NORM there is+ 12 Volts
- Knob A on MAX there is - 12 Volts
(a difference in polarity should be noted).
Is this correct?
no no
no
0 Volts read in both No polarity difference between the 2 12 Volts in 1 position, 0 Volts in the
positions. positions. other.
Permanent + 12 Volts.
Repair the shunts on recycling relay

Refer to Chart 4A on following page. (417) between tracks :
- 2 and 3
Open component unit (419) and - 1 and 4
check for + 12 Volts on track 5 Retest.
yes Is this correct?
of relay 417.
Is this correct?
yes no
no
Correct Change recycling
relay 417.
Repair the wiring between : Repair the wiring between :

- track 5 on the recycling relay and track 7 on - track 7 of relay 417 and track 6 on the
the electronic thermostat (19). electronic thermostat
- track 7 on the thermostat and track A2 on - track 6 on the thermostat and track B4 on
connector R99 connector R99
- Track A2 on the connector R99 and the fuse - track B4 on connector R99 and the vehicle
box. earth M11
Retest. Retest.
Does the recycling motor operate? Does the recycling motor operate?
no yes no yes
Correct Correct
e53531.1
62-30
AIR CONDITIONING
FAULT CHART N° 4A : Recycling flap does not operate
Passenger compartment fan operating and AC on

MAX.
Check for + 12 Volts on relay 417 between tracks yes Change the recycling motor relay 417.
5 and 6.
no
Check the continuity between tracks :

- 6 of relay 417 and B3 of connector R99
- B3 of connector R99 and B3 of the control
no Repair the wiring.
panel 319.
Is this correct?
yes
Passenger compartment fan operating and AC on

MAX.
Disconnect the control panel connector 319 and
no Change the control panel.
check the continuity between tracks B3 and A5 on
the control panel side.
Is this correct?
yes
Repair the wiring between track A5 on the control

panel connector and the vehicle earth M10.
e53531.1
62-31
AIR CONDITIONING
FAULT CHART N° 5 : Recycling flap does not operate
From year of manufacture 1991
Passenger compartment fan operating, AC on

MAX. Check for +12 Volts on connector R99 between
Check for + 12 Volts between track A3 and no
tracks A2 and B4. (A2=+12 Volts, B4 = earth).
track A1 of the recycling motor connector. Is there + 12 Volts ?
Is there+ 12 Volts ?
yes no
yes
Repair the wiring between :

Under these conditions, check Repair the shunt - track B4 on connector R99
for + 12 Volts on track B1 of between tracks A1 and and earth M11
the motor connector. yes
B1 of the recycling - track A2 on connector R99
Is this correct? motor connector. and + 12 Volts after ignition.
yes
Repair wiring between tracks:

Passenger compartment fan - A2 of connector R99 and 5 of relay 690
operating, AC on MAX. Remove the - 5 of relay 690 and B1 of the recycling
Check for + 12 Volts between recycling motor motor connector.
yes
tracks B3 and B1 (relay coil) (on 475 and check if - the shunt between A1 and B1 of the
the recycling motor connector). the flap is stuck. connector for the recycling motor.
Is this correct? - B4 of connector R99 and A3 of the
yes connector for the recycling motor .
no
no
Repair.
Check the continuity between

track B3 of the recycling motor Change motor 475.
connector and track B3 of black
connector R99.
no Correct
yes
Passenger compartment fan operating, AC on MAX. Disconnect

Check the continuity between the control panel connector and check on the control panel side,
track B3 of the black connector yes
that the continuity between tracks B2 and A5 is correct.
R99 and track B2 of the control Is this correct?
panel connector 319.
Repair if necessary. yes no
Change the
no Repair the wiring between control panel.
track A5 of control panel
connector 319 and the vehicle
earth M10.
Correct
e53531.1
62-32
AIR CONDITIONING
FAULT CHART N° 6 : Engine cooling fan only operates slowly
Is the fuse sound? no Change the fuse.
yes
Passenger compartment fan operating, AC on

MAX, engine idling. Change the engine cooling
yes
Check the + 6.5 Volts feed between tracks 1 and 2 fan.
for the engine cooling fan.
Is there+ 6.5 Volts ? * * If the high pressure in the refrigerant circuit
is greater than 19 bars the voltage is + 12
no Volts.
Connect the HP and LP pressure gauges to the

Shunt the pressure pressostat between tracks B1 AC circuit (filling point). Passenger compart-
and B2. ment fan operating, AC on MAX.
Does the engine cooling fan operate at top yes Check the setting of the fan control pressostat.
speed? - HP ≥ 19 bars : the fan operates at high
speed
no - HP ≤16 bars : the fan operates at low
speed.
NOTE : The fan also operates for an engine co-
olant temperature ≥ 92°C.
Is the pressure > 19 bars ?
no yes
A
Change the tri-function
pressostat.
(See next page)
Under the same test conditions, engine idling.

