Vnx.su Master Propulsion 2003

8/11/2019 Vnx.su Master Propulsion 2003

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General Information

MECHANICAL SPECIFICATIONS FOR THEVEHICLE

TOWING - LASHING

OIL CHANGE

ENGINE AND TRANSMISSION ASSEMBLYVALUES AND ADJUSTMENT

AXLE ASSEMBLIES VALUES ANDADJUSTMENT

XHXB - XHXE - XHXF - XHXG

77 11 320 002

"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturerin the production of the various component units and accessories from which hisvehicles are constructed.

FEBRUARY 2003

All copyrights reserved by Renault.

EDITION ANGLAISE

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

RENAULT 2002

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GeneralInformation

Contents

Page

01A

03A

MECHANICAL SPECIFICATIONSFOR THE VEHICLE

Engine - Clutch - Gearbox 01A-1

TOWING - LASHING

All types 03A-1

Page

05A

07A

07B

OIL CHANGE

Engine 05A-1Gearbox 05A-2Power assisted steering 05A-3

ENGINE AND TRANSMISSIONASSEMBLY VALUES ANDADJUSTMENT

Dimensions 07A-1Capacity - Grade 07A-4

Alternator belt tension 07A-6Cylinder head tightening 07A-7

AXLE ASSEMBLIES VALUES ANDADJUSTMENT

Wheels and tyres 07B-1Brakes 07B-2Front axle geometry checking values 07B-3

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SPECIFICATIONSEngine- Clutch - Gearbox 01A

01A-2

A Vehicle type

a = Engine familyb = Vehicle type

B Engine serial number

Table of comparison of engine codes:

RENAULT code IVECO code

S9W206 8140.43B

S9W208 8140.43S

S9W212 8140.43N

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TOWING - LASHINGAll types 03A

03A-1

103ATOWING - LASHINGAll types

WARNING:Observe the national regulations concerning towing foreach country.Never use the driveshafts as an attachment point.The towing points may only be used for towing thevehicle on the road.Never use the towing points for removing the vehiclefrom a ditch or to lift the vehicle, either directly orindirectly.The vehicle is towed using the tow hitch ( 1).

Over a maximum distance of 60 miles (100 km): thegearbox must be in neutral and the maximumauthorised towing speed is 37 mph (60 km/h) .

Over a distance above 60 miles (100 km) or if the

gearbox is damaged: the longitudinal driveshaft mustbe disconnected at the final drive.

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FLUID CHANGE AND REFILLINGEngine 05A

05A-1

105AFLUID CHANGE AND REFILLINGEngine

DRAINING

1 Plug2 Oil filter

FILLING

3 Gauge4 Plug

Essential equipment

Sump plug spanner

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FLUID CHANGE AND REFILLINGGearbox 05A

05A-2

Gearbox

S5.200 gearbox

S6.300 gearbox

1 Fuel filler and level cap2 Drain plug

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FLUID CHANGE AND REFILLINGPower assisted steering 05A

05A-3

Power assisted steering

CHECKING THE LEVEL

Use STARMATIC 3 oil for topping up or refilling

The level, when correct, should be visible between theMIN and MAX marks on the reservoir ( 2).

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ENGINE AND GEARBOX ASSEMBLY VALUES AND ADJUSTMENT

Dimensions 07A

07A-1

107AENGINE AND GEARBOX ASSEMBLY VALUES AND ADJUSTMENTDimensions

Cab chassis

Dimensions in metres:

L1 L2 L3 L4

A 3.130 3.630 4.130 4.630

B 0.949

C 0.950 0.950 1.242 1.807

D 5.029 5.529 6.321 7.386

E 1.678

F (unloaded) 2.277 2.275 2.271 2.268

G 1.600

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Dimensions 07A

07A-2

Cab chassis


L2 L3 L4

A 3.630 4.130 4.630

B 0.949

C 0.950 1.578 2.282D 5.529 6.657 7.861

E 1.678

F (unloaded) 2.279 2.274 2.270

G 1.600

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Dimensions 07A

07A-3

VAN


L2 L3

A 3.630 4.130

B 0.949

C 1.398

D 5.977 6.477

E 1.678

F (unloaded) 2.753 2.751

G 1.600

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Capacities - grades 07A

07A-4

Capacities - grades

NOTE: never go past the MAX mark on the oil gauge.

Brake fluids must be approved by the Technical Department.

EngineAverage capacity (adjust with gauge) (1)

Draining Draining with oil filter replacement

S9W 5.2 6.3

Gearbox Final drive

S5.200 S6.300 569 669

Capacity 2.2 2.7 4.2 5.5

Brake circuit Capacity in litres Grade

Normal bleed 1SAE J 1703 and DOT 4

Bleeding the regulation circuit 1

Components Capacity in litres Grade

Fuel tank 75, 100, 140depending on vehicle

Diesel

Power assisted steering 1.5ELF RENAULT MATIC D2 or

MOBIL ATF 220

Cooling circuit 12 GLACEOL RX (type D) Add coolant only

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Capacities - grades 07A

07A-5

REMOVAL

Place the vehicle on axle stands.

Disconnect the battery.

Remove: the air filter unit, the engine undertray, cooling assembly (see Section 19A Cooling,

Cooling assembly ).

Loosen the bolts ( 1) and the lock nut ( 2 ) on the tensionwheel.

Slacken the belt by loosening the bolt ( 3 ).

Remove the belt.

REFITTING

Refit the air conditioning compressor.

Proceed in the reverse order to removal.

Note:Never refit a belt once it has been removed, always

replace it.

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Alternator belt tension 07A

07A-6

Alternator belt tension

REMOVAL



Remove: the engine undertray, the cooling assembly (see Section 19A Cooling,

Cooling assembly ). the air conditioning belt (see Section 07A Values

and settings of the engine and transmissionassembly, Air conditioning belt tension ) if thevehicle is fitted with air conditioning.

To remove the belt, pivot the automatic belt tensioner

in the direction shown below using a 15 mm angledring spanner .

Remove the alternator belt.

REFITTING


Note:Never refit a belt once removed, always replace it.

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Tightening the cylinder head 07A

07A-7

Tightening the cylinder head

CYLINDER HEAD

Always replace bolts with a thread diameter of lessthan 11.5 mm.

Cylinder head tightening procedures

Lubricate the thread of the cylinder head bolt and thewashers beneath the head with engine oil.

Tighten all the bolts in order and to torque ( 6 daNm ).

Check that all the bolts are correctly tightened to6 daNm then, bolt by bolt, tighten to an angle of180 10 .

Do not retighten the cylinder head bolts after

performing this procedure.

Note:In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil which maybe in the cylinder head mounting holes.

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VALUES AND SETTINGS OF AXLE ASSEMBLIESTyres and wheels 07B

07B-1

107BVALUES AND SETTINGS OF AXLE ASSEMBLIESTyres and wheels

wheel nut tightening torque: 36 daNm .

Pressure values are given as guidelines. The values given are for a fully laden vehicle or for motorway driving. Forvehicles with a chassis to be fitted with equipment which is likely to alter the axle loads, refer to the manufacturer'sinformation relating to the type, brand and operation of the vehicle.

Tyre pressures must be checked when cold. The increase in temperature during driving increases the pressure by0.2 to 0.3 bar .

If the pressure is checked when the tyres are warm, take this increase into account and never deflate the tyres.

Type of tyre Axle load in N for each assemblyTyre inflation pressure

in Bar

185/75 R16 C

Single wheel Twin wheel

1300 2440 3.0

1480 2760 3.5

1800 3400 4.75

185/75 R16

1480 3760 3.5

1640 3080 4.0

1800 3400 4.75

195/65 R16 C

1440 2660 3.5

1600 3020 4.0

1745 3295 4.5

1800 3400 4.75

195/75 R16 C

1350 2565 3.0

1560 2965 3.5

1760 3345 4.0

1950 3700 4.75

205/75 R16 C

1520 2850 3.0

1820 3420 3.75

2120 4000 4.75

205/80 R15 P 1600 3000 7.25

215/75 R16 C(6 tonne vehicle)

1660 3080 3.0

1880 3520 3.5

2300 4360 4.75

215/75 R16 C(6.5 tonne vehicle)

2040 3920 4.0

2300 4360 4.5

2500 4720 5.25

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VALUES AND SETTINGS OF AXLE ASSEMBLIESBrakes 07B

07B-2

Brakes

Vehicle

Disc thickness (in mm) Disc thickness (in mm)

Maximum discrun-out (in mm)Front Rear

Standard Minimum Standard Minimum

3.5 to 5 T 22 1922 19 0.02

5.5 to 6.5 T 26 23

Vehicle

Lining thickness (in mm) (mounting included)

Brake fluidFront Rear

New Minimum New Maximum

ALL TYPES 20 7 20 7 SAE J 1703DOT 4

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VALUES AND SETTINGS OF AXLE ASSEMBLIESFront axle checking values 07B

07B-3

Front axle checking values

GEOMETRY VALUES POSITIONOF FRONTAXLE (mm)

ADJUSTMENT

CASTOR

612' 20' Unladen Not adjustable

CAMBER

1 20' Unladen Not adjustable

PIVOT

6 45' 5' Unladen Not adjustable

WHEEL ALIGNMENT

-0 25' Unladen Adjust by rotating the connectingrod.

