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N.T.

3218A DA03 - EA03

SPECIAL FEATURES OF THE F5R 740 ENGINE (including related assemblies)

Follow the instructions regarding cleanliness when working on this vehicle.


For all parts not dealt with in this Technical Note refer to Workshop Repair Manual MR 312. 77 11 205 759
"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".

JULY 1999
All copyrights reserved by Renault.

Edition Anglaise

Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault.

C RENAULT 1999

Contents
Pages Pages

07 VALUES AND SETTINGS


Capacities - Grades Accessories belt tensioning Timing belt tensioning procedure Cylinder head tightening Tyres - wheels Brakes Brake compensator Underbody height Front axle angle checking values Rear axle angle checking values 07-1 07-3 07-4 07-21 07-22 07-23 07-24 07-25 07-27 07-29

13 FUEL SUPPLY
Specifications Supply pump Supply pressure / Pump output High pressure pump Injection rail / Injectors Pressure sensor Anti-percolation system 13-1 13-2 13-3 13-4 13-6 13-11 13-13

14 ANTI-POLLUTION 10
ENGINE AND PERIPHERALS ASSEMBLY Identification Oil pressure Engine and transmission assembly Sump Multi-function support 10-1 10-2 10-3 10-8 10-11 Oil vapours rebreathing Exhaust gas recirculation E.G.R. Fuel vapours rebreathing 14-1 14-2 14-4

16 STARTING - CHARGING
Alternator Starter 16-1 16-4

11 TOP AND FRONT OF ENGINE


Timing belt Cylinder head gasket 11-1 11-8

12 FUEL MIXTURE
Specifications Inlet manifold Exhaust manifold 12-1 12-4 12-6

Contents
Pages Pages

17 IGNITION - INJECTION
Static ignition General Installation Special features of direct injection Cleanliness / Safety Operation Injection fault warning light Engine immobiliser function Injection / AC strategy Idle speed correction Fuel pressure regulation Mixture regulation Adaptive mixture correction Centralised coolant temperature management Computer Wiring diagram 17-1 17-2 17-3 17-5 17-6 17-9 17-10 17-11 17-12 17-13 17-15 17-16 17-17 17-18 17-19 17-22

21 MANUAL GEARBOX
Identification Gears Capacities - Lubricants Consumables Parts which must always be replaced Special features 21-1 21-1 21-2 21-3 21-3 21-4

33 REAR BEARING ELEMENTS


Brake hub / disc Hub / disc bearing 33-1 33-2

36 STEERING ASSEMBLY 19 COOLING


Filling - bleeding Diagram Coolant pump Catalytic converter 19-1 19-2 19-3 19-4 Mechanical power steering pump Power steering unit 36-1 36-3

37 CONTROLS 20 CLUTCH
Cover - Disc Flywheel 20-1 20-4

MECHANICAL COMPONENT

Master cylinder Brake servo

37-1 37-3

62 AIR CONDITIONING
General Compressor Condenser Connecting pipes 62-1 62-2 62-3 62-5

VALUES AND SETTINGS Capacities - Grades


Capacity in litres (approx.) * When draining

07

Units Petrol engine (oil)

Grade

European Union countries and Turkey PETROL - 15 C - 30 C - 20 C - 10 C 0 C + 10 C + 20 C + 30 C 15W40-15W50 10W30-10W40-10W50

ACEA A2/A3

ACEA A1*/A2/A3

ACEA A1*/A2/A3

0W30-5W30 0W40-5W40-5W50

ACEA A1*/A2/A3

ACEA A1-98 standard * Oil for fuel economy F5R 5.1 5.4 (1)

Other Countries If the lubricants specified for the European Union countries are not available, the following specifications must be taken into account: PETROL - 15 C - 30 C - 20 C - 10 C 0 C + 10 C + 20 C + 30 C

API SH/SJ

15W40-15W50

API SH/SJ

10W40-10W50 10W30

API SH/SJ

API SH/SJ

5W30 5W40-5W50

API SH/SJ

Oil for fuel economy: API SJ-IL SAC GF2 standard * Adjust using a dipstick (1) Following replacement of the oil filter

07-1

VALUES AND SETTINGS Capacities - Grades


Capacity in litres 3.1

07
Special features

Units JC5 gearbox F5R cooling circuit

Grade

All countries: TRANSELF TRX 75 W 80 W (API GL5 or MIL-L 2105 G or D standards) Glacol RX (type D) Protection to - 20 C 2 C for hot, temperate and cold climates. Protection to - 37 C 2 C for very cold climates.

07-2

VALUES AND SETTINGS Accessories belt tensioning


To remove the belt, turn the belts automatic tensioner in the direction indicated below using a 13 mm offset ring ended spanner. Clamp the tensioner using a 6 mm hexagonal wrench (1).
ALTERNATOR, POWER STEERING AND AIR CONDITIONING

07

15304R

15579-1R1

WARNING: the accessories belt rests on the ridged

part on the pulley (F).

A B C D E F T

Crankshaft Air conditioning compressor Alternator Power steering pump Coolant pump Pulley Automatic tensioner

When refitting the belt, it is essential to ensure that the tooth (X) inside the pulleys (timing side) remains "free".

15110R

07-3

VALUES AND SETTINGS Timing belt tensioning procedure

07

ESSENTIAL SPECIAL TOOLS

Mot. 799-01 Mot. Mot. Mot. Mot. Mot. Mot. 1054 1368 1383 1448 1453 1488

Tool for immobilising pinions for toothed timing belt Top Dead Centre pin Tool for tightening camshaft pulleys Pipe wrench for removing HP pipes Clip pliers for spring clips Engine support tool Tool for refitting camshaft covers Tool for fitting the camshaft seals Tool for setting the camshafts Tool for immobilising the camshaft pulleys

Mot. 1512 Mot. Mot. 1526 1535

ESSENTIAL EQUIPMENT

Angular tightening wrench

There are two very distinct procedures for setting the timing.

1st PROCEDURE The first procedure is applied in the event of replacement of any components in the timing face which do not require slackening of the camshaft pulley(s).

Follow the instructions regarding cleanliness and safety when working on the fuel circuit.

07-4

VALUES AND SETTINGS Timing belt tensioning procedure


Setting the timing WARNING: it is essential to degrease the end of the crankshaft, the crankshaft pinion bore and the crankshaft pulley contact surfaces to prevent sliding between the timing and the crankshaft which could destroy the engine. Position the camshaft grooves using Mot. 799-01 as indicated in the diagram opposite. It is essential that the grooves are horizontal and offset downwards.

07

15614S

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

16077R

07-5

VALUES AND SETTINGS Timing belt tensioning procedure


Check that the crankshaft is at Top Dead Centre and not in the balancing hole. Correct position

07

15163-1S

Incorrect position

15163S

07-6

VALUES AND SETTINGS Timing belt tensioning procedure


The crankshaft groove (5) should be between the two marks on the engine block.

07

15577R

The exhaust camshaft pinion mark should be opposite the cylinder position sensor securing hole.

07-7

VALUES AND SETTINGS Timing belt tensioning procedure


Fitting the belt When the timing belt is changed, it is essential to change the timing tensioners and pulleys. Check that the tensioner lug (1) is correctly positioned in the groove (2).

07

15201R

Refit: - the timing belt, - the pulleys (3) tightening the mounting bolts to a torque of: 5 daN.m for the M10 bolts 2.5 daN.m for the M8 bolts - the crankshaft accessories pulley bringing the bolt into position without contact with the pulley (clearance between bolt and pulley 2 to 3 mm).
NOTE:

- the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed 49.1 mm (otherwise change it), - do not coat a new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil.

15578R

07-8

VALUES AND SETTINGS Timing belt tensioning procedure


Align marks (6) and (7) on the tensioner using a 6 mm hexagonal wrench at (B).

07

15256R

Pre-tighten the tensioner nut to a torque of 0.7 daN.m. Tighten the crankshaft pulley bolt to a torque of 2 daN.m (Top Dead Centre pin Mot. 1054 still in place). NOTE: do not turn the tensioner anti-clockwise.

07-9

VALUES AND SETTINGS Timing belt tensioning procedure


Make a mark (C) indicating the position of the camshaft pulleys in relation to the camshaft bearing cap castings.

07

15778-1R

Remove camshaft setting tool Mot. 1526 and Top Dead Centre pin Mot. 1054. Carry out angular tightening of the crankshaft pulley bolt to 115 10, while immobilising the engine flywheel using a screwdriver.

15303S

07-10

VALUES AND SETTINGS Timing belt tensioning procedure


Turn the crankshaft two revolutions clockwise (timing end). Before the end of the two revolutions (that is a half-tooth before alignment of the marks on the camshaft pulleys and the camshaft bearing cap castings), insert the Top Dead Centre pin Mot. 1054 to be between the balancing hole and the pinning hole, then bring the timing to its setting point. Incorrect position

07

15163S

Remove the Top Dead Centre pin Mot. 1054. Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not. Then tighten the nut to a torque of 2.7 daN.m.
15163-2R

Checking the setting and the tension Correct position Checking the tension Turn the crankshaft two revolutions clockwise (timing end), then pin the crankshaft just before the end of the two revolutions aligning the camshaft pulley and camshaft bearing cap casting marks made previously. Remove the Top Dead Centre pin Mot. 1054. Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not.

15163-1S

07-11

VALUES AND SETTINGS Timing belt tensioning procedure


Checking the setting Ensure that the tensioner marks are positioned correctly before checking the timing setting. Fit the Top Dead Centre pin Mot. 1054 checking the alignment of the marks made previously. Fit (without using force) camshaft setting tool Mot. 1526 (the camshaft grooves should be horizontal and offset downwards). If the tool does not engage, the timing setting and tensioning procedure must be repeated.

07

15614S

16077R

07-12

VALUES AND SETTINGS Timing belt tensioning procedure


The second procedure is applied in the event of replacement of any components which require slackening of the timing camshaft pulley(s).

07

Setting the timing WARNING: it is essential to degrease the end of the crankshaft and the crankshaft pinion bore, the crankshaft pulley contact surfaces and the ends of the camshafts (timing end) and the camshaft pulley bores to prevent sliding between the timing, the crankshaft and the camshaft pulleys which could destroy the engine.

15614S

Position the camshaft grooves horizontally, as indicated on the diagram above, using tool Mot. 799-01. It is essential that the grooves are directed downwards. This operation can be made easier by fitting the camshaft pulleys using the old nuts, tightening them to a torque of 1.5 daN.m maximum.

07-13

VALUES AND SETTINGS Timing belt tensioning procedure


Fit tool Mot. 1526 which is secured to the end of the camshafts. Incorrect position

07

15163S 16077R

Remove the old pulley nuts. It is essential to replace them with new nuts. Pre-tighten the nuts, without locking them, with a clearance of 0.5 to 1 mm between the nuts and the pulleys. Check that the crankshaft is pinned at Top Dead Centre and not in the balancing hole (crankshaft groove (5) should be between the two marks (1) of the engine block). Correct position

15114-1R

15163-1S

07-14

VALUES AND SETTINGS Timing belt tensioning procedure


When a timing belt is changed, it is essential to change the timing tensioners and pulleys. Position the exhaust camshaft pulley mark opposite the poition sensor thread. NOTE: incorrect positioning of the exhaust camshaft pulley prevents starting of the engine. Ensure that the tensioner lug (1) is correctly positioned in the groove (2).

07

15201R

Refit: - the timing belt, - the pulleys (3) tightening the mounting bolts to a torque of 5 daN.m in the case of the 10 mm bolts and 2.5 daN.m in the case of the 8 mm. bolts.

15578R

Fit the crankshaft accessories pulley, pre-tightening the bolt (without fully tightening the bolt, clearance of 2 to 3 mm between the bolt and the pulley).
NOTE:

- the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed 49.1 mm (otherwise change it), - do not coat the new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil.

07-15

VALUES AND SETTINGS Timing belt tensioning procedure


Check that there is still a clearance of 0.5 to 1 mm between the camshaft nuts and pulleys. Align tensioner marks (6) and (7) using a 6 mm hexagonal wrench at (B).

07

15256R

Pre-tighten the tensioner nut to a torque of 0.7 daN.m. Turn the timing face through six revolutions via the exhaust camshaft pulley using tool Mot. 79901.
NOTE: during this operation, ensure that the pul-

leys do not come into contact with the nuts. If they do, reposition them from time to time.

07-16

VALUES AND SETTINGS Timing belt tensioning procedure


Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not. Then tighten the nut to a torque of 2.8 daN.m. Turn the exhaust camshaft pulley to position the mark opposite the phasing sensor. Tighten the crankshaft pulley bolt to a torque of 2 daN.m (Top Dead Centre pin still in place in the crankshaft). Make a mark (C) to indicate the position of the camshaft pulleys in relation to the camshaft bearing cap castings.

