VNX Su Kangoo en 1997 PDF

General
SPECIFICATIONS
LIFTING
TOWING
LUBRICANTS CONSUMABLES
DRAINING FILLING
VALUES AND SETTINGS
FC0A - FC0C - FC0D - FC0E - KC0A - KC0C - KC0D - KC0E

77 11 194 217
JULY 1997
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
Edition anglaise
All copyrights reserved by Renault.

Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
Renault.
The methods may be modified as a result of changes introduced by the

manufacturer in the production of the various component units and accessories
from which his vehicles are constructed."
Renault 1997
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SECTION VIEW
PRO00.1
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General
vehicle
Contents
Page
01 SPECIFICATIONS
Engine - Clutch - Gearbox
Vehicle identification
05 DRAINING FILLING
01-1
01-2
02 LIFTING
Trolley jack - Axle stands
Underbody lifts
Page
Engine
Gearbox
Power assisted steering
07 VALUES AND SETTINGS

02-1
02-2
03 TOWING
All types
03-1
04 LUBRICANTS CONSUMABLES
Packaging
05-1
05-3
05-4
04-1
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Dimensions
Capacity - Grades
Belt tension
Accessories belt tension
Timing belt tension
Tightening the cylinder head
Tyres and wheels
Brakes
Brake limiter
Underbody heights
Values for checking the front axle
geometry
Values for checking the rear axle
geometry
07-1
07-2
07-5
07-7
07-11
07-12
07-14
07-15
07-16
07-17
07-20
07-21
The KANGOO Workshop Repair Manual has been prepared by specialists in repair methods
and diagnostics.
The document covers the methods and the diagnostic operations needed in order to obtain
high quality repairs for this vehicle.
However, if a removal - refitting operation involves no particular features, difficulties or
special tools, the method is not described in this manual, being considered very simple for
a vehicle repair specialist.
The labour times are the result of time and motion studies carried out in our workshops,
even though certain methods have not been described in the Workshop Repair Manual.
UNITS OF MEASUREMENT
All dimensions are expressed in millimetres (mm) unless otherwise indicated.

Tightening torques are expressed in decaNewton.metres (daN.m ).
Pressure are given in bars (reminder: 1 bar = 100 000 Pa).
Electrical resistance values are in Ohms ().
Voltages are expressed in Volts (V).
TOLERANCES
Tightening torques given without a tolerance must be accurate to within:

In degrees : 3 .
In daN.m : 10 %.
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SPECIFICATIONS
Engine- Clutch - Gearbox
01
Engine
Vehicle type
Clutch type
Manual gearbox type
Type
Capacity
(cm 3)
FC0A
KC0A
D7F
1149
180 CP 3300
JB1
FC0C
KC0C
E7J
1390
180 CP 3300
JB3
FC0D
KC0D
FC0E
KC0E
F8Q
1870
200 CPOV 3250
JB1
VEHICLE IDENTIFICATION
Example : FC0A
F : Body type
C : Project code
0A : Engine suffix
01-1
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SPECIFICATIONS
Vehicle identification
01
LOCATION OF VEHICLE IDENTIFICATION PLATE
13187R
6
7
8
RENAULT S.A.
9
e0-00/00-0000-000-000-00
1
10
VF000000000000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
11
12
13
000000000000000
1 Type mines of the vehicle and chassis number

2 PTMA [total all up weight of the vehicle]
3 PTR [maximum permitted total train weight vehicle loaded with trailer]
4 Maximum permitted weight on the front axle
(P.T.M.A. front axle)
5 Maximum permitted weight on the rear axle
(P.T.M.A. rear axle)
6
7
8
9
10
11
12
13
Technical specifications of the vehicle

Paint reference
Equipment level
Vehicle type
Trim code
Additional factory optional equipment
Fabrication number
Interior matching trim code
01-2
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LIFTING
Trolley jack - Axle stands
02
Safety symbol (special precautions to be taken when carrying out operations).
SPECIAL TOOLING REQUIRED
Cha. 280 -02