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Engine and peripherals

ENGINE AND PERIPHERALS

TOP AND FRONT OF ENGINE

DIESEL INJECTION

STARTING/CHARGING

COOLING SYSTEM

FUEL TANK

ENGINE MOUNTING


77 11 320 022


The methods may be modified as a result of changes introduced by the manufacturerin the production of the various component units and accessories from which hisvehicles are constructed."

FEBRUARY 2003

All copyrights reserved by RENAULT.

EDITION ANGLAISE

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

RENAULT 2003

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Engineand peripherals

Contents

Page

10A

11A

13B

16A

ENGINE AND PERIPHERALS

Identification 10A-1Oil consumption 10A-2Oil pressure 10A-3

Engine and gearbox 10A-4

TOP AND FRONT OF ENGINE

Timing belt 11A-1Cylinder head gasket 11A-6

DIESEL INJECTION

Features 13B-1Special notes 13B-3Location of components 13B-5Cleanliness 13B-8Diesel prefilter 13B-9High-pressure pump 13B-10Injector 13B-12Injector rail 13B-15Pressure sensor 13B-18Diesel temperature sensor 13B-19Clogging gauge sensor 13B-20

Accelerator potentiometer 13B-21Computer 13B-22Injection warning light 13B-23Computer track allocation 13B-24

STARTING - CHARGING

Alternator 16A-1Starter 16A-2

Page

19A

19C

19D

COOLING SYSTEM

Specifications 19A-1Filling - Bleeding 19A-2Check 19A-3

Diagram 19A-4Radiator 19A-5Cooling system 19A-6Water pump 19A-8

FUEL TANK

General information 19C-1Fuel tank 19C-2Filler neck 19C-3Fuel gauge 19C-4

ENGINE MOUNTING

Suspended engine mounting 19D-1

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ENGINE ASSEMBLY AND PERIPHERALSIdentification 10A

10A-1

110AENGINE ASSEMBLY AND PERIPHERALSIdentification

Vehicle type Engine Gearbox Cubiccapacity (cm 3)

Bore(mm)

Stroke(mm)

Compressionratio

XHXE S9W206 ZF S5.200

ZF S6.3002800 94.4 100 21.7:1

XHXF S9W208 ZF S6.300 2800 94.4 100 21.7:1

XHXG S9W212 ZF S6.300 2800 94.4 100 21.7:1

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ENGINE ASSEMBLY AND PERIPHERALSOil consumption 10A

10A-2

Oil consumption

OIL CONSUMPTION MEASUREMENTPROCEDURE

a) Topping up to the maximum levelThe operation must be performed with a warmengine (after the cooling fan has cut in) and aftera stabilisation period of 15 minutes so that the oilflows into the sump completely.Check using the dipstick.Top up to the MAX mark.Seal the drain plug (with a paint mark on both thefiller plug and the sump drain plug) in order to beable to check later that it has not been removed.

b) Customer driving Ask the customer to drive for approximately

1 200 miles (2 000 km) or wait until the MIN levelis reached.

c) Topping up to the MAX levelThe operation must be performed with a warmengine (after the cooling fan has cut in) and aftera stabilisation period of 15 minutes .Check using the dipstick.Top up to the MAX level.Note the quantity of oil used and mileage drivensince the last top up to MAX level.

d) Measurement of oil consumptionOIL CONSUMPTION =

Additional oil quantity (in litres)miles (in thousands)

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ENGINE ASSEMBLY AND PERIPHERALSOil pressure 10A

10A-3

Oil pressure

CHECKING

The pressure check must be made when the engine iswarm (cooling fan in operation).

Contents of the kit (Mot. 836-05).

USE

MEASURE WITH TOOL (MOT. 836-05)

Remove the oil pressure sensor located behind thealternator and fit tool (Mot. 836-05).

Special tooling required

Mot. 836-05 Oil pressure measuring kit

Engine speed in rpm Pressure in bar

750 0.8

4000 3.5

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ENGINE ASSEMBLY AND PERIPHERALSEngine and gearbox 10A

10A-4

Engine and gearbox

REMOVAL

Remove the side sills.


Remove the engine and gearbox undertrays.

Remove: the battery, the indicators, the lamp units, the radiator grille, the air filter, the upper cross member ( 1), the bumper ( 2).


Mot. 1202-01Pliers for large hose clips

Mot. 1202-02

Mot. 1448 Remote operation pliers for coolingsystem hose clips

Mot. 1390 Adjustable engine support tool

Mot. 1709 Addition for engine support

Tightening torques

longitudinal driveshaft mounting bolt 10 daNm

suspended mounting mounting bolt 5.2 daNm

gearbox support mounting bolt 2.8 daNm

wheel bolt 36 daNm

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10A-5

Remove the front cross members ( 3 ) and ( 4).

Drain: the cooling circuit using the charge station (if fitted to

the vehicle), the cooling system through the radiator bottom hose the gearbox and engine if necessary.

Remove the mounting bolt ( 5 ) from the expansionvalve air conditioning pipes flange.

Remove the mounting bolt ( 6) from the expansionvalve air conditioning pipes.

Remove: the bolt ( 7) from the air conditioning pipes flange on

the condenser, the mounting bolts ( 8) from the condenser pipes.

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10A-6

Disconnect: the air hoses on the intercooler, the cooling hoses.

Remove: the fan assembly bellows clamp, the cooling assembly mounting bolts.

Remove the cooling assembly.

Remove: the diesel filter connectors, the diesel filter.

Disconnect the inlet pipe from the diesel filter.

Disconnect: the return pipe on the high-pressure pump, the computer connectors.

Remove: the expansion chamber and its support, the battery tray, the engine / battery separation plate.

Drain the power assisted steering circuit via the oilinlet hose on the pump.

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10A-7

Remove: the power steering reservoir, the power steering reservoir mounting, the power steering pump union.

Disconnect the connectors from the engineinterconnection unit.

Unclip fuse holders ( 9).

Disconnect: the vacuum pump pipe, the heating hoses using tool (Mot. 1448), the earthing braids on the chassis.

Remove: the clutch slave cylinder, the exhaust downpipe, the gearbox control cables.

Disconnect the gearbox connectors.

Position the engine support beneath the engine.

Remove: the engine / gearbox separation plate, the left and right-hand suspended mountings

mounting bolt.

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10A-8

Remove the gearbox support mounting bolt.

Lift the engine / gearbox assembly using the enginemounting and addition (Mot 1709) to remove theengine mountings.

Pull out the trolley until it is in contact with the axle.

Fit the load positioner.

Remove the engine/gearbox assembly.

REFITTING

Position the engine / gearbox assembly following thesame method as for removal.

Refit: the right-hand suspended engine mounting, the left-hand suspended engine mounting, the gearbox support.

For information on tightening torques , seeSection 19D , Suspended mounting .


Perform the following operations: fill the gearbox with oil, fill the engine with oil, if necessary, fill and bleed the cooling circuit (see Section 19A ,

Filling and bleeding ), fill and bleed the power assisted steering circuit, fill the cooling circuit with the filling station (if fitted to

the vehicle).

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TOP AND FRONT OF ENGINETiming belt 11A

11A-1

111A TOP AND FRONT OF ENGINETiming belt

REMOVAL


Remove: the engine undertray, the air filter unit.

Drain: the cooling circuit through the radiator bottom hose, the refrigerant circuit using the filling station.

Remove the cooling assembly (see Section 19A,

Cooling assembly ).