07

15578-1R

07-17

VALUES AND SETTINGS Timing belt tensioning procedure


Remove the Top Dead Centre pin. Carry out angular tightening of the crankshaft pulley bolt to 115 10, while immobilising the engine flywheel using a screwdriver. Incorrect position

07

15163S

15303S

Fit camshaft pulley immobilising tool Mot. 1535 and secure it using a cover bolt.

Pin the crankshaft aligning the camshaft pulley and camshaft bearing cap casting marks made previously to ensure that the pin is correctly positioned in the pin hole and not in the crankshaft balancing hole.

Correct position

16078R

Tighten the inlet camshaft pulley nut to a torque of 3 daN.m, then turn it through an angle of 90.

15163-1S

07-18

VALUES AND SETTINGS Timing belt tensioning procedure


Tighten the exhaust camshaft pulley nut to a torque of 3 daN.m, then turn it through an angle of 45 then a second angle of 45 using tool Mot. 1368.

07

16218S

Remove camshaft setting tool Mot. 1526, camshaft pulley immobilising tool Mot. 1535 and Top Dead Centre pin Mot. 1054.

Checking the setting and tension Checking the tension Turn the crankshaft two revolutions clockwise (timing side), then pin the crankshaft just before the end of the two revolution aligning the camshaft pulley and camshaft bearing cap casting marks. Remove the Top Dead Centre pin Mot. 1054. Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not.

07-19

VALUES AND SETTINGS Timing belt tensioning procedure


Checking the setting Ensure that the tensioner marks are positioned correctly before checking the timing setting. Fit the Top Dead Centre pin Mot. 1054 checking that the marks made previously are aligned. Fit (without using force) camshaft setting tool Mot. 1526 (the camshaft grooves should be horizontal and offset downwards). If the tool does not engage, the timing setting and tensioning procedure must be repeated.

07

15614S

16077R

07-20

VALUES AND SETTINGS Cylinder head tightening


CYLINDER HEAD TIGHTENING PROCEDURE

07

The bolts can be re-used if the length under the head does not exceed 137.7 mm (otherwise change all the bolts).
REMINDER: to obtain correct tightening of the bolts, remove any oil

from the cylinder head securing holes using a syringe. Do not coat new bolts with oil. However, if the bolts are re-used, it is essential to coat them with oil. Tighten all the bolts to 2 daN.m in the order indicated below.

15659R

Check that all the bolts are correctly tightened to 2 daN.m then carry out angular tightening (bolt by bolt) of 195 6 in the order of tightening. The cylinder head bolts are not re-tightened following application of this procedure.

07-21

VALUES AND SETTINGS Tyres - Wheels

07
Tyre pressure when cold (in bar) (1) Front Rear

Vehicle

Rim

Tyres

DA0 3

6.5 J 16

195/50 R 16 V

2.4

2.2

EA0 3

6.5 J 16

195/50 R 16 V

2.4

2.3

(1) During motorway use with full load. Wheel nut tightening torque: 9 daN.m Rim run-out: 1.2 mm

07-22

VALUES AND SETTINGS Brakes

07
At the rear Drum diameter (in mm) Maximum (1) Minimum -

At the front Vehicle Disc thickness (in mm) Maximum DA0 3 EA0 3 24 Minimum 21.8

Disc thickness (in mm) Maximum 8 Minimum 6.3

(1) Drum: maximum wear diameter (where applicable). The disc run-out is 0.07 maximum

Lining thickness (in mm) Vehicle Front (including support) New DA0 3 EA0 3 18.3 Minimum 6 New 11 Rear Minimum 5
SAE J1703

Brake fluid

DOT 4

07-23

VALUES AND SETTINGS Brake compensator


BRAKING PRESSURE

07
Check pressure (1) (in bar) Front Rear

Vehicle

Fuel level status (driver in vehicle)

DA0 3 EA0 3
90966S

140

49

+ 18 0

(1) The check is carried out using two pressure gauges arranged in an X formation.

07-24

VALUES AND SETTINGS Underbody height

07
Dimension X (in mm) D and G 471 488

Vehicle DA0 3 EA0 3

At the front H1 - H2 = ... mm 116 116

At the rear H4 - H5 = ... mm 51 38

Tolerance: 7.5 mm The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed 5 mm, the drivers side always being the highest. Any alteration to the underbody height also requires adjustment of the brake compensator (if fitted) and of the headlights.

07-25

VALUES AND SETTINGS Underbody height


MEASURING POINTS

07

16102R

H1 : H2 : H4 : H5 :

radius of tyre under load height measured between the lower surface of the sub-frame and the ground in line with the centreline of the wheel radius of rear tyre under load height measured between the centreline of the rear axle joint and the ground

88636-4R

07-26

VALUES AND SETTINGS Front axle angle checking values


DA03 ANGLES CASTOR VALUES POSITION OF THE FRONT AXLE

07
SETTING

403 433 503

30

H5-H2 = H5-H2 = H5-H2 =

71 mm CANNOT BE 51 mm ADJUSTED 31 mm

93012-1S

Maximum right / left difference= 1 H1-H2 = 116 mm CANNOT BE H1-H2 = 124 mm ADJUSTED H1-H2 = 130 mm

CAMBER

- 012 - 011 - 008

30

93013-1S

Maximum right / left difference= 1

KINGPIN INCLINATION

1036 1042 1049

30

H1-H2 = 116 mm CANNOT BE H1-H2 = 124 mm ADJUSTED H1-H2 = 130 mm

Maximum right / left difference= 1


93014-1S

PARALLELISM

(For 2 wheels) toe out + 010 10 + 1 mm 1 mm


93011-1S POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

Adjusted by rotating track rod sleeves 1 turn = 30 (3 mm)

UNLADEN

81603S1

07-27

VALUES AND SETTINGS Front axle angle checking values


EA03 ANGLES CASTOR VALUES POSITION OF THE FRONT AXLE

07
SETTING

347 417 447

30

H5-H2 = H5-H2 = H5-H2 =

83 mm CANNOT BE 63 mm ADJUSTED 43 mm

93012-1S

Maximum right / left difference= 1 H1-H2 = 116 mm CANNOT BE H1-H2 = 125 mm ADJUSTED H1-H2 = 133 mm

CAMBER

- 012 - 010 - 006

30

93013-1S

Maximum right / left difference= 1

KINGPIN INCLINATION

1036 1044 1052

30

H1-H2 = 116 mm CANNOT BE H1-H2 = 125 mm ADJUSTED H1-H2 = 133 mm

Maximum right / left difference= 1


93014-1S

PARALLELISM

(For 2 wheels) toe out + 010 10 + 1 mm 1 mm


93011-1S POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

Adjusted by rotating track rod sleeves 1 turn= 30 (3 mm)

UNLADEN

81603S1

07-28

VALUES AND SETTINGS Rear axle angles checking values


VALUES 4 BAR AXLE POSITION OF THE REAR AXLE

07
SETTING

ANGLES CAMBER

- 050 15

UNLADEN

CANNOT BE ADJUSTED

93013-2S

PARALLELISM

(For 2 wheels) Toe-in - 0 30 20 - 3 mm 2 mm


93011-2S

UNLADEN

CANNOT BE ADJUSTED

POSITION FOR TIGHTENING RUBBER BUSHES

UNLADEN

81603S1

07-29

ENGINE AND PERIPHERALS ASSEMBLY Identification

10
Compression ratio

Type of vehicle DA03 EA03

Engine

Gearbox

Cubic capacity (cm 3) 1998

Bore (mm)

Stroke (mm)

F5R 740

JC5

82.7

93

11.5/1

Manual to be consulted: Mot. F5R.

10-1

ENGINE AND PERIPHERALS ASSEMBLY Oil pressure

10

ESSENTIAL SPECIAL TOOLS

Mot. 836 -05

Boxed kit for measuring oil pressure


ESSENTIAL EQUIPMENT

Douille longue ou cl tube de 22 mm 22 mm long socket or tube wrench


CHECK

The oil pressure check must be carried out while the engine is warm (approximately 80 C). Contents of boxed kit Mot. 836-05.

87363R1

USE
B+F

Connect the pressure gauge in place of the oil pressure switch. Oil pressure Idle 3,000 rpm

1 bar (minimum) 3 bars (minimum)

10-2

ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly

10

ESSENTIAL SPECIAL TOOLS

Mot. 1040-01

Dummy mounting for removing/refitting engine and transmission assembly Tool for retaining the engine on the sub-frame Threaded rods for lowering the sub-frame Clip pliers for spring clips Tool for supporting the engine

Mot. 1159 Mot. 1233-01 Mot. 1448 Mot. 1453

TIGHTENING TORQUES (In daN.m)

REMOVAL

Sub-frame front mounting bolt Sub-frame rear mounting bolt Front right suspended engine mounting cover to engine mounting bolt Front right suspended engine mounting cover mounting nut Rubber engine mounting to front left side member support mounting nut Shock absorber base mounting bolts Brake caliper mounting bolt Steering shaft yoke mounting bolt Wheel bolt Three point clamp nuts Sub-frame - side member tie-rod bolts

6.2 10.5 6.2 4.4 6.2 18 4 3 10 2 3

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 and safety when working on the fuel circuit.

10-3

ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly


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 attach them to the suspension springs, - the shock absorber base bolts, - the heat shield (A) and the gearbox control cable, - 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.

10

SPECIAL FEATURES OF VEHICLES FITTED WITH A DRIVERS AIR BAG WARNING

To prevent any risk of destruction of the rotary switch under the steering wheel, follow the instructions below: Before the steering column and the rack are uncoupled, it is ESSENTIAL that the steering wheel is immobilised with the wheels straight using a "steering wheel immobiliser" tool for the entire duration of the operation. If there is any doubt about the correct centring of the rotary switch, the steering wheel must be removed and the centring procedure described in the "Air bag" section must be applied. REMINDER: in this case, only qualified, trained personnel must carry out the procedure.

Remove: - the front bumper, - the air filter unit and its support, - the accelerator and clutch cables, - the brake servo vacuum pipe (manifold end). Remove the computer fasteners and fold back the assembly on the engine.

15961R

- the horns, - the two power steering pipe fasteners on the sub-frame on the right-hand side, - the steering shaft yoke nut and eccentric bolt after pushing back the protector.

10-4

ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly


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,

10

NOTE: it is essential to fit plugs on the pipes and

the pressure relief valve to prevent the introduction of moisture into the circuit and on the fuel pipes to keep them clean. Fit engine retaining tool Mot. 1453 ensuring that the strap is positioned correctly. Remove the suspended engine mountings cover and the engine tie-bar. Place a shim between the gearbox and the subframe. Remove nut (1), then, using a copper hammer, tap to detach the stud from the suspended engine mountings fastener.

98756R

- the earth strap on the bulkhead, - the air conditioning pipe fasteners on the pressure relief valve, - the starter supply wire.

15959R1

98754R

10-5

ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly


Fit the two tools Mot. 1159 as indicated below.

10

Secure tool Mot. 1040-01 under the sub-frame.

98755R1 99024R2

Lower the lift until the tool comes into contact with the ground. Remove the sub-frame mounting bolts and remove the engine and transmission assembly by lifting the body. When starting to lift the body, be sure to remove the catalytic converter and to extract the radiator from its upper fasteners (then place it on the subframe again).
NOTE: in the case of an operation which requires

15960R

separation of the engine/gearbox/sub-frame assembly, take care to mark the position of the tools Mot. 1159 on the sub-frame.

10-6

ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly


REFITTING

10

The alignment of the sub-frame with the body will be made easier by positioning two threaded rods Mot. 1233-01 in the two front fasteners of the body sub-frame. Be sure to reposition the catalytic converter on lowering the body onto the engine and transmission assembly. Tighten the sub-frame mounting bolts to a torque of: 6.2 daN.m at the front, - 10.5 daN.m at the rear. Refit in the reverse order to removal. Fit the heat shields correctly. Fit the caliper mounting bolts with Loctite FRENBLOC and tighten them to the specified torque. Press the brake pedal several times to bring the pistons into contact with the pads. Carry out the following operations: - fill the engine and gearbox with oil (if necessary), - fill and bleed the cooling circuit (see section 19 "Filling - Bleeding"). Fill the refrigerant circuit using the filling equipment.