Cha. 408 -01
or
Cha. 408 -02
Adaptable cross piece for trolley jack

Adaptable socket for trolley jack
If a trolley jack is used, appropriate axle

stands must always be used.
AXLE STANDS
When putting the vehicle on axle stands, they

must be positioned:
_ either under the reinforcements provided for
lifting the vehicle with the tool kit jack,
- or under the studs located behind the
reinforcements.
Positioning of axle stands at the rear is carried out
by lifting the vehicle at the sides.
It is forbidden to lift the vehicle by supporting its

weight under the front suspension arms or under
the "V" member of the rear axle.
Depending on the type of trolley jack, use sockets
Cha. 408-01 or Cha. 408-02 for positioning the
cross piece Cha. 280-02.
To lift at the front or the rear of the vehicle, take
the weight under the side jacking points.
TROLLEY JACK AT THE SIDE
Use cross piece Cha. 280-02.

Take the weight under the valance at the level of
the front door.
Position the flange correctly in the groove of the
cross piece.
12274-1R
85679-1G15
02-1
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12333-2G
LIFTING
Underbody lifts
02
These must be positioned level with the tool kit

jack supports. They must slot into the openings in
the underbody flanges.
SAFETY INSTRUCTIONS
Various cases have to be considered:
1 - REMOVING COMPONENTS
2 - REMOVING - REFITTING THE ENGINE AND

TRANSMISSION ASSEMBLY
As a general rule, never use a 2 post lift whenever

a four post lift can be used.
In this particular case, the vehicle body must be

secured to the arms of the 2 post lift using special
pads.
If this is not possible, place the lifting pads

beneath the underbody flange at the level of the
tool kit jack supports.
Company FOG
Part Number FOG 449 8111 - 449 8411
or
FRONT
Company CHEMICO
Part Number 39 2550 0001
or
Company SCHENCH
Part Number 776 684
98703S
REAR
98704S
02-2
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TOWING
All types
03
OBSERVE THE LEGAL TOWING REQUIREMENTS OF THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS ATTACHMENT POINTS.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT
REAR
13189S
13366S
03-1
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Packaging
DESCRIPTION
PACKAGING
04
PART NUMBER
LUBRICANTS
1 kg tin
77 01 421 145
100 g tube
77 01 028 179
ANTI-SEIZE
(high temperature grease) Turbo etc.
80 ml tube
77 01 422 307
"MOBIL CVJ" 825 Black star

or MOBIL EXF57C
for driveshaft joints
180 g sachet
77 01 366 100
MULTIPURPOSE LUBRICANT
wheel sensor
Aerosol
77 01 422 308
MOLYKOTE "BR2"
for main bearing journal faces, thrust pad
guide tubes, clutch fork pads, lower suspension
arm bearings, torsion bar splines, steering box,
driveshaft splines
MOLYKOTE "33 Medium"
tubular rear axle rings,
anti-roll bar rings
MECHANICAL SEALANTS
100 g tube
77 01 417 404
1.5 kg tin
77 01 421 161
5661
100 g tube
77 01 421 042
77 01 404 452
HARDENER KIT (RHODORSEAL 5661)

for bearing cap lateral seals
kit
77 01 421 080
100 g tube
77 01 396 227
Perfect-seal "LOWAC"
coating fluid for seals
Mastic
for sealing exhaust pipe unions
RHODORSEAL
AUTO joint blue

sealing paste
04-1
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Packaging
DESCRIPTION
PACKAGING
04
PART NUMBER
MECHANICAL SEALANTS
AUTO joint grey
sealing paste
LOCTITE 518
for sealing the gearbox housing
Leak detector
100 g tube
77 01 422 750
24 ml syringe
77 01 421 162
Aerosol
77 11 143 071
ADHESIVES
"LOCTITE - FRENETANCH"
stops bolts slackening and allows them to be
released
24 cc bottle
77 01 394 070
"LOCTITE - FRENBLOC"
locks bolts
24 cc bottle
77 01 394 071
"LOCTITE SCELBLOC"
for bonding bearings
24 cc bottle
77 01 394 072
"LOCTITE AUTOFORM"
for bonding the flywheel to the crankshaft
50 cc bottle
77 01 400 309
LUBRICANT CLEANING AGENTS