Remove: the four mounting bolts ( 1 ) from the ventilator fan, the three mounting bolts ( 2).

Remove the air conditioning compressor belt (seeSection 07A, Power unit values and adjustment , Airconditioning compressor belt ).


Mot. 910 High-pressure pump adjustmentgauge rod

Mot. 1054 TDC setting pin

Tightening torques

Crankshaft pulley bolt 20 daNm

Tension wheel nut 4.1 daNm

Tension wheel support bolt 2.7 daNm

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11A-2

Remove the alternator belt (see Section 07A, Powerunit values and adjustment, Alternator belt ).

Remove: the air exchanger / inlet manifold pipe, the lifting lug (on the intake air heater side), the injector access flap.

Disconnect the injector connectors ( 3).

Remove the upper timing cover.

FITTING

Turn the crankshaft so that the camshaft pulleymark ( 4) aligns with the cylinder head cover mark ( 5)and the crankshaft pulley mark ( 6) aligns with thecylinder housing ( 7).

IMPORTANTNever turn the engine anti-clockwise while thetension wheel is loosened. The belt could come off.

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11A-3

Remove the exhaust downpipe.

Insert the Top Dead Centre gauge rod (Mot. 1054) inthe adjustment hole ( 8).

Insert gauge rod (Mot. 910) ( 9) into the High-Pressurepump pulley.

Remove: the accessories crankshaft pulley, the lower timing cover.

Compress the timing tension wheel with ascrewdriver ( 10 ) and fit a nut cut into the shape of acalliper behind the push rod to slacken the tensionwheel.

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11A-4

Remove: the tension wheel mounting bolts ( 11 ), the tension wheel support ( 12 ), the timing belt.

REFITTING

Check that the gauge rods (Mot. 910) and (Mot. 1054)are in place.

Align the mark on the camshaft pulley with the mark onthe cylinder head cover.

Check that the key groove is vertical ( 13 ).

Fit the belt in the order shown.

WARNINGCheck that the reels do not have any play or stiffpoints when they are rotated by hand. If they do,replace them.

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11A-5

Apply LOCTITE 542 to the tension wheel supportbolts.

Refit the tension wheel mounting bolt to a torque of2.7 daNm .

Release the timing tensioner.

Remove the gauge rod from the High-Pressure pumppulley (Mot. 910) and the Top Dead Centre gauge rod(Mot. 1054).

Provisionally refit the crankshaft pulley.

Turn the crankshaft twice in the direction of enginerotation and check that the belt is fitted.

Remove the crankshaft pulley.

Refit the lower timing cover.

Insert the tension wheel nut.

Turn the crankshaft twice.

Loosen the tension wheel, then retighten to a torque of4.1 daNm .

Checking the timing gear setting

Turn the crankshaft twice in the usual direction ofrotation and check the four adjustment points usinggauge rods (Mot. 910) and (Mot. 1054).


Tighten the crankshaft pulley bolts to torque(20 daNm ).

Refit: the alternator belt, the air conditioning compressor belt.

Perform the following operations:

fill and bleed the cooling circuit (see Section 19A,Filling/bleeding ), fill the refrigerant circuit using the filling equipment.

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TOP AND FRONT OF ENGINECylinder head gasket 11A

11A-6

Cylinder head gasket



REMOVAL

Remove: the timing belt (see operation), the air filter unit, the air intake pipe, the turbocharger air intake pipe, the expansion bottle and its mounting, the air filter mounting,

the turbocharging hoses, the radiator lower and upper hoses (cylinder head

side).

Disconnect the various sensors and the air intakeheater.

Take out the air intake heater diesel pipes from theinlet manifold.

Remove: the lifting lug (engine flywheel side), the oil decanter.

Remove: the high-pressure pipes, the diesel return pipes.

Disconnect the pressure sensor.


Mot. 910 High-pressure pump adjustmentgauge rod

Mot. 1054 TDC setting pin

Tightening torques

Crankshaft pulley bolt 20 daNm

Tension wheel nut 4.1 daNm

Tension wheel support bolt 2.7 daNm

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11A-7

Remove the injectors.

Remove: the stay between the exhaust manifold and the

cylinder cover, the turbocharger oil return pipe, the turbocharger oil intake pipe.

Remove the cylinder head cover.

Remove: the cylinder head bolts, the cylinder head.

Note:Use a syringe to remove oil from inside the top of the

cylinder head to access the cylinder head bolts.

Note:The cylinder head is centered on the cylinder coverby two pins ( A). Do not swivel the cylinder head, but

detach it by lifting it (no risk of causing the sleeves todetach as they are force-fitted).

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11A-8

Clean the cylinder head.

CHECKING THE GASKET FACE

Check that there is no gasket face bow.

Maximum bow: 0.05 mm .Maximum rectification: 0.4 mm .

Test the cylinder head for possible leaks with the

cylinder head test kit (see Garage equipmentcatalogue ).

Position the pistons at mid-stroke to prevent anycontact with the valves when the camshafts are beingrefitted.

Position the cylinder head gasket then the cylinderhead.

Check the bolts, then tighten the cylinder head (seeSection 07A Engine and transmission assemblyvalues and settings, Cylinder head tightening ).

REFITTING


Refitting the timing belt (see Section 11A Top and

Front of Engine: Timing Belt ).

Perform the following operations: Fill and bleed the cooling system, (see Section 19A

Cooling, Filling and Bleeding ). fill the refrigerant circuit using the filling equipment.

Note:During this operation, make sure that foreign bodies

do not enter the pipes leading to oil under pressure.

WARNING

Do not scratch the aluminium gasket faces.

Wear gloves during this operation.

Clean the gasket faces with DECAPJOINT cleaningproduct to dissolve the part of the gasket which isstuck to the sump and cylinder cover.

Apply the product to the part to be cleaned, waitapproximately 10 minutes, then remove residueusing a wooden spatula.

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DIESEL INJECTIONSpecifications 13B

13B-1

113BDIESEL INJECTIONSpecifications

Vehicles Gearbox

Engine

Type Index Bore

(mm)

Stroke

(mm)

Cubiccapacity

(cc 3 )

Compression

ratio

Depollution

standard

XHXE ZFS5.200 S9W 206 94.4 100 2800 21.7 Euro 3

XHXF ZFS6.300 S9W 208 94.4 100 2800 21.7 Euro 3

XHXG ZF

S6.300 S9W 212 94.4 100 2800 21.7 Euro 3

ENGINE

ENGINE SPEED (rpm) FUME OPACITY

Idle speed No load maximumHomologation

value Legal maximum

S9W 206 780 25 4200 25 0.96 m -1 (32 %) 3 m -1 (70 %)

S9W 208 780 25 4200 25 1.12 m -1 (32 %) 3 m -1 (70 %)

S9W 212 780 25 4200 25 0.95 m -1 (32 %) 3 m -1 (70 %)

DESCRIPTION MANUFACTURER/TYPE SPECIAL NOTES

High-pressure pump BOSCH 4C - VGT Pressure from 300 to 1350 bar

Booster pump (low-pressure) Pressure from 1.5 to 3 bar

Diesel pressure sensor BOSCH Screwed onto the railTightening torque: 3.5 0.5 daNm

InjectorsBOSCH

Solenoid injector Resistance: 0.33 at 20 CMaximum operating pressure: 1350 bar

Pressure regulator Screwed onto the high-pressure pumpResistance: 2.4 at 20 CTightening torque: 0.6 daNm

Injection computer BOSCH 86-track computer

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DIESEL INJECTIONSpecifications 13B

13B-2

DESCRIPTION MANUFACTURER/TYPE SPECIAL NOTES

Accelerator potentiometer HELLA Dual track potentiometer

Resistance across tracks 2 and 3Pedal in rest position: 1134 Pedal depressed: 2010

Resistance across tracks 5 and 6Pedal in rest position: infinitePedal depressed: 1004

Diesel temperature sensor BOSCH Resistance: 2115 58 at 25 C

Engine coolant temperaturesensor

BOSCH Resistance: 2115 58 at 25 C

Engine speed sensor BOSCH Resistance: 774 to 946 to 20 C

Camshaft sensor BOSCH Resistance: 774 to 946 to 20 C

"Flamstart" solenoid valve BERU Resistance: 7.5 to 8.5 at 20 C

"Flamstart" spark plug BERU Resistance: 0.3 at 20 C

Turbocharging pressuresensor

BOSCH Resistance: 5300 2900 at 20 COutput voltage, ignition on, engine off (acrosstracks 1 and 4):0.4 V for an atmospheric pressure of 200 mbar

4.65 V for an atmospheric pressure of 2500 mbar Turbocharging airtemperature sensor

BOSCH Resistance between 97 and 58 k

Atmospheric pressure sensor - Incorporated into the computer

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DIESEL INJECTIONSpecial notes 13B

13B-3

Special notes

The high-pressure direct injection system is intendedto deliver a specific quantity of diesel to the engine at aspecific time.