10-7

ENGINE AND PERIPHERALS ASSEMBLY Sump

10

ESSENTIAL SPECIAL TOOLS T.Av. 1233-01

Tool for working on the subframe - axle

TIGHTENING TORQUES (in daN.m)

Pre-tightening of sump bolts Tightening of sump bolts

0.8 1.35 0.15

REMOVAL

Place the vehicle on a two post lift. Disconnect the battery. Remove the steering shaft yoke nut.

97390-1R2

10-8

ENGINE AND PERIPHERALS ASSEMBLY Sump


Remove the sub-frame tie-rods mounting bolts and lower the sub-frame by approximately 100 mm.

10

13507R2

Drain and remove the sump.

10-9

ENGINE AND PERIPHERALS ASSEMBLY Sump


REFITTING

10

Apply a spot of RHODORSEAL 5661 at (A) on either side of bearing n 1, and at (B) at the intersection of the crankshaft closing plate and the cylinder block.

15159-2R

Refit the sump with a new seal pre-tightening it to a torque of 0.8 daN.m, then carry out a final tightening of 1.35 daN.m in the order shown.

15195R

10-10

ENGINE AND PERIPHERALS ASSEMBLY Multi-function support

10

TIGHTENING TORQUE (in daN.m)

Multi-function support bolts and stud

4.4 0.4

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).

15576R

REFITTING

Refit the support tightening the bolts and the stud to a torque of 4.4 daN.m. Refer to section 07 "Accessories belt tensioning" for the tensioning procedure. Refit in the reverse order to removal.

10-11

TOP AND FRONT OF ENGINE Timing belt

11

ESSENTIAL SPECIAL TOOLS

Mot. 799-01 Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot. 1054 1368 1383 1453 1488 1512 1526 1535

Tool for immobilising pinions for toothed timing belt Top dead centre pin Tool for tightening camshaft pulleys Pipe wrench for removing HP pipes Engine support Tool for refitting camshaft covers Tool for fitting the camshaft seals Tool for setting the camshafts Tool for immobilising camshaft pulleys
ESSENTIAL EQUIPMENT

Angular tightening wrench

TIGHTENING TORQUES (in daN.m or/and )

REMOVAL

Wheel bolt Pulley bolt: - M10: - M8: Tensioner nut Crankshaft pulley bolt

10 5 2.5 2.8 2 + 115 10 6.2 2 1 2.5

Place the vehicle on a two post lift. Disconnect the battery. Remove: - the front right wheel, - the front right wheel arch and the engine undertray. Fit the engine support Mot. 1453.

Mounting bolt on suspended mounting Intermediate timing cover bolt High pressure pump mounting bolt High pressure pipe union

Follow the instructions regarding cleanliness and safety when working on the fuel circuit.

98750R2

11-1

TOP AND FRONT OF ENGINE Timing belt


Remove : - the suspended engine mountings cover and movement limiter assembly, - the bolt (A) and slacken engine tie-bar bolt (B). Raise the engine. Remove: - the Top Dead Centre pin plug,

11

15102-1S

- the air resonator (1), - the ignition coil and harness (2),
15424R3

Lock the accessories belt tensioner. To do this, turn the tensioner towards the right and immobilise it using a 6 mm hexagonal wrench (see section 07 "Accessories belt tensioning").

15617R

- the inlet manifold (3) (see section 12 "Inlet manifold"),

15579-1S

11-2

TOP AND FRONT OF ENGINE Timing belt


- the exhaust camshaft sealing plug (4), - the high pressure fuel pipe using tool Mot. 1383 (5). For this operation, support the unions using open wrenches. Fit blanking pieces to maintain cleanness. Remove: - the high pressure fuel pump (6), - the timing cover mounting bolts then remove the covers (7).

11

15615R2

15578-3R

11-3

TOP AND FRONT OF ENGINE Timing belt


Setting the timing Position the exhaust camshaft pulley mark (1) one tooth before the phase sensor fastener (2). The camshaft grooves must be towards the bottom and almost horizontal as indicated below.

11

15740-1R

15614-1S

11-4

TOP AND FRONT OF ENGINE Timing belt


Insert pin Mot. 1054 to be between the balancing hole and the setting groove of the crankshaft. Correct position

11

15163-1S 15163-2S

Incorrect position

Turn the engine slightly, in the same direction, engaging pin Mot. 1054 at the setting point.

15163S

11-5

TOP AND FRONT OF ENGINE Timing belt


Remove the timing pulley immobilising the engine flywheel using a screwdriver.

11

15303S

Slacken the timing belt using the tensioner. Remove the belt and the pulley. Take care not to let the crankshaft pinion fall as it does not have a key. WARNING: it is essential to degrease the end of the crankshaft, the crankshaft pinion bore and the contact surfaces of the crankshaft pulley to prevent sliding between the timing and the crankshaft which could destroy the engine.

15578S

11-6

TOP AND FRONT OF ENGINE Timing belt


REFITTING

11

When the timing belt is changed, it is essential to change the timing tensioners and pulleys. Refit: - the timing belt (it is essential to follow the procedure described in section 07 "Timing belt tensioning procedure"), - the accessories belt (see section 07 "Accessories belt tensioning procedure"), - the Top Dead Centre pin plug applying a spot of RHODORSEAL 5661 to the thread, - the new exhaust camshaft sealing plug using tool Mot. 1488,

- the high pressure fuel pump and pipe (refer to the procedure described in section 13 "High pressure pump"), Replace the shim (1),

16127R

Refit the inlet manifold (refer to the procedure described in section 12 "Inlet manifold"),

15615S

15617S

- the air resonator and air intake pipe, - the right-hand suspended engine mounting tightening the bolts to the specified torque.

11-7

TOP AND FRONT OF ENGINE Cylinder head gasket

11

ESSENTIAL SPECIAL EQUIPMENT

Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot. Mot.

1054 1159 1368 1383 1448 1453 1488 1512 1526 1530 1532 1533 1535

Top Dead Centre pin Engine support tool Tool for tightening camshaft pulleys Pipe wrench for removing HP pipes Clip pliers for spring clips Engine support tool Tool for refitting camshaft covers Tool for fitting the camshaft seals Tool for setting the camshafts Tool for removing injectors Tool for removing the high pressure rail Tool for fitting injector seals Tool for immobilising camshaft pulleys

ESSENTIAL EQUIPMENT

Cylinder head testing equipment Angular tightening wrench

TIGHTENING TORQUES (in daN.m or/and )

Follow the instructions regarding cleanliness and safety when working on the fuel circuit. 10 5 2.5 2.8

Wheel bolt Pulley bolt: - M10: - M8: Tensioner nut Crankshaft pulley bolt

2 + 115 10 6.2 2 1.2 1.3 1.5 1 2.5

Mounting bolt on suspended mounting Intermediate timing cover bolt Camshaft bearing cap casting bolt Oil separator bolt Injection rail mounting bolt High pressure pump mounting bolt High pressure pipe union

11-8

TOP AND FRONT OF ENGINE Cylinder head gasket


REMOVAL

11

Place the vehicle on a two post lift. Disconnect the battery. Remove: - the front right wheel, - the front right wheel arch and the engine undertray. Drain the cooling circuit (via the lower radiator hose). Fit the engine support tool Mot. 1159.

Remove: - the air intake pipe and resonator, - the ignition coil and harness, - the inlet manifold (see section 12 "Inlet manifold"), - the high pressure fuel pipe using tool Mot. 1383 supporting the unions using open wrenches. 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 the pin Mot. 1054. Remove the timing belt (see section 11 "Timing belt"). Fit tool Mot. 1535 positioning the timing cover bolt in hole (1), and remove the camshaft pulleys.

99024R2

16078R2

15960R

11-9

TOP AND FRONT OF ENGINE Cylinder head gasket


Remove the injection rail mounting bolts (fit the sealing plugs). Fit the injection rail extraction tool Mot. 1532 (the dowels and the threaded rods).

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 carbon deposit. Extract the injector and position the plugs to maintain cleanness.

16126R 16635R

Extract the injection rail. The injector retaining clips remain in place and may allow the injection rail to escape on removal. Fit blanking pieces to maintain cleanness.

11-10

TOP AND FRONT OF ENGINE Cylinder head gasket


Remove: - the oil separator,

11

15612S

- the EGR valve/manifold connecting pipe, - the EGR valve support, - the camshaft bearing cap bolts.

15612-3S

11-11

TOP AND FRONT OF ENGINE Cylinder head gasket


Vertically detach the camshaft bearing cap casting by tapping on the lugs (2) using a mallet and at the same time, slide a screwdriver under the lug.

11

15660-1R

Remove: - the camshafts,

15656S

11-12

TOP AND FRONT OF ENGINE Cylinder head gasket


- the earth strap, - the catalytic converter/ manifold connecting bolts, - the exhaust manifold strut, - the harness supports, - the coolant pipes on the plenum chamber, - the tabs and the hydraulic stops,

11

15657S

- the aluminium timing cover (1).

15574R

11-13

TOP AND FRONT OF ENGINE Cylinder head gasket


Remove the cylinder head.

11

15659S

Cleaning It is very important that the mating surfaces of the aluminium parts are not scratched. Use the product Dcapjoint to dissolve the part of the gasket which remains attached. Apply the product to the section to be cleaned; wait approximately ten minutes, then remove it using a wooden spatula. It is advisable to wear gloves during this operation. Do not allow the product to fall onto the paintwork. Your attention is drawn to the care which must be taken when carrying out this operation to prevent the introduction of foreign bodies into the pressurised oil feed pipes leading to the camshafts (pipes located both in the cylinder block and in the cylinder head).

CHECKING THE MATING SURFACE

Check whether the mating surface is deformed using 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.

11-14

TOP AND FRONT OF ENGINE Cylinder head gasket


REFITTING

11

When removing-refitting the cylinder head, observe the following points: - It is essential to reprime the hydraulic stops as they risk becoming empty after a very prolonged time. To check whether it is necessary to reprime them, press the top of the stop at (A) with the thumb. If the stop piston lowers, immerse it in a container full of diesel.

Refit: - the tabs, - the camshaft lubricating the bearings. WARNING: do not apply oil to the cylinder head cover mating surface.
NOTE: the camshafts are identified by a mark (A).

15653-2R

Details of mark (A) : - mark B is only used by the supplier, - mark C identifies the camshafts: A = Inlet, E = Exhaust, - mark D indicates the type of engine For example:
15658R

F5RE616 330 11 38
D C B

11-15

TOP AND FRONT OF ENGINE Cylinder head gasket


Position the camshaft grooves as indicated on the diagram below (the grooves must be horizontal and offset downwards).

11

15614S

NOTE: the mating surfaces must be clean, dry and not greasy (avoid finger prints). Using a roller (uneven) apply Loctite 518 to the camshaft bearing cap casting mating surface until it is reddish.

15641S

11-16

TOP AND FRONT OF ENGINE Cylinder head gasket


Refit: - the camshafts.

11

15656S

- the camshaft bearing cap castings. Tighten them to a torque of 1.2 daN.m following the order and the procedure indicated.

15612-2R

11-17

TOP AND FRONT OF ENGINE Cylinder head gasket


- the EGR valve support, - the oil separator. Using a roller (uneven) apply Loctite 518 to the mating surfaces until they are reddish.

11

15643S

Tighten the oil separator to a torque of 1.3 daN.m in the order indicated.

15612R

11-18

TOP AND FRONT OF ENGINE Cylinder head gasket


Refit: - the camshaft seals using tool Mot. 1512.

11

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 ENGINE Cylinder head gasket


Refit the injector seals using tool Mot. 1533 (refer to the procedure described in section 13 "Injection rail/injectors"). Refit the injectors and the clips on the rail observing their positions.

11

16125S

Refit the injection rail (see section 13 "Injection rail/injectors").

11-20

TOP AND FRONT OF ENGINE Cylinder head gasket


Setting the timing WARNING: it is essential to degrease the end of the crankshaft, the crankshaft pinion bore and the contact surfaces of the crankshaft pulley to prevent sliding between the timing and the crankshaft which could destroy the engine. Refit: - the timing belt (it is essential to follow the procedure described in section 07 "Timing belt tensioning procedure", - the high pressure pump refitting the shim (1) (see section 13 "High pressure pump"),

11

16127R

- the exhaust camshaft sealing plug using tool Mot. 1488, - the inlet manifold (see section 12 "Inlet manifold"), - the accessories belt (refer to the procedure described in section 07 "Accessories belt"), - the right-hand suspended engine mounting and the engine tie-bar. Before starting the engine, switch on the ignition several times to run the petrol pump and prime the fuel circuit. IMPORTANT: if the exhaust manifold fastening studs have been removed, change them and seal
using "LOCTITE FRENBLOC BLEUE".