If the HP is low and does not reach the setting
value for the pressostat, check for bubbles in
the dehydrating bottle. In this case there is a
lack of refrigerant in the circuit.
Re-adjust the refrigerant level.
e53531.1
62-33
AIR CONDITIONING
FAULT CHART N ° 6 (cont) : Engine cooling fan only operates slowly
Repair the wiring

between track 5 of
Shunt relay 336 between tracks 3 and 5. Check for + 12 Volts on the relay and the
no no
Does the fan operate at high speed? track 5 of relay 336. alternator or the
Is there + 12 Volts ? battery.
yes
yes
Repair the wiring between

track 3 of relay and the
cooling fan.
Check for + 12 Volts between tracks 1

and 2 of relay 336. yes Change relay 336.
no

- 1 on relay 336 and D1 on brown
Is there+12 Volts on track 1 of no
connector R34.
relay 336 ? - D1 on connector R34 and the fuse box.
yes

- 2 on relay 336 and B2 on tri-function
pressostat.
- B1 on the pressostat and the vehicle
earth.
e53531.1
62-34
AIR CONDITIONING
FAULT CHART N° 7A : Passenger compartment fan does not operate
Year of manufacture 1989 and 1990
Check the passenger compartment

fan fuse(s).
no Correct
yes
Check the + 12 Volts feed between

the fan terminals.
yes Change the passenger compartment fan.
Is this correct?
no
With the passenger compartment Check for + 12 Volts

Check for +12 Volts on on connector R99 for
fan operating, shunt the relay track 30 of relay 234 for
connector 234 for the fan between the component unit
no the passenger no between tracks:
tracks 30 and 87. compartment fan.
Does the fan operate? - A3 and earth
Is there + 12 Volts ? - C2 and earth
yes
yes
yes no
See Chart 7C
Repair the wiring
Check for+ 12 Volts between tracks Change relay 234 for between tracks :
85 and 86. yes the passenger - A3 of
Is there + 12 Volts ? compartment fan connector R99
and the fuse
no box.
- C2 of connector
R99 and the fuse
Check for + 12 Volts between track Repair the wiring between box.
85 of relay 234 for the passenger tracks :
yes
compartment fan - 86 on relay 234 and 7 on
Is there+ 12 Volts ? relay 417. Repair the wiring
- 7 on relay 417 and 6 on the between tracks :
no electronic thermostat. - A3 on connector R99
- 6 on the electronic and track 30 on relay
thermostat and B4 on 234
Repair the wiring between tracks : connector R99 for the - C2 on connector R99
- 85 on relay 234 for the passenger component unit and track 30 on relay
compartment fan and track B3 on the - B4 on connector R99 for the 234.
electronic module. component unit and the
- B3 on the electronic module and track 5 on vehicle earth M10.
relay 417.
- 5 on relay 417 and 7 on the electronic
thermostat.
- 7 on the electronic thermostat and A2 on
connector R99 for the component unit.
- A2 on connector R99 for the component
unit and the fuse box
e53531.1
62-35
AIR CONDITIONING
FAULT CHART N° 7B : Passenger compartment fan does not operate
From year of manufacture 1991
Check the passenger compartment fan fuse(s).

no Correct
yes
Check the + 12 Volts feed between the fan

terminals. yes Change the passenger compartment fan.
Is this correct?
no
Check for +12 Volts on Check for + 12 Volts on

With the passenger track 30 of relay 234 for connector R99 for the
compartment fan operating, the passenger component unit between
shunt the relay connector 234 no no tracks:
compartment fan.
for the fan between tracks 30 Is there + 12 Volts ? - A3 and earth
and 87. - C2 and earth
Does the fan operate? Is there + 12 Volts?
yes
no yes no
See Chart 7C on following page

Repair the wiring
between tracks :
Check for+ 12 Volts between Change relay 234 for - A3 of connector
tracks 85 and 86. yes the passenger R99 and the fuse
Is there + 12 Volts ? compartment fan. box.
- C2 of connector R99
no and the fuse box.
Repair the wiring between
tracks:
Check for + 12 Volts - 86 on relay 234 and B4 on
between track 85 of relay connector R99 for the
234 for the passenger yes
component unit (use the
compartment fan. appropriate wiring diagram
Is there+ 12 Volts ? for the vehicle in question).
- Track B4 of connector R99 X538 ; X539 X533 ; X534
no X53A ; X53C X536 ; X537
and the vehicle earth M11.
X53D ; X53Y X53F ; X53H
X535 ; X53V X53I ; X53J
X53G ; X53Z X53K
Repair the wiring between tracks : Repair the wiring Repair the wiring
- 85 of relay 234 for the fan and track A2 of between : between tracks:
connector R99 for the component unit (use - A3 and C2 shunt on - A3 on connector R99
the appropriate wiring diagram for the connector R99. and 30 of relay 234.
vehicle in question). - A3 on connector R99 - C2 on connector R99
- A2 of connector R99 and +12 Volts fuse and 30 of relay 234. and 30 of relay 234.
box.
e53531.1
62-36
AIR CONDITIONING
FAULT CHART N° 7C : Passenger compartment fan does not operate
Check for + 12 Volts between the Repair the wiring between track
positive terminal of the passenger 87 of relay 234 for the passenger
no compartment fan and the
compartment fan and the vehicle earth.
Is there+ 12 Volts ? passenger compartment fan.
yes
X533 ; X534 ; X536 ; X538 ; X539 ; X53A ;