DESCRIPTION

BOSCH 86-track computer controlling the injectionsystem.

The system consists of: a fuel pre-filter, a low-pressure pump, a fuel filter, a high-pressure pump, a pressure regulator mounted on the pump, an injector rail fitted with a diesel pressure sensor,

four solenoid injectors, an engine speed sensor, a camshaft sensor, a turbocharger air temperature and pressure sensor, a coolant temperature sensor, a diesel temperature sensor, an accelerator pedal potentiometer, a declutchable engine cooling fan control.

The common rail direct high-pressure injectionsystem works sequentially (based on the operation ofmultipoint injection for petrol engines).

This new injection system reduces operating noise,reduces the volume of pollutant gases and particlesand produces high engine torque at low enginespeeds thanks to a pre-injection procedure.

The high-pressure pump generates the high-pressure sent to the injector rail. The pressureregulator located on the pump controls the pressureaccording to the requirement determined by thecomputer. The rail supplies each injector through asteel pipe.

The injection computer receives information fromvarious sensors. It calculates the injectioncharacteristics (advance, pre-injection, injectiontime) and controls the opening of the injectors.

The computer: determines the value of injection pressure necessary

for the engine to operate correctly and then controlsthe pressure regulator. It checks that the pressure

value is correct by analysing the value transmitted bythe pressure sensor located on the rail, determines the injection time necessary to deliver the

right quantity of diesel and the moment wheninjection should start,

controls each injector electrically and individuallyafter determining these two values.

The high-pressure pump consists: three pumping pistons, a pressure regulator which controls the output

pressure, a piston cut-off solenoid valve which modulates the

pressure in accordance with the computer.

The computer controls: the idle speed regulation, the fuel supply (advance, flow and rail pressure), the fan assembly control, the authorisation to engage the air conditioning

compressor clutch, the control of the intake air heater.

Injection computer switches on the engine coolingfan and the coolant temperature warning light on theinstrument panel.

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DIESEL INJECTIONSpecial notes 13B

13B-4

CHECKING SEALING AFTER REPAIR

Re-prime the circuit. To do this, start the low-pressurepump by switching on the ignition several times.

The system injects the diesel fuel into the engine at apressure of up to 1350 bar . Check that the injectorrail is depressurised before any work.

It is absolutely vital that you observe the tighteningtorque:

of the high-pressure pipes, of the injector flange, of the pressure sensor and pressure regulator.

When the high-pressure pump, injectors, supplyand return unions are removed, the ports should

be fitted with new and appropriate blanking piecesto prevent contaminants from entering.

Dismantling the interior of the high-pressure pumpis prohibited.

The fuel return pipe fitted to the injectors must bereplaced when it is removed.

Loosening a high-pressure pipe connection whenthe engine is running is prohibited.

You must respect the cleaning and safety advicespecified in this document when working on thehigh-pressure injection system.

After any operation, check that there are nodiesel leaks. Run the engine at idle speed untilthe engine cooling fan starts up, then accelerateseveral times with no load.

WARNINGThe engine must not run with diesel containing morethan 10% diester.

WARNINGALL PIPES REMOVED MUST BE REPLACED.

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DIESEL INJECTIONLocation of components 13B

13B-5

Location of components

51718

High-pressure pumpVariable geometry turbocharger solenoid valveComputer

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13B-6

1 Injector 2 Injector diesel return pipe3 Pressure sensor

4 Common injection rail5 High-pressure pump6 Pressure regulator 7 High-pressure pump/rail fuel supply pipe

8 Diesel filter 9 Diesel heater 10 Water present indicator 11 Diesel fuel temperature sensor 12 Diesel filter clogging indicator

13 Declutchable engine cooling fan connector 14 Coolant temperature sensor 15 Coolant temperature probe

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13B-7

16 Engine speed sensor

17 Variable geometry turbocharger solenoid valve18 Computer

19 Diesel pre-filter 20 Low-pressure pump

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DIESEL INJECTIONCleanliness 13B

13B-8

Cleanliness

INSTRUCTIONS TO BE FOLLOWED BEFOREOPENING THE FUEL CIRCUIT

Use new thinner for each operation (used thinnercontains impurities). Pour it into a clean receptacle.

For each operation, use a clean brush in goodcondition (the brush must not shed its bristles).

Use a brush and thinners to clean the connections tobe opened.

Blow compressed air over the cleaned parts (tools,cleaned the same way as the parts, connections andinjection system zone). Check that no bristles remainadhering.

Wash your hands before and during the operation ifnecessary.

When wearing leather protective gloves, cover themwith latex gloves.

INSTRUCTIONS TO BE FOLLOWED DURING THEOPERATION

As soon as the circuit is open, all openings must beplugged to prevent impurities from entering thesystem. The plugs to be used are available from theParts Stores. They must not, under anycircumstances, be reused .

Close the resealable bag, even if it has to bereopened shortly afterwards. The ambientatmosphere carries impurities.

All components removed from the injection systemmust be stored in a hermetically sealed plastic bagonce the plugs have been inserted.

The use of a brush, thinner, bellows, sponge ornormal cloth is strictly prohibited once the circuit hasbeen opened. In fact, these tools are liable to causedirt to enter the system.

If a component is being replaced, the newcomponent must not be removed from its packaginguntil it is ready to be fitted to the vehicle.

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FUEL SUPPLYDiesel pre-filter 13A

13A-9

2113AFUEL SUPPLYDiesel pre-filter

The cartridge is located under the engine.

REMOVAL

Disconnect: the pipes ( 1 ) coming from the tank, the engine supply ( 2) pipes.

Unclip the pre-filter.

REFITTING


Be careful not to squeeze or damage the pipes.

FOLLOW THE CLEANLINESS INSTRUCTIONSCLOSELY

WARNINGBe careful of the diesel fuel in the pipes.

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DIESEL INJECTIONHigh-pressure pump 13B

13B-10

2213BDIESEL INJECTIONHigh-pressure pump

DISMANTLING THE INTERIOR OF THE HIGH-PRESSURE PUMP IS PROHIBITED

REMOVAL


Remove the air filter unit.

Disconnect the oil vapour rebreathing pipe ( 1) on thefiller neck.

Disconnect: the solenoid valve connector ( 2) for deactivating a

component, fuel supply pipe ( 3), fuel return pipe ( 4) on the high-pressure pump, the pressure regulator connector ( 5).

Remove: the pump - rail pipe ( 6), the return unit ( 7), the three mounting nuts ( 8) from the high-pressure

pump, the high-pressure pump, the seals on the pump.

Tightening torques

high-pressure pump nuts 2.7 daNm

pump - rail pipe 2.2 daNm

WARNING

Before any operation, connect the After-Salesdiagnostic tool, establish dialogue with the injectioncomputer and check that the injection rail is nolonger pressurized.

Wait until the fuel temperature drops.

Order the special high-pressure injection circuit plugkit.

YOU SHOULD FOLLOW THE CLEANLINESSINSTRUCTIONS CLOSELY

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DIESEL INJECTIONHigh-pressure pump 13B

13B-11

Clean the high-pressure pump.

REFITTING

Fit the pump with new seals.

Finger-tighten the high-pressure mounting nuts.

Fit the injection pipe between the high-pressure pumpand the rail and pretighten by hand until it touches.

Tighten the injection pipe to a torque of 2.2 daNm .

Torque tighten the high-pressure pump mountingnuts ( 2.7 daNm ).


Before starting the engine, reprime the fuel circuit. Start the low-pressure pump by switching on the

ignition several times. Start the engine.

Check that there are no stored faults using thediagnostic tool. Clear them if necessary.

WARNING

Do not scratch the aluminium gasket faces.

Wear gloves during this operation.

Clean the gasket faces with DECAPJOINTcompound to dissolve any pieces of gasket whichare still attached.

Apply the product to the part to be cleaned, waitapproximately 10 minutes, then remove residueusing a wooden spatula.