11-21

FUEL MIXTURE Specifications

12
Emission control standard Type of injection

Engine Vehicle Gearbox Cubic Stroke capacity (mm) (cm 3)

Type Index

Bore (mm)

Compression Catalytic ratio converter

DA0 3 EA0 3

JC5

F5R

740

82.7

93

1998

11.5/1

C110 C77

Multipoint direct EU 96 Static ignition

Temperature in C Air sensor NTC type resistance in Ohms Coolant sensor NTC type resistance in Ohms

- 10 8525 to 10450 -

25 1880 to 2120 2140 to 2360

50 760 to 860 770 to 850

80 275 to 290

110 112 to 117

Checks carried out at idle * Idle speed (rpm) 750 50 Emissions of pollutants** CO (%) (1) 0.5 maximum C02 (%) 14.5 minimum HC (ppm) 100 maximum Lambda () 0.97 < < 1.03

Fuel *** (minimum octane rating) Super unleaded (IO 95)

(1) * ** ***

at 2,500 rpm the CO should be 0.3 maximum. At a coolant temperature greater than 80 C and after a constant engine speed of 2,500 rpm for approximately 30 seconds. For the legislative values, refer to the specifications for the country concerned. Compatible IO 91 unleaded.

12-1

FUEL MIXTURE Specifications

12
SPECIAL NOTES

DESCRIPTION

BRAND/TYPE SIEMENS "SIRIUS 3H"

Injection and ignition computer Injectors control computer Injection Ignition Idle stepper motor Throttle potentiometer Magnetic sensor (TDC and engine speed) Camshaft position sensor Canister solenoid valve

SIEMENS "Driver" PHILIPS CTS - MAGNETI MARELLI

90 tracks 55 tracks Direct multipoint sequential Static with monobloc coil Resistance : 53 5 at 25 C Incorporated in the throttle housing Resistance of track : 1,200 240 Resistance of cursor < 1,050 Variable reluctance type Resistance = 200 to 270 Hall Effect sensor Incorporated in the canister Resistance : 26 4 to 23 C Resistance of sensor track 5 K Resistance of valve 6 K Track 1 : sensor signal Track 2 : sensor earth Track 3 : sensor supply Track 4 : valve earth Track 6 : valve supply 1 2 3

ELECTRIFIL

SAGEM SAGEM

EGR solenoid valve

SIEMENS

4 Injector Fuel pressure sensor Fuel pressure regulator Manifold pressure sensor Knock sensor
SIEMENS SIEMENS SIEMENS

Resistance 1.78 5 C Operation under high pressure Resistance 3,8 Resistance between tracks 2 and 3 2,084 Resistance 50 K Piezo-electric type. Tightening to 2 daN.m

DELCO SAGEM

12-2

FUEL MIXTURE Specifications

12
SPECIAL NOTES

DESCRIPTION

BRAND/TYPE

Upstream oxygen sensor

BOSCH

Heating resistance: 9 1 at 23 C Rich mixture > 750 240 mV Lean mixture < 150 50 mV Heating resistance : 3.4 0.7 at 23 C Rich mixture > 750 70 mV Lean mixture < 150 50 mV Monobloc coil with four outputs Primary resistance 0.5 Secondary resistance : 11 1 K A B C D : : : : cylinder 1 and 4 coil supply cylinders 2 and 3 coil supply supply common wire

Downstream oxygen sensor

BOSCH

Ignition coils

SAGEM

Spark plugs Idle manifold pressure

CHAMPION REC 14 PYC

WARNING: long thread Tightening : 2.5 to 3 daN.m

310 40 mbars upstream of the pre-catalytic converter 59 176 409 520

Exhaust counter-pressure

1,500 rpm 3,000 rpm 4,500 rpm 5,500 rpm BOSCH

Scavenge pump

Pressure : 4.5 0.06 bars

12-3

FUEL MIXTURE Inlet manifold

12
2.5 1 2.5 1

TIGHTENING TORQUES (in daN.m)

Inlet manifold 8 mounting bolt Inlet manifold 6 mounting bolt Side mounting bolt Throttle housing bolt

REMOVAL

Disconnect the battery. Remove: - the air intake pipe, - the air resonator (1),

- the pressure sensor (2) and air temperature sensor (3) connectors, - the ignition coil, - the ignition harness,

15616R1

- the manifold side bolt (4), - the inlet manifold mounting bolts and nuts.

15618R

12-4

FUEL MIXTURE Inlet manifold

12

REFITTING

Replace the manifold seal and the EGR valve. Refit: - the inlet manifold replacing the seals and observing the tightening torque of the 6 mm and 8 mm bolts and nuts.

15617R1

- the manifold side bolt, - the coil (3) and the ignition harness (4), - the air resonator and air intake pipe. In the case of removal of the throttle housing, refer to the procedure described in section 12 "Throttle housing").

12-5

FUEL MIXTURE Exhaust manifold

12

ESSENTIAL SPECIAL TOOLS

Mot.

1495

Tool for removing the oxygen sensor

TIGHTENING TORQUES (in daN.m)

REMOVAL

Catalytic converter/manifold connecting nuts Exhaust manifold mounting nuts Engine tie-bar Oxygen sensor Shock absorber lower bolts Lower ball joint

1.2 1.8 6.2 4.5 17 6

Place the vehicle on a two post lift. Disconnect the battery. Remove: - the idle regulation solenoid valve (1), - the EGR pipe (2),

16080R

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,

12-6

FUEL MIXTURE Exhaust manifold


the exhaust strut (1), the manifold heat shields, the engine tie-bar, the manifold to catalytic converter connection mounting bolts.

12

Slacken the catalytic converter / exhaust line connection clamp to move the catalytic converter back a few centimetres. Remove the exhaust manifold nuts. Tilt the engine and detach the manifold from underneath.

15619R

REFITTING

Replace all the seals removed and the EGR pipe clamps. It is essential to tighten all the bolts to the specified torque. Refit the heat shield. IMPORTANT: in the case of removal of the exhaust manifold mounting studs, replace them and
seal using "LOCTITE FRENETANCH BLEUE".

16079S

12-7

FUEL SUPPLY Specifications


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 removed) (4), - four electromagnetic injectors opening directly into the combustion chamber (5).

13

16310R

Removal of the interior of the high pressure pump and the injectors is prohibited. The pressure regulator cannot be separated from the injection rail, it is essential to replace the assembly.

OBSERVE THE RULES REGARDING CLEANLINESS DESCRIBED IN THIS DOCUMENT (SECTION 17) STRICTLY WHEN WORKING ON THE FUEL SUPPLY SYSTEM.

13-1

FUEL SUPPLY Supply pump


The low pressure supply pump is immersed in the fuel tank. It is installed on the pump/gauge assembly and has a low pressure regulator (4).

13

15754R

For the removal of the low pressure supply pump, refer to the procedure described in section 19 "Pump - gauge" of Workshop Repair Manual MR 312.

13-2

FUEL SUPPLY Supply pressure / Pump output

13

ESSENTIAL SPECIAL TOOLS

Mot. 1311

Fuel pressure checking kit with pressure gauge and adapters

ESSENTIAL EQUIPMENT

2,000 ml graduated receptacle

SUPPLY PRESSURE CHECK

SUPPLY PUMP OUTPUT CHECK

Disconnect the fuel supply union (1) on the high pressure pump and fit in its place a "T" union fitted with the checking pressure gauge Mot. 1311. Start the engine to run the low pressure fuel pump. Pressure measured: 4.5 0.06 bars Maximum pressure: 6 bars

Disconnect the supply union (R) located after the fuel filter and place it in the graduated receptacle. Run the supply pump shunting the control relay or using the diagnostic equipment. Minimum output measured: 165 litres/hour.

15615R

15755R1

WARNING: THE PRESSURE READ UNDER THE "FUEL PRESSURE" PARAMETER ON THE DIAGNOSTIC EQUIPMENT CANNOT BE MEASURED USING A PRESSURE GAUGE. NO ATTEMPT MUST BE MADE TO READ IT IN ANY CIRCUMSTANCES.

13-3

FUEL SUPPLY High pressure pump

13

ESSENTIAL SPECIAL EQUIPMENT

Mot. 1383

Tool for removing high pressure unions

TIGHTENING TORQUES (in daN.m)

High pressure pump mounting bolt High pressure pipe union

1 2.5

Disconnect the low pressure fuel supply and return unions (1). Fit appropriate plugs to maintain cleanness. Remove: - the inlet manifold (refer to the procedure described in section 12 "Inlet manifold"),

The high pressure pump is a mechanical pump located at the end of the inlet camshaft. Removal of the interior of the high pressure pump is prohibited, it is sold complete. WARNING: when removing the injectors, the rail or the high or low pressure pumps, be aware of the quantity of the fuel in the unions. Protect areas susceptible to damage.

REMOVAL

WARNING:

Before carrying out any work, connect the after sales service diagnostic equipment, enter into dialogue with the injection computer and check that the pressure in the rail is below 5 bars. Be aware of the fuel temperature.

15615R3

Place the vehicle on a two post lift. Disconnect the battery.


THE RULES REGARDING CLEANLINESS MUST BE OBSERVED STRICTLY.

- the high pressure pipe (2) using tool Mot. 1383. To do this, support the pumps intermediate steel union during slackening (3) and the rail union (4), - the pump mounting bolts (5), - the intermediate shim between the pump and the cylinder head and clean its mating surface.

13-4

FUEL SUPPLY High pressure pump


REFITTING

13

Replace the intermediate shim between the pump and the cylinder head.

16127S

Fit: - the pump on its support and tighten the bolts to the specified torque, - the pipe and tighten the unions to the specified torque using tool Mot. 1383. To do this, support the intermediate steel unions of the pump and the rail.
WARNING:

After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan assembly cuts in, then accelerate several times while stationary. Check that there are no leaks.

13-5

FUEL SUPPLY Injection rail / Injectors

13

ESSENTIAL SPECIAL TOOLS

Mot. 1383 Mot. 1530 Mot. 1532 Mot. 1533

Tool for removing high pressure unions Tool for extracting injectors Tool for removing the injection rail Tool for replacing injector seals

TIGHTENING TORQUES (in daN.m)

Rail mounting bolt High pressure pipe union Pressure sensor

1.5 0.2 2.5 0.3 2 0.2

NOTE: removal of the intermediate union located between the rail and the high pressure pipe and removal of the pressure regulator is prohibited. In this case, replace the injection rail. The injectors are secured to the injection rail by means of clips. They open directly into the cylinder head combustion chamber.

13-6

FUEL SUPPLY Injection rail / Injectors


REMOVAL

13

WARNING:

Before carrying out any work, connect the after sales service diagnostic equipment, enter into dialogue with the injection computer and check that the pressure in the rail is below 5 bars. Beware of the fuel temperature.

Disconnect the battery.


THE RULES REGARDING CLEANLINESS MUST BE OBSERVED STRICTLY.

Disconnect the injection rail and injector connectors. Remove the inlet manifold (see section 12 "Inlet manifold"). WARNING: when removing the injectors, the rail or the high or low pressure pumps, be aware of the quantity of the fuel in the unions. Protect areas susceptible to damage.

15613S

13-7

FUEL SUPPLY Injection rail / Injectors


Remove the high pressure union using tool Mot. 1383 supporting the unions on the rail and on the pump (1). Fit blanking pieces to maintain cleanness.

13

NOTE: the injectors are secured to the rail by re-

taining clips. It is not necessary to remove them to extract 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 injector nozzle.

15615R4

Remove the fuel return pipe (low pressure). Fit blanking pieces to maintain cleanness. Remove the rail mounting bolts.
16635R

Extract the rail using tool Mot. 1532. Remove the injectors. Fit blanking pieces to maintain cleanness.

16126R

13-8

FUEL SUPPLY Injection rail / Injectors


REPLACEMENT OF THE INJECTOR NOZZLE SEAL

13

the seal on the cone and fit it slowly by hand,

It is essential to replace the Teflon injector seals. To do this: - clean the injector soaking it in a suitable, clean thinner. The use of a metal brush, sandpaper, or an ultrasound cleaner is prohibited, - wipe the injector nozzle using a lint-free wipe, - cut the seal carefully using circlip pliers taking care not to mark the injector, clean the injector again.

16375S

- remove the cone and retract the seal from the injector using the body of tool Mot. 1533 pushing it to its limit.

16373S

- place: the cone of tool Mot. 1533 on the injector,

16376R

16374R

13-9

FUEL SUPPLY Injection rail / Injectors


REFITTING

13

Change: - the O-rings, - the clips, - the injector Teflon seals. Position the injectors on the injection rail. Fit the injector retaining clips taking care to position them correctly.