X537 ; X53F ; X53H ; X53C ; X53D ; X53Y ;
X53I ; X53J ; X53K ; X53V ; X535 ; X53G ; X53Z
Check the continuity between

Check the continuity between the passenger compartment
the passenger compartment fan earth and the shunt for
fan earth and tracks A4 and B5 no Repair the wiring. no
tracks A4 and B5 of the
of the electronic module 6. electronic module 6.
Is this correct? Is this correct?
yes
yes
Check for + 12 Volts on Repair the wiring between tracks :

track B3 of the electronic - B3 of the electronic module 6 and the fuse box.
module and earth on track no - tracks B1 and A2 of the electronic module 6 and
A2 and track B1. the vehicle earth (use the vehicle wiring diagram in
Is this correct? both cases)
yes
Check for a voltage of 0 to 12

Volts on the electronic module Check for + 12 Volts
connector on track A1, between tracks B4
depending on the passenger yes and B3 of the yes Change the electronic module
compartment fan control knob electronic module .
position. Is there+ 12 Volts ?
Do you read a voltage?
no
no
A (See next page ) B
e53531.1
62-37
AIR CONDITIONING
FAULT CHART N° 7C (cont) : Passenger compartment fan does not operate
A B
On the control panel connector With the control panel Change control panel 319.
319, check for 0 to 12 Volts on connector disconnected, check no
track A1 , which is dependent on between tracks A1 and A2 that
the position of the control knob the voltages in the table below
for the passenger compartment are correct (dependent on fan Repair the wiring between
fan. control knob position). tracks :
Do you read a voltage? - 0 > 50000 Ω - A2 on control panel
- 1 = 2900 to 3600 Ω and B2 on connector
yes no - 2 = 2200 to 2600 Ω R99 for the
- 3 = 1400 to 1700 Ω component unit.
- 4 = 750 to 900 Ω - B2 on connector R99 for
- 5 = 300 to 400 Ω yes the component unit and
- 6 = 0 to 1 Ω B4 on the computer.
Is this correct ?
Repair the wiring between Check feeds for control

tracks : panel 319.
- A1 on the control panel - Earth on track A2. no Change the control panel.
and A4 on the black - + 12 Volts after ignition
connector R99 for the on track B1
component unit. Is this correct ?
- A4 on the component
unit and A1 on the
yes
electronic module.

- A5 on the control panel and earth
M10.
- B1 on the control panel and + 12
Volts after ignition for the fuse
box.
e53531.1
62-38
AIR CONDITIONING
FAULT CHART N° 8 : Air distribution problem
Set the passenger compartment fan on maximum Air distribution is correct. Return to the
and the temperature control on fully cold (blue customer and explain the operation of the
spot). yes system in detail,
Move the air distribution control and check that Eg : close ventilators to improve de-icing, ...
the air is being ventilated correctly.
Is this correct?
no
Visually check that moving the control moves the

flap.
yes Re-adjust the cable.
Does the flap move ?
no
Check that the cable is correctly connected to the

control panel and the assembly.
no Correct
yes
Check the moving parts on the assembly (pinions, Repair if possible otherwise
levers). no change the assembly or the
Are these correct? control panel.
yes
Remove the assembly, check the air distribution

flaps and change the assembly if necessary.
e53531.1
62-39
AIR CONDITIONING
FAULT CHART N° 9A : Air flow problem (air distribution control in position )
For testing, position the temperature control on max. hot and the AC control on 0.
Check the operation of the passenger

compartment fan at all speeds. no See Charts 7A and 7B
Is this correct?
yes
Check the air intake circuit from the scuttle panel,

the heating member (water box)...
no Correct
yes
Check the air extraction circuit.

Repair if necessary. no Correct
yes
Remove the heating assembly; the heating

radiator is probably blocked.
Clean or change the heating radiator.
e53531.1
62-40
AIR CONDITIONING
FAULT CHART N° 9B : Air flow problem (air distribution control in position )
For testing, position the temperature control on max and the AC on 0.

Is this correct?
yes

no Correct
yes
Check the operation of the recycling flap.

no See Charts 4 and 5.
Is this correct?
yes

yes
Check that the de-misting / de-icing ducts are

correctly connected.
no Correct
yes

e53531.1
62-41
AIR CONDITIONING
FAULT CHART N° 9C : Air flow problem (air distribution control in position and when the air
temperature control is on max. heat).
For testing, position the AC control on 0 and open all the dashboard ventilators.