After any operation, check that there are no leaks inthe diesel circuit.Proceed as follows:

run the engine at idle speed until the fan starts up,

accelerate several times under no load, carry out a road test, switch the ignition off and check that there is no

leakage of diesel.

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DIESEL INJECTIONInjector 13B

13B-12

Injector

DISMANTLING THE INTERNAL COMPONENTS OFAN INJECTOR IS PROHIBITED

REMOVAL


Remove: the air filter unit, the lifting bracket, the engine cover.

Disconnect: the injectors ( 1), the pressure sensor ( 2).

Tightening torques

high-pressure pipe unions 2.2 daNm

injector flange bolt 4.4 daNm

WARNING

Before any operation, connect the After-Salesdiagnostic tool, establish dialogue with the injectioncomputer and check that the injection rail is nolonger pressurized.



YOU SHOULD FOLLOW THE CLEANLINESSINSTRUCTIONS CLOSELY

Note: injectors may be replaced individually. all high-pressure pipes which are removed must

always be replaced.

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13B-13

Remove: the diesel return pipes ( 3), the injection pipes ( 4 ).

Remove: the injector flanges, the injectors.

Fit anti-pollution plugs.

CLEANING

It is strictly forbidden to use the following whencleaning the injector:

a wire brush, an emery cloth, an ultrasound cleaner.

To clean the nose of the injector, let it soak indegreaser, then wipe it with a lint-free cloth.

REFITTING

Refit: the injectors the injector brackets.

Tighten to torque: the injector flange bolts to 4.4 daNm , the injection pipes to 2.2 daNm .

Note:Remove the blanking plugs at the last moment.

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13B-14

Refit the fuel return pipe to the injectors.


Throw away the bag of used plugs after the operation.

Use the diagnostic tool to clear any faults which maybe stored by the computer before restarting theengine.

After any intervention, check that there are no leaksin the diesel circuit.Proceed as follows:

run the engine at idle speed until the fan starts up, accelerate several times under no load, carry out a road test, switch the ignition off and check that there is no

leakage of diesel.

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DIESEL INJECTIONInjector rail 13B

13B-15

Injector rail

REMOVAL


Remove: the air filter unit, the engine cover, the lifting bracket.

Remove the bolts ( 1) from the oil decanter.

Remove: the lifting bracket ( 2), the bolts ( 3) from the rail protector, the rail protector.

Tightening torques

injection pipe union 2.2 daNm

injection rail mounting bolt 2.7 daNm

WARNING

Before any operation, connect the After-Salesdiagnostic tool, establish dialogue with the injectioncomputer and check that the injection rail is nolonger under pressure.

Make a note of the fuel temperature.



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13B-16

Disconnect the pressure sensor and the injectorwiring.

Remove the injection pipe ( 4) between the high-pressure pump and the rail.

Remove pipes ( 5) from the injectors.

Remove the three nuts ( 6) from the injector rail.

Fit plugs to maintain cleanliness.

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13B-17

REFITTING

Fit the injector rail.

Finger tighten the rail mounting bolts 6).

Fit and hand tighten: the pipe between the pump and the rail, the pipes between the rail and the injectors.

Tighten to torque:

the three injector rail mounting bolts (2.7 daNm ), the injection pipe unions on the rail and the high-pressure pump (2.2 daNm ).

Refit the rail protector and tighten the bolts to torque(2.7 daNm ).

Tighten to torque: the oil circuit metal tube , the lifting bracket nuts , the oil decanter bolts , the injection pipe unions on the rail and injectors

(2.2 daNm ).

Continue the refitting procedure in the reverse order toremoval.

Throw away the bag of plugs used during theoperation.

Use the diagnostic tool to clear any faults which maybe stored by the injection computer before restartingthe engine.

Before starting the engine, reprime the fuel circuit. Start the low-pressure pump by switching on the

ignition several times. Start the engine.Note:

Leave removal of the anti-pollution plugs from any

component until last.

After any intervention , check that there are noleaks in the diesel circuit.Proceed as follows:


leakage of diesel.

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DIESEL INJECTIONPressure sensor 13B

13B-18

Pressure sensor

REMOVAL


Remove the access flap on the engine cover.

Disconnect the pressure sensor.

Unscrew the pressure sensor using tool (Mot. 1495).

Remove the pressure sensor.

Fit anti-pollution plugs.

REFITTING

Replace the pressure sensor seal.

Remove blanking plugs.

Screw in the sensor then tighten it to torque.

Connect the sensor connector.

Refit the access flap.

Tightening torque

pressure sensor 3.5 0.5 daNm

WARNING

Before any operation , connect the After-Salesdiagnostic tool, establish dialogue with the injectioncomputer and check that the injection rail is nolonger under pressure.

Make a note of the fuel temperature.



After any intervention , check that there are noleaks in the diesel circuit.Proceed as follows:


leakage of diesel.

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DIESEL INJECTIONDiesel fuel temperature sensor 13B

13B-19

Diesel fuel temperature sensor

1 Diesel fuel temperature sensor

Tightening torque

diesel fuel temperature sensor 1.8 daNm

WARNINGBefore any operation , connect the After-Salesdiagnostic tool, establish dialogue with the injectioncomputer and check that the injection rail is nolonger under pressure.


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DIESEL INJECTIONClogging gauge sensor 13B

13B-20

Clogging gauge sensor

1 Clogging gauge sensor

Tightening torque

clogging gauge sensor 3 daNm

WARNING

Before any operation, connect the After-Salesdiagnostic tool, establish dialogue with the injectioncomputer and check that the injection rail is nolonger under pressure.


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DIESEL INJECTIONAccelerator potentiometer 13B

13B-21

Accelerator potentiometer

REMOVAL

Disconnect: the battery, the accelerator pedal connector ( 1 ).

Remove: the three pedal mounting bolts ( 2 ), the pedal.

REFITTING


CONNECTION

Track Description

1 Not used

2 Track 1 earth

3 Track 1 signal

4 Track 1 feed

5 Track 2 feed

6 Signal: track 2

Pedalposition

Resistance(in ) of track 1across tracks 2

and 3

Resistance(in ) of track 2across tracks 5

and 6Released 1134 infinite

Depressed 2010 1004

Note: A fault on the accelerator position potentiometercauses changes in the idle speed or engineoperation.

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DIESEL INJECTIONComputer 13B

13B-22

Computer

REMOVAL

Remove: the battery, the computer nuts ( 1 ), the computer and disconnect it.

REFITTING


Program the immobiliser code following the proceduredescribed in Section 82A , Engine immobiliser .

If necessary repair the faults that appear then clearthem.

Check that the vehicle is operating correctly.

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DIESEL INJECTIONInjection warning light 13B

13B-23

Injection warning light

Vehicles with the high-pressure diesel injection systemhave injection fault warning lights and a coolanttemperature warning light.

The preheating warning light is represented by anorange coil along with the electronic fault symbol. Thecoolant temperature warning light is represented by anengine along with the message ST OP.

PRINCIPLE FOR WARNING LIGHTS COMING ON

When the ignition is switched on, the preheatingwarning light comes on during the preheating phasethen goes out (see Section 13 , Preheating control ).

When there is an injection fault (severity level 1), the

injection warning light comes on permanently (it isnecessary to contact a RENAULT Dealer). Thesefaults are:

turbocharging pressure sensor fault, diesel temperature sensor fault, coolant temperature sensor fault, engine speed sensor fault, camshaft sensor fault, engine cooling fan control relay fault, injector fault, 3 rd high-pressure pump component cut-out

solenoid valve, engine speed synchronisation fault, battery voltage fault, injection computer fault.

When there is a serious injection fault (severity level2), the injection fault warning light comes on andflashes, in this case the vehicle must be stoppedimmediately. These faults are:

diesel pressure sensor fault, sensor supply fault, injector fault, injector supply fault, diesel pressure regulator fault, booster pump relay fault, injection computer fault, accelerator potentiometer fault.

When the engine overheats, the coolant temperaturewarning light comes on.