16125S

Fit: - the injection rail, - the pipe and tighten it to the specified torque using tool Mot. 1383 taking care not to place it under stress. Refit the connectors.
WARNING:

After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan assembly cuts in, then accelerate several times while stationary. Check that there are no leaks.

13-10

FUEL SUPPLY Pressure sensor

13

ESSENTIAL SPECIAL TOOLS

Mot.

997 -01

Socket for removing the pressure sensor

TIGHTENING TORQUES (in daN.m)

Injection rail pressure sensor

2 0.2

REMOVAL

WARNING:

Before carrying out any work, connect the after sales service diagnostic equipment, enter into dialogue with the injection computer and check that the pressure in the rail is below 5 bars. Be aware of the fuel temperature.

Disconnect the battery.


THE RULES REGARDING CLEANLINESS MUST BE OBSERVED STRICTLY.

Disconnect the injection rail connectors. WARNING: when removing the injectors, the rail or the high or low pressure pumps, be aware of the quantity of the fuel in the unions. Protect areas susceptible to damage.

13-11

FUEL SUPPLY Pressure sensor


Disconnect the pressure sensor (1) and unscrew it. Fit a blanking piece to maintain cleanness.

13

15613R

REFITTING

Change the seal. Fit the sensor then tighten it to the specified torque. Refit the connector.

WARNING:

After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan assembly cuts in, then accelerate several times while stationary. Check that there are no leaks.

WARNING: removal of the fuel pressure regulator

is strictly prohibited.

13-12

FUEL SUPPLY Anti-percolation system


PRINCIPLE OF OPERATION

13

The anti-percolation system is controlled directly by the injection computer. The coolant temperature information is taken from the injection coolant temperature sensor (see section 17 "CCTM"). When the ignition is switched off, the injection computer changes to monitoring mode. If the engine coolant temperature exceeds the threshold of 100 C during the two minutes which follow switching off of the engine, the fan low speed relay is supplied. If the temperature again falls below 96 C, the fan assembly relay is cut off (operation of the fan assembly cannot exceed a duration of 10 minutes).

13-13

ANTI-POLLUTION Oil vapours rebreathing


BASIC DIAGRAM OF THE CIRCUIT

14

13042R

1 2 3 4
CHECK

Engine Oil separator Air filter housing Inlet manifold

To ensure correct operation of the anti-pollution system, the oil vapours rebreathing circuit must be kept clean and in good condition.

15612S

14-1

ANTI-POLLUTION Exhaust gas recirculation E.G.R.


PRESENTATION OF CIRCUIT

14

16080R1

3 4 5

Inlet manifold Exhaust manifold EGR valve

14-2

ANTI-POLLUTION Exhaust gas recirculation E.G.R.


PRINCIPLE OF OPERATION

14

TIGHTENING TORQUES (in daN.m)

EGR valve mounting bolt EGR valve support

2.7 1

REMOVAL OF THE VALVE

The valve is controlled by an RCO signal emitted by the injection computer. The RCO signal permits modulation of the opening of the valve, and consequently, the quantity of exhaust gas directed back towards the inlet manifold. The computer continuously carries out a test to detect the position of the EGR valve flap.

Remove: - the lower gas recirculation clip (pipe/valve), - the mounting bolts, - if necessary, the valve support (1).

OPERATING CONDITIONS

The parameters which determine the activation of the EGR solenoid valve are as follows: - air temperature, - coolant temperature, - atmospheric pressure, - accelerator pedal position, - engine speed, - vehicle speed, - battery voltage. EGR is authorised if: - the air temperature is greater than 10 C, - the coolant temperature is greater than 70 C, - the manifold pressure is between 300 and 650 mbars, - the engine speed is between 1,700 and 3,800 rpm, - a map (torque/engine speed/load potentiometer) is above a given threshold.
15615R5

REFITTING

It is essential to change the valve seal.

PURPOSE OF THE EGR SYSTEM

The computer controls the EGR except in the following 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.

The recirculation of the exhaust gas is used to reduce the nitrogen oxide (NOx) content of the exhaust gas. Passage of the gas is authorised by the control of an electromagnetic valve by the injection computer. Programming conditions: - engine speed 2,800 100 rpm, - manifold pressure of 630 150 mbars, - for a duration of approximately 30 seconds.

14-3

ANTI-POLLUTION Fuel vapours rebreathing


BASIC DIAGRAM OF THE CIRCUIT CANISTER PURGE CONDITION

14

The canister purge solenoid valve is controlled by track 4 of the computer when: - the coolant temperature is greater than 70 C, - the air temperature is greater than 10 C, - the throttle position potentiometer is not at no-load and is outside idle regulation. It is possible to display the canister purge solenoid valve opening cyclic ratio using the diagnostic equipment by consulting the parameter "Canister purge solenoid valve RCO". The solenoid valve is closed if the value is below 1.5 % (minimum value).

CANISTER PURGE OPERATION CHECK

97393-1R1

A system malfunction may result in an unstable idle or stalling of the engine. Check the conformity of the circuit (refer to the basic diagram) and the condition of the pipes to the tank (refer to Workshop Repair Manual MR 312).

1 2 3

Inlet manifold Incorporated canister purge solenoid valve Fuel vapours absorber (canister) with solenoid valve 4 Tank M Breather

14-4

STARTING - CHARGING Alternator


IDENTIFICATION

16
Intensity

Vehicle DA0 3 EA0 3

Engine

Alternator

F5R 740

BOSCH 14 V 53 98 A

100 A

CHECK

After 15 minutes of warming up under a voltage of 13.5 volts.

RPM

100 Amperes

2,000

63 A

3,000

86 A

4,000

95 A

16-1

STARTING - CHARGING Alternator


REMOVAL

16

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.

Lock the accessories belt tensioner using a 8 mm pin, then remove the belt (see section 07 "Accessories belt tensioning").

15579-1S

Remove the power steering reservoir support fasteners and unclip the power steering reservoir. Move aside the power steering reservoir and support assembly to allow access to the alternator. Remove: - the power steering pump pulley,

98710S

15576-2S

16-2

STARTING - CHARGING Alternator


- the power steering pump.
REFITTING

16

Refit in the reverse order to removal.


NOTE: on refitting, use the upper alternator and

power steering support mounting bolt to position the alternator. Take care not to crush the wiring between the compressor and the power steering support. Refer to section 07 "Accessories belt tensioning" for the tensioning procedure.

15576-4S

Disconnect the alternator. Remove the alternator mounting bolts.

15576-3S

Remove the alternator from above.

16-3

STARTING - CHARGING Starter


IDENTIFICATION

16
Starter

Vehicle DA0 3 EA0 3

Engine

F5R

BOSCH 0001 106 012

REMOVAL

From above Disconnect the starter energising connector. Remove the starter mounting bolts.

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 absorber strut to uncouple the right-hand driveshaft. Remove the air intake pipe and the resonator.

16316S

Remove the starter. To do this: - tilt the starter downwards, - free the fastener on the engine block side.

REFITTING

Refit in the reverse order to removal.

15618S

16-4

IGNITION Static ignition


TIGHTENING TORQUES (in daN.m)

17
1 to 1.5 2.5 to 3

Ignition coil bolts Spark plugs

DESCRIPTION

The ignition system is of the static type supplied with signals from the engine speed and exhaust camshaft position sensors. The power module is incorporated in the injection computer.

16124S

WARNING: the spark plugs fitted to the F5R engine are specific and have a long thread.

17-1

INJECTION General
SPECIAL FEATURES OF THE MULTIPOINT DIRECT INJECTION FITTED TO THE F5R ENGINE

17

SIEMENS "SIRIUS 3H" 90-way computer controlling the injection and the ignition. 55-way computer controlling the opening of the injectors. Multipoint direct injection operating in sequential mode from the time the engine is started. Injection warning light on the instrument panel. Use of the engine overheating warning light in the event a major fault on the high pressure circuit. Special precautions relating to the engine immobiliser. Adoption of a 2nd generation type engine immobiliser making a special computer replacement procedure necessary. High pressure fuel circuit with an electric scavenge pump (low pressure) and a mechanical high pressure pump. Idle speed - nominal idle when warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idle speeds corrected in line with: - air conditioning, - power steering, - coolant temperature, - electrical balance. Maximum engine speeds: - maximum engine speed when the coolant temperature is below 75 C . . . . . . . . . . . . . . . . . . . . 5,900 rpm - maximum engine speed for T > 75 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,500 rpm Canister purge solenoid valve controlled by opening cyclic ratio (RCO). Electric exhaust gas recirculation (E.G.R.) valve controlled by opening cyclic ratio (RCO). Use of two oxygen sensors placed upstream and downstream of the catalytic converters. Automatic configuration for AC operation by exchange of signals between computers. Control of the fan assemblies and of the coolant temperature warning light on the instrument panel by the injection computer (CCTM).

750 rpm

17-2

INJECTION Installation

17

16219

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fuel vapours absorber with solenoid valve Injection computer Pressure regulator Manifold pressure sensor Fuel pressure sensor Idle stepper motor Electric E.G.R. valve Throttle position potentiometer High pressure pump Engine speed sensor Ignition coil Air temperature sensor Knock sensor Power steering pressure switch Injectors control computer

17-3

INJECTION Installation
3 5 16 17 Pressure regulator Fuel pressure sensor High pressure injection rail Oil separator

17

15613R1

4 6 9 11 12 13 18

Manifold pressure sensor Idle stepper motor High pressure pump Ignition coil Air temperature sensor Knock sensor Coolant temperature sensor

7 8 19

Electric E.G.R. valve Throttle position potentiometer Oxygen sensor (upstream)

15617R2 16079R

17-4

INJECTION Special features of direct injection


The multipoint direct injection operates in sequential mode from the time the engine is started.

17

The computer uses a camshaft sensor to detect the position of the engine and to determine which cylinder to inject into and which spark plug to supply.

98406R1

A B C D 1 2 3 4 5 6 7 X Y Z

1 revolution of the crankshaft 1 revolution of the camshaft Top dead centre 1 - 4 Top dead centre 2 - 3 Cylinder 1 intake Cylinder 2 intake Cylinder 3 intake Cylinder 4 intake Long tooth 84 or 14 teeth 30 teeth Engine flywheel target Camshaft target Voltage supplied by the cylinder position sensor

NOTE: all values are expressed in degrees top dead centre.

The injection time is corrected in line with the fuel supply pressure.
IMPORTANT: IT IS ESSENTIAL TO FOLLOW THE INSTRUCTIONS REGARDING CLEANLINESS AND SAFETY DESCRIBED ON THE NEXT PAGE WHENEVER ANY WORK IS CARRIED OUT.

17-5

INJECTION Cleanliness / Safety

17

INSTRUCTIONS REGARDING CLEANLINESS WHICH IT IS ESSENTIAL TO FOLLOW WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM RISKS RELATING TO CONTAMINATION

The petrol direct injection system is very sensitive to contamination. The risks incurred by the introduction of contamination are: - damage to or destruction of the high pressure injection system, - seizing of a component or a component which is not sealed, - destruction of the engine (by continuous injection into the cylinder). All after sales service operations must be carried out under extremely clean conditions. This means that no impurities (particles a few microns in size) have penetrated into the high pressure injection system during removal or into the circuits via the fuel unions. The principles of cleanness must be applied from the filter to the injectors.

WHICH ELEMENTS CAUSE CONTAMINATION?

The elements which cause contamination are: - metal or plastic splinters, - paint, - fibres: cardboard, brush, paper, clothing, cloth. - foreign bodies such as hair, - ambient air, - etc...
WARNING: it is possible to clean the engine using a high pressure washer at the risk of damaging the connec-

tions. Also, the moisture may stagnate in the connectors and cause electrical connection problems. The water may also be stored in the recesses of injectors and spark plugs opening directly into the cylinder.

17-6

INJECTION Cleanliness / Safety


INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM

17

Ensure that the plugs for the unions which you wish to open are available (bag of plugs sold by the Parts Department). The plugs can be used only once. After use, they must be thrown away. (Cleaning is not sufficient to make them reusable). Ensure that plastic bags which will hermetically seal several times are available for storing removed parts. There is less risk of parts stored in this way being subjected to impurities. The bags can be used only once. After use, they must be thrown away. Ensure that lint-free cleaning wipes are available (wipes with SODICAM part numbers). The use of conventional cloth or paper is prohibited. In fact, these create lint and may contaminate the systems fuel circuit. Each wipe can be used only once.

CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE THE FUEL CIRCUIT IS OPENED

Use new thinner for each operation (used thinner contains impurities). Pour it into a clean receptacle. For each operation, use a clean brush which is in good condition (the brush must not shed its bristles). Use a brush and thinner to clean the parts to be removed, the tools which will be used and the part of the workbench used. Wash your hands before and during the operation if necessary. When using protective gloves, cover leather gloves with latex gloves (available from SODICAM).

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

As soon as the circuit is opened, it is essential to plug the openings which could allow contamination to enter. The plugs to be used are available from the Parts Department. They must not be reused in any circumstances. Reseal the bag hermetically, even if it has to be re-opened only a short time later. The ambient air carries contaminants. All components of the injection system which are removed must, after being plugged, be stored in a hermetically sealed plastic bag. After opening the circuit, the use of a brush, thinner , a blower, a scraper, or a conventional cloth is strictly prohibited. In fact, these elements are liable cause the entry of impurities into the system. If a component is replaced with a new one, do not remove this from its packaging until it is to be fitted on the vehicle. When cleaning a mating surface, use lint-free absorbent paper. Start from the centre of the part and clean gradually towards the outside to push away any impurities.

17-7

INJECTION Cleanliness / Safety

17

DI1325

17-8

INJECTION Operation
OPERATION OF THE DIRECT INJECTION

17

The low pressure pump (also called the scavenge pump) supplies the HP pump, via the filter, under a pressure of 4.5 bars. The sole purpose of the HP pump is to supply the output which it directs towards the rail. The pressure regulator located on the rail modulates the high pressure values in line with the requirements of the computer and the pressure sensor data. The fuel circulates in the rail to supply each injector.

The computers: - determine the pressure value necessary for correct operation of the engine, then control the pressure regulator. They check that the pressure value is correct by analysing the value transmitted by the HP sensor located on the rail. - determine the injection time necessary to supply the correct quantity of fuel, and the start of the injection. After determining these two values, they control each injector individually. The system can inject fuel into the engine at a pressure between 50 to 100 bars, - control the ignition.

The system consists of: - a low pressure pump (1) located in the intake assembly, - a fuel filter (2), - a high pressure pump (3) located at the end of the camshaft, - a pressure regulator and a pressure sensor (4) installed on the rail, - an injection rail (5), - four electromagnetic injectors (6), - various sensors (coolant and air temperature, pressure sensor, ...), - a 90-way injection computer and a 55-way injector control computer.

16310R1

17-9

INJECTION Injection fault warning light

17

Vehicles which operate with the multipoint direct injection system use two injection warning lights illuminated 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 possible.

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, extinguishes briefly then illuminates again depending on the fault.

PRINCIPLE OF ILLUMINATION OF THE COOLANT TEMPERATURE WARNING LIGHT

In the event of a major high pressure injection system fault, the engine overheating warning light flashes. In this case, it is essential to switch the engine off as soon as possible. These faults are: - fuel pressure regulator fault (pressure above 125 bars), - pressure sensor fault (pressure above 125 bars), - jamming of the EGR valve. In this situation, the scavenge pump (low pressure), the ignition and the injection are cut off after a few seconds.

17-10

INJECTION Engine immobiliser function

17

This vehicle is fitted with an engine immobiliser system which is controlled by a random rolling code key recognition system.

REPLACEMENT OF AN INJECTION COMPUTER

The injection computers are supplied without a code but they can all be programmed with one. When a computer is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine immobiliser function must be checked. To do this, simply switch on the ignition for a few seconds without starting the engine then switch it off. With the ignition off, the engine immobiliser function comes into operation after approximately 10 seconds (the red engine immobiliser warning light flashes).

WARNING:

In the case of this engine immobiliser system, the computer retains the engine immobiliser code for life. Furthermore, this system does not have a security code. Consequently, it is prohibited to carry out tests using computers borrowed from the warehouse or another vehicle which must then be returned. It will not be possible to erase the code.

17-11

INJECTION Injection / AC strategy


THE COMPRESSOR IS OF THE VARIABLE CUBIC CAPACITY TYPE INJECTION COMPUTER/AC COMPUTER CONNECTION

17

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 authorisation 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 information signal. When the AC switch is pressed, the AC computer requests operation of the compressor. The injection computer authorises or prohibits engagement of the compressor and imposes a modified idle speed. In this case, the engine speed may reach 200 rpm.

COMPRESSOR OPERATION STRATEGY

During certain phases of operation, the injection computer prohibits operation of the compressor.

Engine starting strategy Compressor operation is prohibited for 10 seconds after the engine is started.

Overheating protection strategy The compressor is not engaged if the coolant temperature is above 110 C.

17-12

INJECTION Idle speed correction


IDLE SPEED CORRECTION IN LINE WITH THE TEMPERATURE

17

COOLANT ( C)

Idle speed reference (rpm) 1,360 1,264 1,200 1,200 1,200 1,152 1,104 1,056 992 880 800 752 752 752 752 800 848

- 40 - 30 - 20 - 10 0 10 20 30 40 50 60 70 80 90 100 110 120

IDLE SPEED CORRECTION IN LINE WITH THE INLET MANIFOLD PRESSURE

In the event of failure of the manifold pressure sensor, the idle sped is increased to 1,020 rpm.

17-13

INJECTION Idle speed correction


POWER STEERING PRESSURE SWITCH - INJECTION COMPUTER CONNECTION

17

The injection computer receives information from the power steering pressure switch (which can be displayed on the diagnostic equipment). This depends on the pressure in the hydraulic circuit and on the fluidity of the power steering fluid. The higher the pressure, the more energy is used by the power steering pump. The injection computer alters the engine idle speed to a speed of 815 rpm.

ELECTRICAL CORRECTION IN LINE WITH THE BATTERY VOLTAGE AND THE ELECTRICAL BALANCE

The purpose of this correction is to compensate for the drop in voltage due to operation of a power consuming component while the battery is at low charge. To do this, the idle speed is increased, thus permitting the rotation of the alternator to be increased and, consequently, the battery voltage. The lower the voltage, the more significant the correction. Therefore the engine speed correction is variable. It begins when the voltage falls below 12.7 Volts. The idle speed may reach a maximum 910 rpm.

ADAPTIVE IDLE SPEED CORRECTION

The adaptive idle speed correction only takes effect if the coolant temperature is above 70 C, 30 seconds after starting the engine and if the idle regulation phase is active (no-load and vehicle stationary). The idle adaptation value makes it possible to reset the regulation in line with the age and variations of the engine.

PARAMETER

F5R 740 engines X = 750 rpm 9 % X 15 % Limit: - minimum : - 6 % - maximum : +6 %

Nominal idle speed Idle RCO Idle RCO adaptation value

Every time the engine is switched off, the computer resets the stepper motor to its lower limit.
IMPORTANT: it is essential, after erasing the computer memory, to start the engine and then switch it off to

permit resetting of the potentiometer. Start the engine again and let it run at idle so that the adaptive correction can take place.

17-14

INJECTION Fuel pressure regulation

17

The fuel pressure is regulated by the computer by supplying a regulator (1) located on the injection rail. This regulator is controlled by a reference value which takes into account the variations and the age of the engine. This control reference value can be displayed by the diagnostic equipment in "parameters" mode. The fuel pressure regulation takes into account the following components: - the injection rail pressure sensor, - the coolant temperature sensor (for the starting phase), - the engine speed sensor, - the throttle position potentiometer.

15613R2

The pressure read under the "fuel pressure" parameter should be between 45 and 100 bars (engine running) when the pressure regulation is active (Status: "Pressure regulation: CONFIRMED"). The "Fuel regulation solenoid valve RCO" parameter should fluctuate between 20 and 30 %.
NOTE: a regulation error (Parameter: "Fuel pressure regulation error") results in illumination of the fault warning light.

17-15

INJECTION Mixture regulation


OXYGEN SENSOR HEATING

17

ENTRY INTO THE MIXTURE REGULATION PHASE

The upstream oxygen sensor is heated by the injection computer from the time the engine is switched on. The downstream oxygen sensor is heated after a given period determined in line with the coolant temperature and the engine speed. Heating of the upstream oxygen sensor is stopped: - 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.

Entry into the mixture regulation phase takes effect after a given starting delay if the coolant temperature is above 20 C and if the upstream sensor is ready (sufficiently warm). The starting delay depends on the coolant temperature (between 20 C and 80 C) and is between 20 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 of operation during which the computer does not take into account the value of the voltage supplied 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 information, - in the event of failure of the oxygen sensor, - in the event of limitation of the engine speed (excessive pressure, failure...).

UPSTREAM SENSOR VOLTAGE

The value read on the diagnostic equipment under the parameter: "upstream sensor voltage" represents the voltage (expressed in millivolts) supplied to the computer by the oxygen sensor. When the engine is looped, the voltage should fluctuate 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 and minimum values, the less reliable is the information from the sensor (this gap is usually at least 500 mV).
NOTE: in the case of a small gap, check the heating of the sensor.

DOWNGRADED MODE IN THE EVENT OF FAILURE OF THE OXYGEN SENSOR SENSOR

If the voltage supplied by the oxygen sensor is incorrect during the mixture regulation phase for a minimum duration of 10 seconds, the computer switches to downgraded mode. If a failure is detected and if the failure has already been stored, the system goes straight into an open loop (mixture correction value 128).

MIXTURE CORRECTION

The value read on the diagnostic equipment under the parameter: "mixture correction" represents the average of the mixture corrections made by the computer in line with the richness of the carbonised mixture seen by the oxygen sensor. The correction value has a mid-point of 128 and limits of 0 and 255 : - value below 128: leaner mixture required, - value above 128: richer mixture required.

17-16

INJECTION Adaptive mixture correction


PRINCIPLE

17

In the looping phase the mixture regulation corrects the injection time to obtain a dosage as close as possible to mixture 1. The correction value is close to 128, with limits of 0 and 255. The adaptive correction makes it possible to offset the injection map to realign the mixture regulation around 128. Therefore, it is necessary, following reinitialisation of the computer (return to 128 of the adaptive corrections), to carry out a special road test.
PARAMETER

F5R 740 engines 96 X 192 32 X 224

Operating mixture adaptation value Idle mixture adaptive value


ROAD TEST

Conditions: - engine warm(coolant temperature > 75 C), - do not exceed an engine speed of 3650 rpm. Pressure zones which must be passed through during the test

Range n 1 (mbars) 221 F5R 740 Average 271 321

Range n 2 (mbars) 421 Average 371

Range n 3 (mbars) 521 Average 471

Range n 4 (mbars) 621 Average 571

Range n 5 (mbars) 780 Average 700

Following this test, the corrections are operational. The test must be followed by normal, smooth and varied driving for a distance of 3 to 6 miles (2 to 10 kilometres). After the test, read the mixture adaptation values. Initially 128, they should have changed. If they have not, repeat the test taking care to observe the conditions strictly.

INTERPRETATION OF THE VALUES GATHERED FOLLOWING A ROAD TEST

In the case of a lack of fuel (injectors clogged, pressure and flow of fuel too low, ...), the mixture regulation increases to obtain a mixture as close as possible to 1. The adaptive mixture correction increases until the mixture correction again fluctuates around 128. In the event of an excessive amount of fuel the reasoning is reversed: the mixture regulation decreases and the adaptive correction decreases as well to realign the mixture correction around 128.

17-17

INJECTION Centralised coolant temperature management


CCTM

17

This system is fitted with a single coolant temperature sensor which is used by the injection, the fan assembly and the temperature warning light on the instrument panel.

Operation Sensor 244 enables: - the coolant temperature to be indicated on the instrument panel, - the injection computer to be informed of the engine coolant temperature. Depending on the coolant temperature, the injection computer controls: - the injection system, - the fan assembly relays: the fan assembly is controlled at low speed if the coolant temperature exceeds 99 C and stops when the temperature falls below 96 C, the fan assembly is controlled at high speed if the coolant temperature exceeds 102 C and stops when the temperature falls below 99 C, the fan assembly may be controlled for the AC and in the event of a temperature sensor failure. - the coolant temperature warning light. In the event of failure of the coolant temperature sensor, the fan assembly is controlled continuously at low speed.

15615S

244

Coolant temperature sensor (injection and coolant temperature indication on the instrument panel). Three-way sensor, two for the coolant temperature information and 1 for the indication on the instrument panel.

COOLANT TEMPERATURE WARNING LIGHT

The coolant temperature warning light is controlled by the injection computer if the coolant temperature exceeds 118 C. When the ignition is switched on, the warning light illuminates for a few seconds. The engine overheating warning light flashes in the event of a major HP injection system fault.