"NETELEC"
unseizes, lubricates
150 g aerosol
77 01 408 464
Carburettor cleaner
300 ml aerosol
77 11 171 437
355 ml can
77 01 423 189
500 ml aerosol
77 01 408 466
Aerosol
77 01 405 952
400 ml aerosol
77 11 170 801
Injector cleaner
Super-concentrated unseizing agent
"DECAPJOINT " (FRAMET) for cleaning the
gasket faces of aluminium cylinder heads
Brake cleaner
04-2
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Packaging
DESCRIPTION
PACKAGING
04
PART NUMBER
VARNISHES
"CIRCUIT PLUS"
varnish for repairing heated screens
Bottle
77 01 421 135
Kit
77 01 422 752
"CONTACT PLUS"
varnish for repairing rear screen supply terminals
BRAKES
Brake fluid
0.5 l bottle
04-3
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DOT4
77 01 421 940
DRAINING - FILLING
Engine
TOOLING REQUIRED
Engine drain plug spanner
DRAINING : plug (1)
FILLING: plug(2)
D7F ENGINE
13369R
12560R
E7J ENGINE
13367R
13357R
05-1
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05
DRAINING - FILLING
Engine
DRAINING: plug (1)
05
FILLING: plug (2)
F8Q ENGINE
13368R
13358R
05-2
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DRAINING - FILLING
Gearbox
05
DRAINING: plug (1)

FILLING: plug (2)
D7F ENGINE
E7J ENGINE
13369R1
13367R1
F8Q ENGINE
13368R1
05-3
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DRAINING - FILLING
Power assisted steering
CHECKING THE LEVEL
POWER ASSISTED STEERING PUMP LEVEL
For topping up or filling, use ELF RENAULTMATIC

D2 or MOBIL ATF 220 oil.
The level, when correct, should be visible between
the MIN and MAX marks on the reservoir (1).
D7F - E7J - F8Q ENGINES
12422R1
05-4
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05
VALUES AND SETTINGS

Dimensions
07
Dimensions in metres
12333R
(1) Unladen
(2) Laden
07-1
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VALUES AND SETTINGS

Capacity - Grades
Capacity
in litres
(approx.)*
Components
Petrol engine
(oil)
When
draining
07
Grade
E.E.C. country
-15 C
-30 C -20 C
-10 C
+25 C
0 C +10 C +20 C +30 C
CCMC-G4
15W40-15W50
ACEA A2-96/A3-96 15W40-15W50
CCMC-G5
ACEA A2-96/A3-96
10W30-10W40-10W50
10W30-10W40-10W50
CCMC-G5
5W30
ACEA A2-96/A3-96 5W30
D7F
3,5
3.7 (1)
E7J
2.7
2.9 (1)
CCMC-G5
5W40-5W50
ACEA A2-96/A3-96 5W40-5W50
Other countries
-15 C
-30 C -20 C
-10 C
0 C
+10 C +20 C +30 C
API SH 15W40
API SH 10W40
API SH 10W30
API SH 5W30
* Check with dipstick

(1) After replacing the oil filter
07-2
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VALUES AND SETTINGS

Capacity - Grades
Capacity
in litres
(approx.)*
Components
Diesel engine
(oil)
When
draining
07
Grade
E.E.C. country
-15 C
-30 C -20 C
+25 C
-10 C
0 C +10 C +20 C +30 C
CCMC-PD2
15W40
ACEA B2-96/B3-96 15W40
CCMC-PD2
10W40
ACEA B2-96/B3-96 10W40
CCMC-PD2
5W30
ACEA B2-96/B3-96 5W30
CCMC-PD2
5W40
ACEA B2-96/B3-96 5W40
4.7
F8Q
5.2 (1)
Other countries
-15 C
-30 C -20 C
+15 C
-10 C
0 C
+10 C +20 C +30 C
API CF 15W40
API CF 10W40
API CF 10W30
* Check with dipstick