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DIESEL INJECTIONAllocation of computer tracks 13B

13B-24

Allocation of computer tracks

CONNECTOR A CONNECTOR B

A1 A2 A3

A6

A7 A8 A9

A10 A12 A13 A14

A15 A18 A19

A20

A21

A23 A24 A29 A30

A31 A32 A33 A34 A35 A37 A39

A40 A41

A42 A43

---

---

---

---

---

---

---

---

------

Coolant temperature sensor signal Air temperature sensor signalTurbocharging air temperature and

pressure sensor supplyTurbocharging temperature andpressure sensor earthFuel pump relay controlVariable geometry turbocharger controlHigh-pressure flow regulation solenoidvalve supplyInjector no. 4 controlInjector no. 1 controlPressure sensor supplyEngine immobiliser computerconnection

Diesel temperature sensor signal Air temperature sensor signalTurbocharging air temperature andpressure sensor earthHigh-pressure flow regulation solenoidvalve earthHigh-pressure pump component cut-out solenoid valve controlInjector no. 2 controlInjector no. 3 controlSpeed sensor signalCoolant and fuel temperature sensorsearthCamshaft sensor earthDiesel heater relay controlPressure sensor signalTurbocharging pressure sensor signalDeclutchable engine cooling fan supplyEngine speed sensor earthDeclutchable engine cooling fan relaycontrolInjector no. 1 controlInjector no. 3 control

Injector no. 2 controlInjector no. 4 control

B2

B4

B6B7B9B10B11

B12B14B19B20B21B22

B23B24B26B27

B29

B30B31B35

B38B40B41B42B43

------

------

---

------

---

---

---

---

Potentiometer track no. 1 potentiometersignalEngine speed sensor signal

Air-conditioning relay controlFault finding procedure+ After ignition+ After ignition

Air intake heater solenoid valve relaycontrolEarthEngine speed sensor earthFault finding procedure+ After ignitionPreheating warning light+ After ignition

High-pressure circuit warning lightEarthBrake switch track no. 1 signal

Accelerator pedal potentiometer trackno. 1 earth

Accelerator pedal potentiometer trackno. 2 signalPower take-off signalBrake switch track no. 2 signal

Accelerator pedal potentiometer trackno. 1 supplyClutch switch signalSupply relay control+ After ignitionIntake heater plug relay controlEarth

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STARTING - CHARGINGAlternator 16A

16A-1

116ASTARTING - CHARGINGAlternator

REMOVAL


Remove the engine undertray.

Disconnect: the battery, the alternator electrical connections.

Remove: the air conditioning compressor belt (see

Section 07A , Air conditioning compressor belt ) iffitted to the vehicle,

the alternator belt (see Section 07A , Alternatorbelt ),

the alternator mounting bolts, then remove it using ascrewdriver.

REFITTING

To facilitate fitting the alternator, compress rings ( 1)using pliers or a vice.


Refit: the air conditioning compressor belt, the alternator belt.

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STARTING - CHARGINGStarter 16A

16A-2

Starter

REMOVAL


Remove the shield from underneath the gearbox.

Disconnect the starter motor feed.

Remove the starter motor.

REFITTING

Check for the presence of the centring dowel.


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COOLING SYSTEMSpecifications 19A

19A-1

119ACOOLING SYSTEMSpecifications

VOLUME AND GRADE OF COOLANT

THERMOSTAT

Engine Volume (in litres) Grade Special notes

S9W 206

12 GLACEOL RX Type D usecoolant only

Protection down to- 20 C 2 for hot,temperate and cold

countries.

Protection down to- 37 C 2 for very cold

countries.S9W 208

S9W 212

Engine Start of opening (in C) Fully open (in C)

S9W 206

76 86S9W 208

S9W 212

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COOLING SYSTEMFilling - Bleeding 19A

19A-2

Filling - Bleeding

FILLING

Open the bleed screw on the radiator top hose.

Fill the circuit through the expansion bottle opening.

Close the bleed screw as soon as the fluid runs out ina continuous jet.

Fill the bottle until the coolant overflows.

Refit the bottle cap and tighten it.

AUTOMATIC BLEED

Turn on the engine.

Let the engine run at 2500 rpm , until the enginecooling fan has completed three operating cycles (time required for automatic degassing).

If necessary, adjust the coolant level in the expansion

bottle.

Note:The engine must be stopped and the air-conditioning

system off so that the engine cooling fan is notrunning when you start.

WARNING do not open the bleed screw while the engine is

running and hot, do not open the expansion bottle while the engine

is hot (over 50 C) or running, top up if required, retighten the expansion bottle cap while the

engine is hot, using approved equipment, measure the degree

of coolant protection, check for any possible leaks, make sure the passenger compartment heating

works properly.

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COOLING SYSTEMChecking 19A

19A-3

Checking

1 - Checking sealing

Turn the heater matrix tap to the "heating" position.

Replace the expansion bottle valve with adapterMs. 554-01.

Warm up the engine then switch it off.

Pump to pressurise the circuit.

Put the circuit under a maximum pressure of 0.9 bar .

The pressure should not drop; if it does, look for theleak.

Slowly unscrew the union of tool M.S. 554-07 todepressurise the cooling circuit, then remove toolM.S. 554-01 and refit the expansion bottle valvecomplete with a new seal.

2 - Checking the valve rating

If liquid passes through the expansion bottle valve, thevalve must be replaced.

Adapt tool Ms. 554-06 on pump Ms. 554-07, and fit thevalve to be checked onto it.

Increase the pressure, which should stabilise at thevalve rating pressure with a test tolerance of 0.1 bar .

Valve rating: 0.8 bar.

Essential special tooling

Ms. 554-01 Adapter for Ms. 554-07

Ms. 554-06 Adapter for Ms. 554-07

Ms. 554-07 Kit for testing cooling circuit sealing

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COOLING SYSTEMDiagram 19A

19A-4

Diagram

1 Engine2 Radiator 3 "Hot" bottle with permanent degassing4 Coolant pump5 Thermostat6 Temperature switch

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COOLING SYSTEMRadiator 19A

19A-5

Radiator

REMOVAL


Remove: the air filter unit, the direction indicators, the radiator grille, the upper cross member ( 1), the bumper ( 2 ).

Remove the front cross members ( 3) and ( 4 ).

Disconnect the radiator temperature sensor connector.

Remove the radiator top and bottom hoses.

Remove the radiator mounting bolts.

REFITTING


Fill and bleed the cooling system (see Filling andbleeding ).

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COOLING SYSTEMCooling system 19A

19A-6

Cooling system

REMOVAL


Drain: the cooling circuit through the top hose, the refrigerant circuit using the filling station.

Remove: the air filter unit, the engine oil filler neck mounting bolt.

Remove: the direction indicators, the radiator grille, the upper cross member ( 1), the bumper ( 2).

Remove the front cross members ( 3) and ( 4 ).

Disconnect the fan assembly connectors.

Remove: the intercooler hoses, the radiator coolant hoses.

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COOLING SYSTEMCooling system 19A

19A-7

Cooling system

Remove bracket ( 5 ) from the pressure relief valveconnecting pipes.

Remove mounting ( 6) from the pressure relief valveconnecting pipes.

Remove: bolts ( 7) mounting the connecting pipes on the

condenser, bracket ( 8) from the connecting pipes, the fan assembly gaiter clip, the four cooling assembly mounting bolts.

Remove the cooling assembly.

REFITTING



It is vital to replace the seals and lubricate them with

refrigerant fluid.

Create a vacuum, then fill the refrigerant circuit usingthe filling equipment.

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COOLING SYSTEMCoolant pump 19A

19A-8

Coolant pump

REMOVAL



Drain the cooling circuit through the radiator bottomhose.

Remove: the timing belt (see Section 11A Timing belt ), the tensioning roller, the timing tensioner, the coolant pump by disconnecting the thermostat

unit.

REFITTING

Clean the coolant pump.

Fit the new seal.

Pretighten mounting bolts ( 1) until they come intocontact with the coolant pump, then tighten them to atorque of 5.5 daNm .

Refit the timing belt (see Section 11A Timing belt ).


Tightening torques

coolant pump bolts 5.5 daNm

WARNINGDo not scratch the aluminium gasket faces.Wear gloves during this operation.Clean the gasket faces with DECAPJOINT product

to dissolve any pieces of gasket which are stillattached.

Apply the product to the part to be cleaned, wait 10minutes, then remove residue using a woodenspatula.

Note: Apply a drop of LOCTITE FRENETANCH to thecoolant pump bolts.

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TANKGeneral information 19C

19C-1

119CTANKGeneral information

There are three types of tank for this vehicle: 95 litres , 100 litres , 140 litres .

The removal and refitting procedures are similar.

The tank is vented via a valve ( 1 ).

This valve also has the function of preventing fuel leaks if the vehicle rolls over.