17-18

INJECTION Computer
ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS
1 3 4 6 8 9 10 11 12 13 15 32 33 34 37 38 39 41 42 43 44 45 62 63 65 66 68 70 72 73 74 75

17
IGNITION COIL 2-3 CONTROL POWER EARTH CANISTER PURGE CONTROL FUEL PRESSURE REGULATOR CONTROL FAN ASSEMBLY 1 RELAY CONTROL COOLANT TEMPERATURE WARNING LIGHT AC COMPRESSOR CONTROL FUEL CONSUMPTION OUTPUT INFORMATION IDLE REGULATOR CONTROL (TRACK B) COOLANT TEMPERATURE SENSOR INPUT PRESSURE SENSOR EARTH IGNITION COIL 1-4 CONTROL POWER EARTH OBD WARNING LIGHT CONTROL FAULT WARNING LIGHT CONTROL FAN ASSEMBLY 2 RELAY CONTROL ACTUATOR RELAY CONTROL IDLE REGULATOR CONTROL (TRACK A) IDLE REGULATOR CONTROL (TRACK C) THROTTLE POTENTIOMETER SIGNAL DOWNSTREAM OXYGEN SENSOR SIGNAL UPSTREAM OXYGEN SENSOR SIGNAL EGR VALVE CONTROL UPSTREAM OXYGEN SENSOR HEATING CONTROL DOWNSTREAM OXYGEN SENSOR HEATING CONTROL +AFTER IGNITION FUEL PUMP RELAY CONTROL TDC ENGINE SPEED INFORMATION IDLE REGULATOR CONTROL (TRACK D) COOLANT TEMPERATURE SENSOR EARTH THROTTLE POTENTIOMETER AND FUEL PRESSURE SENSOR SUPPLY THROTTLE POTENTIOMETER AND FUEL PRESSURE SENSOR EARTH

-- -- -- -- -------

PRO15097

17-19

INJECTION Computer
ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS (cont)

17

16 18 19 20 23 24 26 27 28 29 30 46 49 53 54 56 57 58 59 60 76 77 78 79 80 82 83 85 87 88 89 90

-- ---------- ---- ------------ --

MANIFOLD PRESSURE SENSOR SIGNAL INPUT EGR VALVE POSITION SIGNAL KNOCK SENSOR SHIELDING KNOCK SENSOR SIGNAL INPUT AC COMPRESSOR POWER ABSORBED INFORMATION ENGINE SPEED SENSOR SIGNAL INPUT DIAGNOSTICS INTER-COMPUTER CONNECTION POWER EARTH +AFTER IGNITION +BEFORE IGNITION CAMSHAFT SENSOR SIGNAL AIR TEMPERATURE SENSOR INPUT VEHICLE SPEED INPUT ENGINE SPEED SENSOR SIGNAL INPUT DIAGNOSTICS INTER-COMPUTER CONNECTION ENGINE IMMOBILISER SYSTEM INJECTOR 1 CONTROL (TO CONTROL COMPUTER) INJECTOR 3 CONTROL (TO CONTROL COMPUTER) DOWNSTREAM OXYGEN SENSOR SIGNAL AIR TEMPERATURE SENSOR EARTH PRESSURE SENSOR SUPPLY KNOCK SENSOR EARTH UPSTREAM OXYGEN SENSOR EARTH EGR VALVE EARTH EGR VALVE SUPPLY POWER STEERING PRESSURE SWITCH INFORMATION INTER-COMPUTER CONNECTION ELECTRIC HEATED WINDSCREEN SIGNAL INJECTOR 4 CONTROL (TO CONTROL COMPUTER) INJECTOR 2 CONTROL (TO CONTROL COMPUTER)

PRO15097

17-20

INJECTION Computer
ALLOCATION OF INJECTOR CONTROL COMPUTER INPUTS AND OUTPUTS
1 2 3 4 5 22 23 25 26 27 28 29 30 33 34 35 36 37 38 40 41 42 43 51

17
INTER-COMPUTER CONNECTION INJECTOR 3 CONTROL INFORMATION (COMPUTER) INJECTOR 1 CONTROL INFORMATION (COMPUTER) TDC INFORMATION INTER-COMPUTER CONNECTION POWER EARTH POWER EARTH + AFTER IGNITION + AFTER IGNITION + AFTER IGNITION INTER-COMPUTER CONNECTION INJECTOR 4 CONTROL INFORMATION (COMPUTER) INJECTOR 2 CONTROL INFORMATION (COMPUTER) + AFTER IGNITION + BEFORE IGNITION INJECTOR 1 CONTROL INJECTOR 1 CONTROL INJECTOR 4 CONTROL INJECTOR 4 CONTROL INJECTOR 3 CONTROL INJECTOR 3 CONTROL INJECTOR 2 CONTROL INJECTOR 2 CONTROL POWER EARTH

-- -------------- ---- ---

PRN15557

17-21

INJECTION Wiring diagram

17

16414G

17-22

INJECTION Wiring diagram

17

16414D

17-23

INJECTION Wiring diagram


PARTS LIST

17

104 107 120 146 147 193, 194 195, 196 199 222 224 225 242 244 247 250 272 273 371 419 565 597 645 777 778 927

Engine immobiliser system Battery Injection computer Knock sensor Air temperature sensor Injectors Fuel gauge Throttle potentiometer Power steering pressure switch Diagnostic socket Oxygen sensor Coolant temperature sensor Instrument panel Speed sensor Air temperature sensor Speed threshold sensor Canister solenoid valve AC control unit Throttle housing Engine compartment fuse box and relays Passenger compartment ECU transponder Power fuse board Ignition coil Impact sensor

17-24

COOLING Filling - Bleeding


The circulation in the heater matrix is continuous, thus contributing to the cooling of the engine.
BLEEDING

19

FILLING

Run the engine for 20 minutes at 2,500 rpm, until the fan(s) cut in (time required for automatic degassing). Check that the fluid level is close to the "Maximum" mark.
DO NOT OPEN THE BLEED SCREW WHILE THE ENGINE IS RUNNING. RETIGHTEN THE EXPANSION BOTTLE PLUG WHILE THE ENGINE IS WARM.

Open the bleed screw located on the plenum chamber. Fill the circuit via the expansion bottle opening. Close the bleed screw when the liquid starts to flow in a continuous stream. Start the engine (2,500 rpm). Adjust the level by overflow for approximately 4 minutes. Close the reservoir.

Location of the bleed screw (1) on the plenum chamber

15615R6

19-1

COOLING Diagram

19

14887-2R1

1 2 3 4 5 6 7

Engine Radiator "Warm" reservoir with degassing in line with thermostat Heater matrix Thermostat support 3 mm nozzle 8 mm nozzle

Coolant pump Thermostat Bleed screw The expansion bottle valve calibration value is 1.6 bar (brown).

19-2

COOLING Coolant pump

19

ESSENTIAL SPECIAL TOOLS

Mot.

1202

Circlip pliers

TIGHTENING TORQUE (in daN.m)

Cleaning 1.7 It is very important that the mating surfaces are not scratched. Use the Dcapjoint product to dissolve the part of the seal which remains attached. Apply the product to the section to be cleaned, wait approximately ten minutes, then remove it using a wooden spatula. It is advisable to wear gloves during the operation. Do not allow any of the product to fall onto the paintwork.

Coolant pump bolt

REMOVAL

Place the vehicle on a two post lift. Disconnect the battery. Drain the cooling circuit via the lower engine radiator 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.

REFITTING

Refit: - the coolant pump (fitted with a new seal) tightening the bolts to a torque of 1.7 daN.m, - the accessories belt an tension it (see section 07 "Accessories belt tensioning"). Fill and bleed the cooling circuit (see section 19 "Filling - Bleeding").

19-3

COOLING Catalytic converter

19

ESSENTIAL SPECIAL TOOLS T.Av.

1233 -01

Tools for working on the subframe - axle

REMOVAL

Place the vehicle on a two post lift. Disconnect the battery. Remove the mounting nuts of the connection of the manifold and the catalytic converter. Slacken the catalytic converter / exhaust line connecting clamp to move the catalytic converter back a few centimetres. Remove: - the steering shaft yoke bolt,

- the sub-frame tie-rod mounting bolts and lower the sub-frame by 40 mm at the front and 90 mm at the rear,

15870R

- the catalytic converter.

REFITTING

Change the catalytic converter/exhaust manifold connection seal and the exhaust clamp.
IMPORTANT: ensure that the steering shaft yoke
97390-1S1

bolt is positioned correctly.

19-4

CLUTCH Cover - Disc

20
DISC

VEHICLE TYPE

ENGINE TYPE

COVER

26 splines D = 215 mm E = 6.8 mm

VM : Moss Green V : Green BC : Capri Blue BL : Light Blue

DA0 3 EA0 3

F5R 740

85873S

90693-2R16

215 CPON 4400

94990R1

Monodisc clutch operating dry, cable controlled. Clutch stop in constant contact.

20-1

CLUTCH Cover - Disc


REPLACEMENT (following removal of the gearbox)

20

ESSENTIAL SPECIAL TOOLS

Mot.

582 -01

Immobilising tool

TIGHTENING TORQUE (en daN.m)

REFITTING

Cover mounting bolt

Clean the clutch shaft splines and refit the assembly without any lubricant. Fit the disc (hub offset gearbox side). Align it.

REMOVAL

Fit immobilising tool Mot. 582-01. Remove the cover mounting bolts and remove the clutch disc. Check and change any faulty parts.

95414S

99055R1

Gradually screw in the bolts in a star formation, then tighten the cover mounting bolts to the specified torque. Remove immobilising tool Mot. 582-01. Coat with MOLYKOTE BR2 grease: - the tube guide, - the fork pads.

20-2

CLUTCH Cover - Disc


After refitting the gearbox, place the cable on the clutch fork and check the operation of the play compensation system. Check the clutch release travel. The fork travel should be: X = 25.4 to 25.9 mm

20

NOTE: in the event of an operation which does

not require removal of the gearbox, or after fitting the gearbox, DO NOT LIFT the fork as it may come free of the notch (A) of the stop.

99054R

97758-1R

20-3

CLUTCH Flywheel
REPLACEMENT OF THE FLYWHEEL ESSENTIAL SPECIAL TOOLS

20

Mot. 582-01

Immobilising tool

TIGHTENING TORQUE (in daN.m)

Flywheel bolt

5.5

REMOVAL

After removing the clutch disc, remove the engine flywheel mounting bolts (the bolts cannot be reused). Reworking of the clutch face is prohibited.

REFITTING

Clean the flywheel mounting bolt threads on the crankshaft. Degrease the contact surface of the flywheel with the crankshaft. Refit the flywheel immobilising it using tool Mot. 582-01.
COMMENT: the flywheel mounting bolts must al-

ways be replaced.

20-4

MANUAL GEARBOX Identification


"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.

21

14834-1R

A mark (1), located on the gearbox casing, indicates: A B C D Type of gearbox Gearbox index Manufacturing number Factory of manufacture

A D

JCX 000 X 000000

B C

90775R

Gears

JC5
Step down ratio 16 -57 Speedometer drive gear Without speedometer Reverse gear 11 -39

Index

Vehicle

1st

2nd

3rd

4th

5th

106

DA0 3 EA0 3

11 -41

21 -43

28 -39

31 -34

42 -31

21-1

MANUAL GEARBOX Capacity - Lubricants


CAPACITY (in litres)

21

5-speed gearbox JC5 3.1

Grade - Viscosity

TRX 75W 80W

LEVEL CHECK

92081S

Fill to the level of the opening.

21-2

MANUAL GEARBOX Consumables

21
UNIT

TYPE

PACKAGING

PART NUMBER

Right-hand sun wheel splines


MOLYKOTE BR2

1 kg box

77 01 421 145

Fork pivot Stop guide Fork pads

Clutch

LOCTITE 518

24 ml syringe

77 01 421 162

Casing assembly surfaces Threaded plugs and switches Bearing plugs Ends of the roll pins on the driveshafts Input and output shaft nuts Fixed gear and hub of 5th Differential lock drive stud

RHODORSEAL 5661

100 g tube

77 01 404 452

LOCTITE FRENBLOC

(locking and sealing resin)

24 cc vial

77 01 394 071

Parts which must always be changed


When they have been removed: - lip seals, - O-rings, - stop guide tubes, - output shaft and differential nuts, - bushes under the gears.

21-3

MANUAL GEARBOX Special features


TIGHTENING TORQUES (in daN.m)

21
2.2 3.5 2.5 6.5 17 3 6 10

Drain plug Brake caliper bolt Driveshaft gaiter bolt Lower ball joint nut Shock absorber base bolt Gearbox surround and starter bolt Suspended engine mounting to gearbox bolt Wheel bolt

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

to support the clutch control fork using string (1) to prevent it from coming free from its ball joint (located on the clutch housing).