Is this correct?
yes

the heating member (water box)... no Correct
yes

yes
Check that the ventilation ducts are correctly

connected. no Correct
yes

e53531.1
62-42
AIR CONDITIONING
FAULT CHART N° 9D : Air flow problem (air distribution control in position and when the air
temperature control is on max. cold)
For testing, position the AC control on 0

Is this correct?
yes

yes

yes
Check that the ventilation ducts are correctly

connected.
no Correct
yes

e53531.1
62-43
AIR CONDITIONING
FAULT CHART N° 10 : Controls difficult to operate
Check the cable path: stop the cable catching,

no Correct
kinking or rubbing on collars etc, ...
Change the cable if necessary.
yes
Unhook the cable from the control panel or the Change the control panel or the heating /
assembly and check the operation of the control ventilation assembly.
no
knob and the flap (mixing or distribution). (If the flap is difficult to operate).
Is this correct?
yes
If the controls are very difficult to operate, inform

your local After Sales Head Office (For UK, contact
the Technical Services Department).
e53531.1
62-44
AIR CONDITIONING
FAULT CHART N° 11 : Smells in passenger compartment
Check that the air extraction outlets are not

blocked.
no Correct
yes
Check that the heating member is correctly

sealed (water box) and the bonnet is sealed
from the passenger compartment.
no Correct
(Seals, plugs, bonnet, ...)
Is the smell present in

yes no
position (max. heat)?
Check the operation of the air recycling flap yes

which may be stuck in the recycled air position.
no Correct
Remove the heating assembly

yes and check the radiator
condition (dirty, leaking anti-
freeze, poor de-greasing...).
Is the smell in position (max. cold) ? Repair or change the heating
no radiator.
yes no
yes Correct
Set the AC on MAX and the passenger
compartment fan on slow and use the
refrigerant detector in the central ventilator to Change the
no
check that there is no refrigerant leak. evaporator.
Is this correct?
If the vehicle is new, the smell

yes may be caused by the
evaporation of solvents,
plastifiants ...
Remove the evaporator unit and check that it is

not dirty (leaves, insects, ...), and check the
seals.
Clean or change the evaporator unit.
e53531.1
62-45
AIR CONDITIONING
FAULT CHART N° 12 : Water in the passenger compartment
Check that the leak is not coming from the

heating radiator.
no Correct
Change the radiator if necessary.
yes
Check that the evaporator unit and the low

pressure pipe are thermally insulated (if they pass
inside the passenger compartment). no Correct
yes
Check the condensation drain tube.

Check that the water is running away to the
outside.
no Correct
Set the AC on NORM. and check that water is
coming from under the vehicle.
Repair if necessary. Does the fault persist?
yes
If the customer is complaining of droplets of

water coming from the central ventilators or from
the front footwell vents, the evaporator may be The leak is not from the air
no
icing up. conditioning system
Are water droplets coming from these vents ?
yes
Test the air conditioning system : set the AC on

MAX, passenger compartment fan on max.,
windows and doors closed, measure the
temperature of the air blown from the central
ventilators; it should be ≥ 2°C when the
compressor is operating. If it is lower, the
evaporator may ice up.
Change the evaporator sensor or the electronic
module.
e53531.1
62-46
AIR CONDITIONING
Operating diagram 62
OPERATING DIAGRAM - AIR CONDITIONING CUT-OUT ( Diesel and Turbo Diesel Versions)
PRJ95707
171 Air conditioning clutch

257 Pre-heating unit
405 Pump load lever switch
412 Accelerated idle solenoid valve
421 Clutch pedal switch
584 AC compressor clutch relay
589 Injection pump
635 AC cut-out timer relay
661 AC cut-out timer control relay
+ after ignition (on relay 584) fed by double threshold temperature switch
62-47
AIR CONDITIONING
Consumables 62
COMPRESSOR OIL :
• ELF RIMA 100 : for circuit with refrigerant R12
• SANDEM SP 20 : for circuit with refrigerant R134a
REFRIGERANT FLUID :
• R12
• R134a
REFRIGERANT QUANTITY (in grammes) :
• R12
Model Year
(up to 1 st July/ FRANCE)
Type 1992 1993
X533 F2N 850 1050
X536 850 850
X537 E6J 1050 1050
X53C F3N 850 750
X53H 1050 -
X53F F3N 850 750
X53G E6J 1050 1050
X534 F8Q 1050 1050
X53J F8Q 1050 1050
X53A E7J - 1050
X53D F7P - 850
X53Y F3P - 750
X538 F3N - 750
X53K F8QT - 850
X53T F8QT - 850
• R134a : 800 ± 50 grammes
62-48
AIR CONDITIONING
R12 / R134a conversion 62
Following the ban on the production of R12 refri-
gerant from 31 December 1995 onwards, and in
order to assure the operation and maintenance of
vehicles which contain this refrigerant, the follo-
wing recommendations apply to all vehicles in
the range.
NEW VEHICLES USED VEHICLES
No conversion may be carried out on a new vehi- Foreword:

cle containing R12 before it is sold.
Vehicles whose refrigerant circuits operate using
Even if the "R12/R134a conversion" operation R12 must only be converted to R134a if there is no
does not affect its reliability, it will alter the per- R12 available. Otherwise, filling the circuit with
formance and level of operating noise of the air the refrigerant for which it was designed is still
conditioning system. preferable.
These vehicles can only be made correct to specifi-

cation by changing the entire system. General information:
That is: the compressor, the condenser, the dehy-
drating bottle, the pressure relief valve, the eva- Before adapting the vehicle, it is advisable to
porator, the pipes and the seals. check the operation of the air conditioning
system.
Any component of the refrigerant circuit which is
found to be faulty must be changed.
Any O-ring seals which are removed at this point
must be changed.
For any work on the vehicle’s refrigerant circuit

following its conversion to R134a:
- only use refrigerant R134a and SANDEN SP 20
oil,
- fill in the information card accurately (refer to
the "Vehicle conversion procedure" section).
IMPORTANT: when ordering replacement parts

following conversion, retain the criterion "R12"
when making your selection.
NOTE: you may receive parts marked "R12" or

"R134a" until standardisation of the parts has
been completed.
62-49
AIR CONDITIONING
VEHICLE CONVERSION PROCEDURE
1. Retrieve the R12 refrigerant contained in the 2. Disconnect the R12 filling-retrieval point.
vehicle’s refrigerant circuit then create a va-
cuum using the filling-retrieval point suitable 3. Change:
for this gas. - the dehydrating bottle (the parts supplied
can now be used with R12 and R134a).
IMPORTANT: it is advisable to take great care - the seals using kits:
during this operation in order to minimise the 77 01 204 314 .
quantities of R12 and mineral oil (ELF RIMA
100) remaining in the circuit. 4. Connect the R134a filling-retrieval point and
create a vacuum in the circuit.
In order to improve retrieval, start the vehicle
and operate the air conditioning system in re- NOTE: as the vehicle circuit filling valves are
cycling mode, with a low passenger compart- not compatible with the R134a point end
ment fan speed, until the compressor has cut pieces, conversion and marking components
in twenty times (10 to 15 minutes of opera- must be fitted to the vehicle (kit 77 01 204
tion). 882).
If DIAVIA AT 41 166 type filling equipment, or

equivalent, is available, retrieval of the oil and
separation of the refrigerant is automatic.
Otherwise, the compressor must be removed

and drained of its mineral oil, refer to the pro-
cedure in the "Compressor oil level" section.
62-50
AIR CONDITIONING
CONVERSION 5. Filling with oil: 135 cc of SANDEN SP 20 oil:
- if one of the filling-retrieval points mentio-
a) Remove the vehicle filling valve caps. ned is available, filling with oil is via the ma-
chine,
b) Remove the blanking pieces (1) from the vehi- - if the equipment available is not suitable for
cle valves using a conventional blanking piece the filling procedure, the compressor must
remover (for wheel valves). be removed in order to fill it with oil.
c) Fit the markers (2) around the filler valves. 6. Fill the circuit. Fill the refrigerant circuit with
800 ± 50 g.
d) Coat the thread of adaptors (3) and (4) with
LOCTITE FRENBLOC and screw them to the fil- 7. Check that the air conditioning system ope-
ler valves. rates correctly.
High pressure: 8. To eliminate any risk of filling the circuit with

⇒ small vehicle pipe, refrigerant R12 during subsequent operations,
⇒ 16 mm diameter adaptor (3). affix a grid containing an information label
around the pipes, as close as possible to the
Low pressure: filler valves (date of conversion, type and
⇒ large vehicle pipe, quantity of the new refrigerant and oil, etc...).
⇒ 13 mm diameter adaptor (4). (Label : 77 11 178 677 (technical documenta-
tion part number).
Grid: 49 39 125 600 (stationary part number)).
Tightening torque: 1 daN.m.
e) Replace the vehicle caps with those supplied

with the adaptors (5).
98880R
62-51
AIR CONDITIONING
LABEL
Example of the information label to be ordered and to be affixed close to the filler valves:
AIR CONDITIONING
This vehicle has undergone the: "R12 / R134a" Conversion
Date of conversion:
Quantity of R134a : Quantity of SANDEN SP 20 oil:
Parts changed at time of conversion and subsequently:

Parts Dates Parts Dates
Dehydrating bottle Pipes:
Condenser - Dehydrating bottle-pressure release valve
Evaporator - Pressure relief valve-compressor
Pressure relief valve - Compressor-condenser
Compressor - Condenser-dehydrating bottle
THIS VEHICLE CAN NO LONGER USE REFRIGERANT TYPE R12 77 11 178 677
REMINDER: Following R134a conversion, the cold circuit must be filled with 800 ± 50 g of refrigerant.
62-52
AIR CONDITIONING
Fan unit 62
REMOVAL Drain the refrigerant circuit from the filling point.
Disconnect the battery. Disconnect the refrigerant pipes from the

pressure relief valve (bolt D ).
Remove:
- the transverse bar between the shock absorber
housings,
- the AEI (integral electronic injection) (for
carburettor versions) or the MPA (ignition
power module) (for injection versions),
- the coolant reservoir cover (5 bolts A ).
92286R
Separate the air conditioning unit from the

ventilation body (3 bolts B ).
92287-1R
Disconnect the connector from the component

unit.
92285R
92284R2
62-53
AIR CONDITIONING
Fan unit 62
Remove:
- the air conditioning unit mounting bolt (C) after removing the component unit.
92284R
- the air conditioning unit and the ventilation unit separately having removed the two ventilation unit
mounting bolts under the dashboard (left hand side).
92420S
REFITTING
There are no special notes for refitting. Check that all seals are in good condition.
62-54
AIR CONDITIONING
Evaporator 62
REPLACEMENT Remove the evaporator.
The fan unit must be removed before changing When refitting, check that the connection pipes
the evaporator. are not touching anything (noise).
Remove: Refitting is the reverse of removal.

- the twelve clips (1) on the 1/2 housing and the
three bolts (2), Torque tighten the bolts connecting the
evaporator to the pressure relief valve to
1 daNm (ensure that the seals are in good
condition).
Fill the refrigerant circuit at the filling point.
REMINDER: refer to the "Consumables" section

for the required amount of refrigerant.
IMPORTANT: When changing the evaporator, add

approximately 30 cm3 of ELF RIMA 100 oil to the
compressor (approximately.1/4 glass) (refer to
the "Consumables" section for the type of oil to
be used).
WARNING
AIR CONDITIONING
R12 / R134a conversion
92391R Following the ban on the production of R12 refri-
- the pressure relief valve (bolt L). vehicles which contain this refrigerant, refer to
the "R12 / R134a conversion" section.
92392R
62-55
AIR CONDITIONING
E ENGINE
Compressor 62
REMOVAL
Drain the refrigerant circuit (See method in ”Air

Conditioning” manual).
Undo the two bolts (A) and slacken the

compressor drive belt using bolt (B).
Remove the belt.
Disconnect the compressor feed (+ 12 V) (C).

96180R
- the oil filter,

- the nut and the spring on the exhaust flange
on the manifold (compressor side),
- the upper compressor mounting,
- the compressor.
IMPORTANT : The compressor pipes do not need

to be removed when removing the engine and
transmission assemblies.
Remove the upper and lower mountings and put
the assembly to one side.
96179R
Remove:
- the compressor refrigerant pipes,
- the front right hand wheel,
- the lower compressor mounting (D),
62-56
AIR CONDITIONING
F ENGINE
(petrol) Compressor 62
REMOVAL Disconnect the + 12 Volts compressor feed.
Disconnect the battery. Remove:

- the retaining bolt (C) holding the refrigerant
Drain the refrigerant circuit (See method in ”Air pipes on the compressor,
Remove:
- the alternator,
- the alternator mounting (A).
This operation may only be carried out after

removing the lower mounting nut and stud (B).
92282R
- the four compressor mounting bolts (D) and

remove the compressor (the 4th bolt is behind
the compressor).
96181R
96182R
96183R
62-57
AIR CONDITIONING
F8Q ENGINE
Compressor 62
REMOVAL
Drain the refrigerant circuit (See method in ”Air

Remove the alternator belt.
Disconnect the alternator electrical connections.
Remove:
- the belt tensioner completely (1),
- the front right hand side headlight and
headlight embellisher, so that the alternator
mounting shaft may be removed (2),
- the alternator.
95734R
Remove:
- the engine undertray,
- the front right hand wheel,
- the mud guard in the front right hand wheel
arch,
- the lower compressor mountings.
95732R
Then remove :
- the power-assisted steering pump pulley,
- the belt guide wheel (3).
Loosen the alternator mounting.
95733R
62-58
AIR CONDITIONING
F8Q ENGINE
Compressor 62
Tilt the compressor and remove the alternator
mounting.
Disconnect the + 12 Volts compressor feed.
Remove:
- the two refrigerant pipes from the compressor
(4),
- the compressor.
96176R
WARNING
AIR CONDITIONING
vehicles which contain this refrigerant, refer to
62-59
AIR CONDITIONING
F ENGINE
(petrol) Compressor 62
REFITTING
When refitting: if the compressor is changed, it is