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TANKFuel tank 19C

19C-2

Fuel tank

REMOVAL

Drain the tank.


Remove the side sills.Place the vehicle on axle stands.

Remove: the spout sleeve ( 1 ), the venting pipe ( 2 ).

Disconnect the supply pipe quick-release couplingfrom the tank with tool (Mot. 1265-01).

Position two trolley jacks underneath the tank.

Remove the four tank mounting nuts.

Partially lower the tank and disconnect the gaugeconnector.

Remove the fuel tank.

REFITTING


During refitting, take care to: systematically replace the tightening clamps, not restrict the pipes, fit quick release couplings by hand and check that

they are correctly locked into place.

IMPORTANTDuring this operation, it is essential to:

refrain from smoking or bringing hot objects closeto the work area,

use suitable protection against petrol splashescaused by the residual pressure in the pipes,

protect sensitive areas from petrol.

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TANKFiller neck 19C

19C-3

Filler neck

REMOVAL


Tilt the part marked ( 1 ) of the plastic protector ( 2).

Remove screw ( 3) and then unclip the plastic protector(2).

Remove: the sleeve ( 4 ), the venting pipe ( 5 ) on the fuel filler neck side.

Remove: the four fuel filler neck mounting bolts, the three mounting nuts from the fuel filler neck

mounting plate, the filler neck.

REFITTING


During refitting, take care to: systematically replace the tightening clamps, not restrict the pipes.

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TANKFuel gauge 19C

19C-4

Fuel gauge

REMOVAL

To remove the gauge, it is necessary to remove thetank (see Section 19C , Tank, Tank ).

Disconnect: the quick release supply coupling ( 1) using tool

(Mot. 1265-01), the venting pipe ( 2).

Remove the gauge mounting nut with tool (Mot. 1397).

Allow all the fuel in the gauge to flow out, then removeit.


Mot. 1397 Fuel gauge dismounting nut

Mot. 1265-01 Pliers for quick release couplings

Tightening torque

gauge nut 6 daNm

IMPORTANTDuring this operation, it is essential to:

refrain from smoking or bringing hot objects closeto the work area,

use suitable protection against petrol splashes

caused by the residual pressure in the pipes, protect sensitive areas from petrol.

WARNINGBefore any removal, check the flow of fuel (do notrestrict pipes as they risk being damaged).

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TANKFuel gauge 19C

19C-5

REFITTING

Replace the O-ring seal.

Refit the gauge.

Position the nut and tighten it until the indexing pointson it correspond with the indexing points on the gauge.

Refit the tank (see Section 19C, Tank, Tank ).

CONNECTION

Note:If several hours will pass between removing andrefitting the pump / sender assembly, screw the nutback onto the tank to avoid any damage.

Track Description

A1 Earth

A2 Minimum level warning light

B1 Sender unit information to instrumentpanel

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TANKFuel gauge 19C

19C-6

CHECKING THE GAUGE SENDER UNIT

Ensure that the resistance varies when the float ismoved.

Measuring height H

Place the removed sender unit on a flat surface.

H is the height measured between the float pin and theseal contact surface (upper part of the gauge,connection between the fuel tank and the gauge).

Indication Value between terminals A1 and B1(in )

95 litres 100 litres 140 litres

4/4 7 7 20 4 7 7

3/4 54.5 7 40 6 54.5 7

1/2 98 10 68 10 98 10

1/4 155 16 109 15 155 16

Spare 275 15 137 15 275 15

Indication Height H (in mm)

95 litres 100 litres 140 litres

4/4 0 0 0

3/4 94 99.65 87.6

1/2 141 160.40 150.6

1/4 196 224.45 199.9Spare 235 254.45 254.9

Note: All the above values are given merely as anindication.

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ENGINE MOUNTINGSuspended engine mounting 19D

19D-1

119DENGINE MOUNTINGSuspended engine mounting

Tightening torques

A 9.4 daNm

B 9 daNm

C 5.5 daNm

D 3.9 daNm

E 3.9 daNm

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Engine and peripherals

DIESEL INJECTION


77 11 315 502


The methods may be modified as a result of changes introduced by the manufacturerin the production of the various component units and accessories from which hisvehicles are constructed."

APRIL 2002

All copyrights reserved by Renault.

EDITION ANGLAISE

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

RENAULT 2002

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Engineand peripherals

Contents

Page

13B DIESEL INJECTION

Introduction 13B-1Interpretation of faults 13B-2

Customer complaints 13B-97Fault finding chart 13B-98Components sheet 13B-111Glossary 13B-115

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DIESEL INJECTIONFault finding - Introduction 13B

13B-1

S9W BOSCH MS6.3Electronic version: MS6.3Engine type number: 140

DIESEL INJECTIONFault finding - Introduction

FAULT FINDING PROCEDURE:

Use one of the diagnostic tools to identify the system fitted to the vehicle (reading the computer family,program No., Vdiag No., etc.).

Locate the Fault finding documents corresponding to the system identified. Take note of information contained in the Introduction sections. Read the faults in the computer memory and use the Interpretation of faults section of the documentation.

Reminder: Each fault is interpreted by a particular type of storage (fault present, fault stored in memory, faultpresent or stored). The checks specified for dealing with each fault are therefore only to be carried out if the faultshown by the diagnostic tool is described for its type of storage. The storage type should be considered when usingthe diagnostic tool following ignition switch-off and switch-on.

If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the notes box.If the conditions are not satisfied, use the fault finding strategy to check the circuit of the faulty part since the fault isno longer present on the vehicle. Perform the same operation when a fault is declared as stored by the diagnostictool but is only interpreted in the documentation as a present fault.

Carry out the conformance check (appearance of possible faults not yet identified by the system's self-diagnosticprocedure) and implement the associated fault finding strategies according to the result.

Confirm the repair (customer complaint disappears). Use the diagnostic procedure for each customer complaint according to the fault finding chart if the problem

persists.

TOOLING REQUIRED

To enter into dialogue with the injection computer: NXR and CLIP (Optima).

For miscellaneous electrical checks: Optima 5800 with optional garage multimeter and temperature sensor.

Connector A carries the Engine harness wires.

Connector A carries the Passenger Compartment harness wires.

WARNING:

Any fault finding procedure requiring work to be carried out on the high pressure injection system requiresfull understanding of the cleanliness and safety instructions in Section 13 of the Workshop Repair Manualfor the vehicle concerned.

This document introduces the generic fault finding procedure applicable to all:

Bosch MS6.3, Electronic version: MS6.3, Engine type number: 140 (bhp).

A Fault Finding Special Features Technical Note is available for every vehicle fitted with this computer.It covers all the fault finding special features in this document for the vehicle concerned.The following are required for carrying out fault finding on this system:

the fault finding special features Technical Note for the vehicle,

the wiring diagram of the function for the vehicle concerned,

the tools listed under the Special Tooling Required section.

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DIESEL INJECTIONFault finding - Interpretation of faults 13B

13B-2

S9W BOSCH MS6.3Electronic version: MS6.3Engine type number: 140 Fault finding - Interpretation of faults

DF075

ATMOSPHERIC PRESSURE SENSORDEF : Internal electronic fault

NOTES The fault is detected if: the computer detects a problem with the internal pressure sensor.

DEF Clear the faults from memory and then start the engine.

If the fault is still there, contact the Techline.

AFTER REPAIR

Deal with any other possible faults.Clear the fault memory.Switch off the ignition.Carry out a road test, then a check with the diagnostic tool.

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13B-3


DF074

TURBOCHARGER PRESSURE SENSORCO.0 : Open circuit or short circuit to earthCC.1 : Short circuit to + 12 V1.DEF : Feed voltage too high2.DEF : Feed voltage too low3.DEF : Measured pressure too high

NOTES The fault is detected:

if the manifold pressure sensor voltage is less than 0.25 V , when the + after ignition is switched on.

CO.0 Disconnect the "inlet manifold pressure sensor/air temperature sensor" connectorand the injection computer connector.

Check the continuity and insulation of the pressure signal lines:track 3 of the pressure sensor track A3 of the injection

computer track 4 of the pressure sensor track A34 of the injection

computer

Check the earth insulation on track A3 of the injection computer. It must be morethan 10 M .

Check the earth insulation on track A34 of the injection computer. It must be more

than 10 M .Repair if necessary.

Reconnect the injection computer and check the presence of + 5 V on track 3 andtrack 1 of the pressure sensor connector with + after ignition.