14834R

21-4

REAR BEARING ELEMENTS Hub / Brake disc


The brake discs cannot be ground. The disc must be changed if it significantly worn or scratched.

33

TIGHTENING TORQUE (in daN.m)

Caliper mounting bolt Wheel bolt Stub axle bolt

6 10 17.5

REMOVAL

Remove - the brake linings, - the two caliper mounting bolts,


99582S

- the disc.

REFITTING

Fit the hub/disc and secure it using the stub axle nut. Tighten the nut to the specified torque. Coat the bolt with Loctite FRENBLOC. Fit the caliper and tighten the bolts to the specified torque. Press the brake pedal several times to bring the piston into contact with the linings.
99583-1R1

- the stub axle nut,

33-1

REAR BEARING ELEMENTS Hub/disc bearing


REFITTING

33

TIGHTENING TORQUES (in daN.m)

Caliper mounting bolt Wheel bolt Stub axle nut

6 10 17.5

By means of a press, refit the bearing using tubes (C) and (D).

Place the vehicle on a two post lift.

REMOVAL

Remove: - the brake/hub disc; to do this refer to the procedure described on the previous page, - the circlip. By means of a press, remove the bearing using tubes (A) and (B).

16214R

IMPORTANT: ensure that the bearing is positio-

ned correctly: the dust cover should be at the rear.


NOTE: the bearing dust cover plastic protector

should be removed at the last moment. Refit: - the circlip, - the hub/disc.

16215R

NOTE: ensure that the disc is positioned correctly for the removal of the bearing. The ABS crown wheel should be facing upwards.

33-2

STEERING ASSEMBLY Mechanical power steering pump

36

ESSENTIAL SPECIAL TOOLS

Mot.

453 -01

Hose clamps

Place the vehicle on a two post lift.

REFITTING

Refit in the reverse order to removal.


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, be prepared for the flow of power steering fluid. Remove: - the pulley (3 bolts), - the power steering pump (4 bolts).

Fill and bleed the circuit turning from lock to lock with 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 between 86 and 93 bars.

16213S

36-1

STEERING ASSEMBLY Mechanical power steering pump

36

ESSENTIAL SPECIAL TOOLS

Dir.
T.Ar.

1083 -01 1094

Tool for refitting the pulley Tool for extracting differential bearing

REPLACEMENT OF THE HUB

Place the pump on the workbench, in a vice. Fit tool T.Ar. 1094 and extract the hub.

14836R

Observe the fitting dimension: X = 41.5 mm

14837R

NOTE: insert a bolt (1) between the pump shaft and 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 to make refitting easier.
NOTE: insert a shim (2) of approximately 25 mm between tool Dir. 1083-01 and the hub.

1 Power steering pump 2 Hub

36-2

STEERING ASSEMBLY Power steering unit

36

ESSENTIAL SPECIAL TOOLS T.Av.

476 453 -01

Tool for extracting ball joints Hose clamps

Mot.

TIGHTENING TORQUES (in daN.m)

In the engine compartment: 10 2.5 6.5 7.5 5 3.5 Fit hose clamps Mot. 453-01 onto the power steering reservoir hoses. Remove the air filter unit.

Wheel bolt Universal joint bolt Engine tie-bar nut: - on gearbox - on sub-frame Steering unit to sub-frame mounting nut Steering ball joint nuts

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.

16209S

Disconnect the high and low pressure pipes on the steering unit. Plug the pipes to prevent the entry of impurities. Remove the universal joint bolt. To do this, direct the nut upwards and fit a steering wheel immobilising tool to retain the same position for refitting.

36-3

STEERING ASSEMBLY Power steering unit


Underneath the vehicle: Remove the front engine tie-bar bolt. Uncouple: - the exhaust downpipe from the exhaust assembly, - the gearbox control lever. Fit a shim to move the engine forwards.

36

- the steering unit mounting nuts, - the left-hand sub-frame/body tie-rod (2 bolts).

16210S

Removal of the tie-rod makes it possible to remove the steering unit easily. Remove the steering unit from the left-hand scuttle panel side by means of successive rotations to detach the steering with its valve/ram pipes.
16212S

Never unscrew the steering rack axial ball joints unless they are to be changed. If a steering unit is to be changed, the steering ball joints must be retained.

Remove: - the heat shield on the steering unit (2 bolts),

16211S

36-4

STEERING ASSEMBLY Power steering unit


REFITTING

36

In the case of a new steering assembly Fit the steering ball joints. Refit in the reverse order to removal observing the tightening torques. Bleed the power steering circuit, turning from lock to lock with the engine running.
NOTE: it is ESSENTIAL to observe the marking of

the steering ball joints (one mark for the righthand ball joint, two marks for the left-hand ball joint). Adjust the parallelism if necessary.

36-5

MECHANICAL COMPONENT CONTROLS Master cylinder


REFITTING

37

TIGHTENING TORQUES (in daN.m)

Pipes on master cylinder Mounting nuts on brake servo

1.7 2.3

Refit in the reverse order to removal. Check the length of the push rod. Dimension X = 22.3 mm.

Place the vehicle on a two post lift.

Adjustment according to model using rod (P).

REMOVAL

Disconnect the battery. Remove the air filter unit.

91101R

NOTE: these vehicles are fitted with a master cy-

16209S

linder incorporated in the brake servo. The sealing of the brake servo is directly connected to the master cylinder. When carrying out any work, a new seal (A) must be fitted. Position the master cylinder in alignment with the brake servo so that the push rod (P) correctly enters the master cylinder location.

Move aside the expansion bottle. Disconnect the accelerator cable. Drain the brake fluid reservoir and remove it. Disconnect the pipes on the master cylinder marking their position. Remove the two master cylinder mounting bolts and remove it.

DI3718

37-1

MECHANICAL COMPONENT CONTROLS Master cylinder


Fill the brake fluid reservoir and bleed the brake circuit.

37

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 CONTROLS Brake servo


TIGHTENING TORQUES (en daN.m)

37

Pipes on master cylinder Mounting nuts on brake servo Brake servo nuts on bulkhead

1.7 2.3 2

- the acoustic mass on the left-hand side member (2 nuts), this will make removal of the brake servo easier.

The brake servo cannot be repaired. Work is only permitted on the: - air filter, - check valve.

REMOVAL

Disconnect the battery. Remove the air filter unit.

16208R

Unhook the clutch fork cable.

16209S

Move aside the expansion bottle. Disconnect the accelerator cable. Remove: - the master cylinder (see previous page),
89204S

Disconnect the vacuum hose on the brake servo.

37-3

MECHANICAL COMPONENT CONTROLS Brake servo


In the passenger compartment Remove the pin (A) of the yoke connecting the brake pedal to the push rod by acting on the clip,
REFITTING

37

Before refitting, check: - dimension L = 104.8 mm, - dimension X = 22.3 mm.

97860R

Remove: - the stiffener, - the pedal assembly pin nut,


91101R2

Refit in the reverse order to removal. Before refitting the clutch pedal, coat the pin and the grooved sector with grease. Ensure that the clutch cable is positioned correctly on the grooved sector.

PRG37.9

Remove the pin to detach the clutch and brake pedals.


NOTE: it is not necessary to unhook the cable from the clutch pedal grooved sector.

It is necessary to remove the pedals to gain access to the mounting nuts securing the brake servo to the bulkhead. Remove: - the four brake servo mounting nuts, - the brake servo.

37-4

MECHANICAL COMPONENT CONTROLS Brake servo


Refit the cable on the clutch fork. Check that the assembly operates correctly. With the pedal at rest, in the clutch engaged position, pull the cable at the clutch fork on the gearbox. The cable should have at least 2 cm "slack". Check the fork travel. It should be: X = 27.4 to 30.7 mm.

37

91830R1

Bleed the brake circuit.

89204S

37-5

MECHANICAL COMPONENT CONTROLS Brake servo

37

ESSENTIAL SPECIAL TOOLS

Mot. 1311-01

Pressure gauge and unions for measuring pressure

SEALING CHECK

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

14213R

- position the assembly connecting the valve on the brake servo on one side and the manifold outlet pipe on the other.
14287R

NOTE: ensure that the closing valve is on the ma-

To do this: - remove the vacuum pipe completely, - retain the check valve/hose assembly (1), removing the clamp,

nifold side. Run the engine at idle for one minute. Close the valve and switch off the engine. The vacuum in the circuit is approximately 613 mbar, if the vacuum falls to 33 mbar in 15 seconds, there is a leak which may be located either: - at the check valve (change it), - at the push rod diaphragm (in this case, change the brake servo).

14216R

37-6

AIR CONDITIONING General


CONSUMABLES

62

- DELPHI HARRISON V5 compressor oil: PLANETELF PAG 488 : 220 cm3 15 (to be ordered from ELF) - Refrigerant: R134a : 750 g 30 - Compressor:
DELPHI HARRISON V5

62-1

AIR CONDITIONING Compressor

62

TIGHTENING TORQUES (In daN.m)

Remove the two R134a connecting pipes (B) on the compressor. 0.6 0.8 0.8 0.8 0.8 0.8 2.1 0.8 Fit plugs to prevent the entry of moisture. Remove: - the four fasteners (B) of the power steering pump assembly with its support then move it aside on the engine, - the compressor from above (3 bolts).

Pressure relief valve on evaporator bolt Connecting pipes on pressure relief valve nut Connecting pipes on dehydration canister retaining bolt Connecting pipes on condenser retaining bolt Condenser connecting pipe on compressor retaining bolt Pressure relief valve connecting pipe on compressor retaining bolt Compressor retaining bolt Circuit pressure sensor

REMOVAL

Drain the R134a refrigerant circuit using the filling equipment. Disconnect the battery. Remove: - the wheel arch protector, - the accessories belt.
15575R

Move aside the power steering reservoir. Disconnect the compressor clutch.
REFITTING

Check the condition of the seals and coat them with oil. If the compressor is changed, it is supplied filled with oil. Refit in the reverse order to removal. Create a vacuum, then fill the R134a refrigerant circuit using the filling equipment.
IMPORTANT: when changing the compressor, it is

essential to top up the oil correctly.

62-2

AIR CONDITIONING Condenser


REMOVAL

62

Fit plugs to prevent the entry of moisture. Remove the two cooling assembly upper fasteners.

Drain the R134a refrigerant circuit using the filling equipment. Disconnect the battery. Remove: - the air inlet on the upper crossmember, - the six upper crossmember mounting bolts,

15901R1

Remove the cooling assembly and move it back as far as possible.


98838S

Remove the four mounting bolts securing the condenser on the radiator and remove it carefully.

- the mounting nut of the connecting pipes on the condenser.

15975R

62-3

AIR CONDITIONING Condenser


REFITTING

62

Check the condition of the seals and coat them with oil. Refit in the reverse order to removal. Create a vacuum, then fill the R134a refrigerant circuit using the filling equipment.
IMPORTANT: when changing the compressor add

30 ml of oil to the circuit.

62-4

AIR CONDITIONING Connecting pipes


LOW PRESSURE PIPE REMOVAL REMOVAL

62

HIGH PRESSURE PIPE BETWEEN THE PRESSURE RELIEF VALVE AND THE DEHYDRATION CANISTER

Drain the R134a refrigerant circuit using the filling equipment. Disconnect the battery.

Drain the R134a refrigerant circuit using the filling equipment. Disconnect the battery.

Remove: - the air filter unit, - the air filter unit support, - the connecting pipes on pressure relief valve retaining bolt. Move aside the power steering reservoir. Remove the mounting bolt securing the low pressure pipe on the compressor. Fit plugs to prevent the entry of moisture. Remove the pipe.

Remove: - the air filter unit, - the air filter unit support, - the connecting pipes on pressure relief valve retaining bolt. - the mounting bolt which secures the pipes on the dehydration canister. Fit plugs to prevent the entry of moisture.

PRG62.4

Unclip the pipe from the body and remove it.


PRG62.2

REFITTING REFITTING

Check the condition of the seals and coat them with oil. Refit in the reverse order to removal. Create a vacuum, then fill the R134a refrigerant circuit using the filling equipment.
IMPORTANT: when changing a pipe, add 10 ml of

Check the condition of the seals and coat them with oil. Refit in the reverse order to removal. Create a vacuum, then fill the R134a refrigerant circuit using the filling equipment.
IMPORTANT: when changing a pipe, add 10 ml of

oil to the circuit or if a pipe bursts (rapid leak), add 100 ml of oil.

oil to the circuit or if a pipe bursts (rapid leak), add 100 ml of oil.

62-5