supplied from the parts department filled with oil.
Before refitting, check the oil level.
Check that all the seals and pipes are in good

condition.
Torque tighten the bolts holding the refrigerant

pipes to the compressor to 3.5 + 0.5 daNm.
0
WARNING
AIR CONDITIONING

When the compressor is changed subsequent to

the R12 / R134a conversion, the oil must be
removed from the compressor supplied and it
must be filled with SANDEN SP 20 oil (for specific
use with R134a).
62-60
AIR CONDITIONING
Compressor oil level 62
SD 508 COMPRESSOR Top up the compressor by injecting 120 cm 3 (15
cm3 remains in the compressor body even after
To check the oil level correctly, the testing gauge draining, approximately 1 glass) of oil (example:
must be made. ELF RIMA 100 or other depending on the
refrigerant; refer to the "Consumables" section.
The oil level on the gauge should be 14 to 16 mm,
when the compressor is removed. Refit the drain plug ensuring the seal and the
sealing surface are clean (torque tighten to
IMPORTANT: If a pipe bursts, the oil level must be 1 daN.m).
topped up.
Refit the compressor.
Fill the circuit with R12 or R134a refrigerant (refer

SD 709 COMPRESSOR to the "Consumables" and "General" sections).
The compressor must be removed.
Unscrew and remove the oil plug (A).
WARNING
AIR CONDITIONING
95124R
Turn the compressor over and let the oil drain out
(to drain all the oil out, turn the compressor by
hand).
62-61
AIR CONDITIONING
Condenser 62
Disconnect the engine cooling fan feed connectors.
Remove the upper engine coolant radiator mountings (J).
Remove the radiator and condenser assembly upwards.
Remove the condenser bolt (M).
WARNING
AIR CONDITIONING
92559R
There are no special notes for refitting except

when fitting the pipes on the condenser,
WARNING
remember to oil them and support them using a AIR CONDITIONING
spanner. R12 / R134a conversion
Refit all components removed. Following the ban on the production of R12 refri-
Top up the engine cooling circuit (see order to assure the operation and maintenance of
corresponding section). vehicles which contain this refrigerant, refer to
IMPORTANT: when changing the condenser, add

approximately 30 cm3 of oil to the compressor
(example: ELF RIMA 100 or other depending on
the refrigerant; refer to the "Consumables"
section.
62-62
AIR CONDITIONING
Condenser 62
REPLACEMENT
Drain the refrigerant circuit (see method in ”Air

Remove the refrigerant pipes (G) and (H) from

the condenser (hold on the condenser side with a
spanner as the pipes are delicate).
92279R
92280R
62-63
AIR CONDITIONING
Pressure release valve 62
REPLACEMENT When refitting, ensure that the pipe seals are in
good condition.
Drain the refrigerant circuit from the filling point
(see method in ”Air Conditioning” manual). Torque tighten the bolts to :
- bolt K 1 daN.m
Remove: - bolt L 1 daN.m
- the pipe mounting bolt (K),
- the two bolts (L) holding the pressure relief Fill the refrigerant circuit at the filling point.
valve on the evaporator.
WARNING
AIR CONDITIONING
92286R1
62-64
AIR CONDITIONING
Dehydrating bottle 62
REPLACEMENT
Drain the refrigerant circuit from the filling point

(see method in ”Air Conditioning” manual).
Disconnect the pipes (N).
92280R1
When refitting, oil the threads using compressor

oil and check that the seals are in good condition.
WARNING
AIR CONDITIONING
62-65
AIR CONDITIONING
Electrical controls 62
PASSENGER COMPARTMENT FAN (320) Use a screwdriver to push the three rubber
retaining pins back which hold the motor in the
The fan unit must be removed in order to change housing.
the fan.
Remove:
- the rubber cover over the engine connections
and remove the 2 feed wires (use a soldering
iron of at least 50 W),
- the 9 clips and separate the 2 half cowlings of

the ventilation unit (cut the foam seal).
92389S
Remove the motor by pulling out as shown below.
92388S
92390R
When refitting, remember to re-solder the motor

connections.
62-66
AIR CONDITIONING
ELECTRONIC MODULE (6) RECYCLING MOTOR (475)
The fan control module is mounted on the body The fan unit must be removed to reach the
of the air conditioning unit in the water box. recycling motor.
Remove the coolant reservoir cover to reach the Remove the 2 mounting bolts on the recycling
module (5 bolts A ). unit.
The motor is not set in any particular position and

does not need to be adjusted when refitted.
92287-1R1
It is mounted with 2 bolts on the air conditioning

unit. 92395R1
92287R1
62-67
AIR CONDITIONING
COMPONENT UNIT (419) EVAPORATOR SENSOR (408)
This is located in the water box, held by a strap The evaporator sensor is mounted on the body of
(P) on the body of the ventilation unit. the air conditioning unit in the water box.
Remove the water box cover to reach the sensor