If the fault persists, contact your Techline.

Clear the faults from memory and then start the engine.

If the fault persists, change the pressure sensor.

AFTER REPAIR


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13B-4


DF074

CONTINUED 1


if the manifold pressure sensor voltage is more than 4.75 V ; when the + after ignition is switched on.

CC.1Disconnect the "inlet manifold pressure sensor/air temperature sensor" connectorand the injection computer connector.

Check the continuity of the manifold pressure signal lines:track 4 of the pressure sensor track A34 of the injection

computer track 1 of the pressure sensor track A19 of the injection

computer

Check the insulation to + 12 V on tracks A34 and A19 of the injection computer.

Repair if necessary.

Reconnect the injection computer and check the presence of + 5 V on track 3 andtrack 1 of the pressure sensor connector with + after ignition.

If the fault persists, contact your Techline.


If the fault is still present, change the pressure sensor.

AFTER REPAIR


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13B-5


DF074

CONTINUED 2


if the measured voltage is more than 5.2 V , when the + after ignition is switched on.

1.DEF

YES Check the condition and continuity of the computer's earth connections ontracks B24 , B43 and B12 or go to the next step.

Repair if necessary.



NO Measure the manifold pressure sensor feed voltage on track 4 .

If it is more than 5.2 V , replace the manifold pressure sensor.

If not, contact your Techline.

Measure the "inlet manifold pressure sensor / air temperature sensor" connector feed

voltage on track 3 .Is the voltage more than 5.2 V ?

AFTER REPAIR


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13B-6


DF074

CONTINUED 3


if the measured voltage is less than 4.8 V , when the + after ignition is switched on.

2.DEF

YES Disconnect the manifold pressure sensor and measure the voltage on track 3 again.

If the voltage is stable at 5 V , replace the pressure sensor.



NO Contact the Techline.

Measure the inlet manifold pressure sensor / air temperature sensor feed voltage on

track 3 with the sensor connected.Is the voltage less than 4.8 V ?

AFTER REPAIR


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13B-7


DF074

CONTINUED 4


if the measured pressure is more than 2300 mbar , when the + after ignition is switched on.

3.DEFThe measured pressure is outside the manufacturer's specification. Check that theturbocharger wastegate valve is operating correctly and check with a pressuregauge that the turbocharging pressure never exceeds 2.2 bar .

Checking the inlet manifold pressure sensor / air temperature sensor:

The sensor delivers a voltage proportional to the manifold pressure:

2.5 bar absolute ( 1.5 bar relative) = 4.65 V

0.2 bar absolute ( - 0.8 relative) = 0.4 V

Check first that the sensor is correctly fed with a voltage of + 5 V across tracks 1and 3 with the sensor connected.

Use a vacuum pump connected to the sensor's vacuum coupling to check that thesignal corresponds to the graph. Disconnect track 4 linking the computer to thesensor and connect the "+" lead of a multimeter (set at between 5 and 10 V ) totrack 4 of the sensor and the "-" lead to track 1 of the sensor (sensor earth stillconnected to the computer).

At atmospheric pressure, the voltage should be approximately equal to 1.7 V .

At a pressure close to 2.5 bar absolute, the voltage should be approximately equalto 4.65 V .

At a pressure close to 0.2 bar absolute, the voltage should be approximately equal

to 0.4 V .If the voltages do not correspond to the pressures, replace the sensor.

AFTER REPAIR


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13B-8

S9W BOSCH MS6.3Electronic version: MS6.3 Engine type number: 140

DF128

INTAKE AIR TEMPERATURE SENSOR CIRCUITCC.0 : Short circuit to earthCC.1 : Short circuit to + 12 VCO : Open circuit

NOTES The fault is detected if:

the air temperature sensor voltage is less than 0.250 V , the + after ignition is switched on.

CC.0Disconnect the injection computer connector and the inlet manifold pressuresensor / air temperature sensor connector.

Check the resistance of the air temperature sensor and its earth insulation (seeconformity check): the resistance should be 2400 at 20 C .

Check the continuity and insulation on the following tracks:track 1 of the air temperature sensor track A19 of the

injection computer track 2 of the air temperature sensor track A2 of the

injection computer


AFTER REPAIR


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13B-9


DF128

CONTINUED 1


the air temperature sensor voltage is more than 4.75 V , the + after ignition is switched on.

CC.1Disconnect the injection computer connector and the inlet manifold pressure sensor/ air temperature sensor connector.

Check the resistance of the air temperature sensor and its insulation to + 12 V (seeconformity check): the resistance should be 2400 at 20 C .

Check the continuity and insulation of the following tracks:track 1 of the air temperature sensor track A19 of the


injection computer


AFTER REPAIR


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13B-10


DF128

CONTINUED 2


the air temperature sensor voltage is between 4.6 and 4.75 V , the + after ignition is switched on.

CO

YES Measure the voltage again on tracks A2 and A19 of the injection computer.

If the voltage is less than 4.6 V , contact the Techline.

Otherwise, check the continuity and insulation on the following tracks:track 1 of the air temperature sensor track A19 of the injection

computer track 2 of the air temperature sensor track A2 of the injection

computer

NO Carry out a conformity check on the air temperature sensor.

Replace the inlet manifold pressure sensor / air temperature sensor if necessary.

Measure the inlet manifold pressure sensor / air temperature sensor voltage on tracks 1

and 2 with the sensor connected.Is the voltage less than 4.6 V ?

AFTER REPAIR


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13B-11


DF002

COOLANT TEMPERATURE SENSOR CIRCUITCC.0 : Short circuit to earthCC.1 : Short circuit to + 12 VCO : Open circuitDEF : Voltage too high


the coolant temperature sensor voltage is less than 0.250 V , the + after ignition is switched on.

CC.0Disconnect the injection computer connector and the coolant temperature sensorconnector.

Check the resistance of the coolant temperature sensor and its earth insulation (see conformity check): the resistance should be 2575 at 20 C .



injection computer


AFTER REPAIR


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13B-12


DF002

CONTINUED 1


the coolant temperature sensor voltage is more than 4.75 V , the + after ignition is switched on.


Check the resistance of the coolant temperature sensor and its insulation to+ 12 V (see conformity check): the resistance should be 2575 at 20 C .



injection computer


AFTER REPAIR


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13B-13


DF002

CONTINUED 2


the coolant temperature sensor voltage is between 4.6 and 4.75 V , the + after ignition is switched on.

CO

YES Measure the voltage again on tracks A1 and A30 of the injection computer.

If the voltage is less than 4.6 V , contact the Techline.

Otherwise, check the continuity and insulation on the following tracks:track 1 of the air temperature sensor track A1 of the injection

computer track 2 of the air temperature sensor track A30 of the injection

computer

NO Carry out a conformity check on the air temperature sensor.

Replace the temperature sensor if necessary.

Measure the air temperature sensor voltage on tracks 1 and 2 with the sensorconnected.Is the voltage less than 4.6 V ?

AFTER REPAIR


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13B-14


DF002

CONTINUED 3


the measured temperature is more than 130 C , the + after ignition is switched on.

DEFIf there is a stored fault, check that the cooling system is operating correctly and thatthe fan switches on.

If there is a present fault, check that the engine is not overheating, or treat the faultas an open circuit.

AFTER REPAIR


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13B-15


DF021

FUEL TEMPERATURE SENSOR CIRCUITCC.0 : Short circuit to earthCC.1 : Short circuit to + 12 VCO : Open circuitDEF : Voltage too high


the fuel temperature sensor voltage is less than 0.250 V . the + after ignition is switched on.

CC.0Disconnect the injection computer connector and the fuel temperature sensorconnector.

Check the resistance of the fuel temperature sensor and its earth insulation (seeconformity check): the resistance should be 2575 at 20 C .

Check the continuity and insulation of the following tracks:track 1 of the fuel temperature sensor track A15 of the injection

computer track 2 of the fuel temperature sensor track A30 of the injection

computer


AFTER REPAIR


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13B-16


DF021

CONTINUED 1


the coolant temperature sensor voltage is more than 4.75 V , the + after ignition is switched on.


Check the resistance of the coolant temperature sensor and its insulation to+ 12 V (see conformity check): the resistance should be 2575 at 20 C .

Check the continuity and insulation of the following tracks:track 1 of the fuel temperature sensor track A15 of the injection

computer track 2 o

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