(see method for removing the electronic module
page 62-67).
92393R
92284R1 When removing, lift the indexing tab and turn the
unit 1/4 turn to the right having removed the
connector.
ELECTRONIC THERMOSTAT (19)
Sensor testing values :
This is located in the component unit. 0°C = 14 700 to 18 000 Ω
5°C = 11 400 to 14 000 Ω
10°C = 9 200 to 10 700 Ω
15°C = 7 250 to 8 450 Ω
20°C = 6 050 to 6 600 Ω
25°C = 4 750 to 5 250 Ω
Testing should be carried out with the sensor in

place, passenger compartment fan on high speed,
AC on position 0, measuring the temperature at
the air inlet to the fan.
92394R
62-68
AIR CONDITIONING
TRI-FUNCTION PRESSOSTAT (411) or (206) RELAYS:
The tri-function pressostat protecting the Relay (234) for the passenger compartment fan
refrigerant circuit has three settings:
Relay (234) is mounted on the fan body, in the
- low pressure (2 bars) water box.
- high pressure (27 bars) The protective cover must be removed to reach
the relay (A).
- engine cooling fan high speed (19 bars).
It is located near to the dehydrating bottle.
The refrigerant circuit does not need to be

drained to work on the pressostat ; it is mounted
on a "SKRADER" valve.
96177R
92280R2
92285R1
62-69
AIR CONDITIONING
Relays: RELAYS:
- fuel pump (236)
- 1st fan speed (335) Recycling motor relay (417)
- 2nd fan speed (336)
- AC compressor (petrol version) (474) Model Year 1989 and 1990
- AC compressor (diesel version) (584)
Relay (417) is located in the component unit near
These are in a protective unit under the left hand the electronic thermostat (19).
side cowl side panel.
92394R1
From Model Year 1991 onwards
Relay (417) is no longer in the component unit .

96178R
It is now located in the recycling motor (475).

ATTENTION: location in the protective unit may
be different depending on version.
92395R
62-70
AIR CONDITIONING
Relay (690) for the electronic thermostat
From year of manufacture 1991, the electronic

thermostat is fed by a relay.
This is located in the component unit near the

electronic thermostat.
92394R2
0.28 Ω RESISTANCE (321)
This is mounted on the engine cooling fan

mounting.
96175S
62-71

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Heating and ventilation

77 11 190 859 NOVEMBER 1996 Edition Anglaise

C Renault S.A. 1988

A External air intake a Central ventilator outlets

a Central ventilator outlets

Controls the hot / cold air flap (3).

R19 Phase I R19 Phase II

Controls the air distribution flaps (4).

R19 Phase I R19 Phase II

Each ventilator has three settings :

FAN CONTROL KNOB (C)

Ventilation is by means of blown air. The amount

NOTE : To improve de-misting and de-icing of the

Mot. 453 -01 Hose clamp

REMOVAL Fit hose clamps Mot. 453-01 or Mot. 583.

Disconnect the battery.

Disconnect the fan feed connector (A).

Remove the 2 fan mounting bolts (B) and remove

Fit the fan unit on the bulkhead (ensure that the

Fit the fan with the 2 fan mounting bolts (B). Do

Refit the dashboard.

Check the control cable adjustment and re-adjust

Connect the radiator hoses.

Tighten the 2 fan mounting bolts (B) and refit the

Top up and bleed the engine cooling circuit (see

The fan unit is removed after removing the upper

Remove the feed connector (A) and the 2

When refitting, put the motor back in position so

Refasten the two half covers using the clips (D)

Fit the new seal provided in the kit to the

IMPORTANT: the seal must be in perfect

Disconnect the motor connector.

Open the two half covers.

Pull the motor out as shown below.

The radiator is removed after removing the air

Spread the 4 retaining clips (E) and remove the

NOTE: take care not to damage the radiator fins.

When refitting, ensure that the radiator is fitted

Ensure that the 4 tabs are correctly fastened.

Fit the 2 mounting bolts (F) onto the body of the

The resistance unit is reached after removing the

Disconnect connector (A) and remove the two

Detach clips (H) and remove the resistance unit.

NOTE: if the resistance unit is being removed due

There are no special precautions for refitting the

Remove the two mounting bolts for the lower

When refitting, change the cable sleeve stops and

Remove the two mounting bolts securing the

Push the control panel in and release it from the

The control panel facade may be changed by

Unclip the cable to be changed and turn it 1/4 Refit:

F External air or recycled air

5 High pressure bleed

6 Pressure relief valve

7 Thermostat control for pressure relief valve

9 Low pressure bleed

10 Air conditioning fan

13 High pressure liquid

14 Low pressure vapour

15 High pressure vapour

1 Fan unit A External air intake

AIR CONDITIONING CUT-OUT

Principle of the system Special notes