(1) After replacing the oil filter
07-3
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VALUES AND SETTINGS

Capacity - Grades
Components
Capacity
in litres
Manual gearbox
Notes
All countries: TRANSELF TRX 75 W 80 W

( API GL5 or MIL-L 2105 C or D standards)
JB1
3.4
JB3
3.4
Brake circuit
Grade
07
Normal : 0.7
Brake fluids must be approved by the Technical

Department
SAE J 1703
ABS : 1
and DOT 4
Fuel tank
approx.
50
Unleaded
petrol/diesel
Power assisted
steering
Separate
reservoir
1.1
ELF RENAULT MATIC D2
Cooling
circuit
or
MOBIL ATF 220

GLACOL RX
D7F
E7J
5.5
F8Q
7.4
(type D)
Only add coolant of the
same type
07-4
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VALUES AND SETTINGS

Belt tension
07
Mot.
1273
Tool for checking belt tension
96601R
A
B
C
D
Sensor
Display
Connecting cable
Calibration checking plate
Calibrating the device

The device is set in the factory; however it must be
recalibrated every six months.
Procedure
Principle
Resetting the zero:
The sensor, through the presser button (1), the
presser (2) and the outer pads (3), applies a
constant force to the belt.
- switch on the device (button E) with the presser

button (1) face down,
- if 0 is displayed, do not touch anything,
- if nothing is displayed, check the condition of
the 9 volt battery in the device ,
- if a value other than 0 is displayed, adjust screw
(F) until 0 is obtained.
The reaction from the belt is measured using a

test piece (4) fitted with strain gauges.
Any movement on the gauges creates a variation
in their electrical resistance. This variation, once it
has been converted by the device, is displayed on
the display in SEEM units (US).
07-5
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VALUES AND SETTINGS

Belt tension
07
Checking the calibration

Switch on the device (button E).
Position the calibration spring plate (Z) on the sensor as shown on the diagram (control value engraved towards the top, (A) minimum value, (B) maximum value).
Tighten the presser button (1) until it goes "CLICK - CLICK - CLICK".
Check that a value X between the values (A and B) (A X B) is displayed.
NOTE: it may be necessary to perform several preliminary tests in order to obtain the correct value.
If the correct value if still not obtained after several attempts, contact SEEM.
NOTE : each device has its own calibration spring plate and they are not interchangeable.
96602R
GENERAL INSTRUCTIONS:
1 Knurled button (presser)

A
Calibration plate control value
B
Z Calibration plate
_ Never refit a belt which has been removed, replace it.

- Never retighten a belt for which the tension
reading is between the fitting value and the
minimum operating value.
SEEM
Contact your After Sales Head Office for further
information.
- When checking, if the tension is below the minimum operating value, change the belt.
07-6
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VALUES AND SETTINGS

RIBBED BELT
Tensioning process
Engine cold (ambient temperature).
Fit the new belt.
Position the sensor of Mot. 1273.
Turn the wheel of the sensor until it disengages (three "CLICKS").
Tension the belt until the recommended fitting value is displayed on Mot. 1273 .
Lock the tensioner, check it, adjust the value.
Turn the crankshaft over three times.
Check that the tension value is within the fitting tension tolerance, otherwise readjust it.
NOTE :
Never refit a belt which has been removed.

Replace the belt if the tension is below the minimum operating tension.
Small cuts or cracks do not mean that the belt has to be replaced.
07-7
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07
VALUES AND SETTINGS

D7F
ENGINE
07
Mot.
1273
Tool for checking the belt tension
ALTERNATOR BELT
POWER ASSISTED STEERING BELT
10071R2
A
B
C
T
97267R4
Crankshaft
Alternator
Power assisted steering pump
Tensioner
Point for checking belt tension
Power assisted
steering belt,
multitooth
Tension
(US=SEEM unit)
Alternator
belt,
multitooth
Fitting
102 7
96 5
Minimum
operating
53
43
07-8
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VALUES AND SETTINGS

E7J
ENGINE
07
Mot.
1273
ALTERNATOR BELT
POWER ASSISTED STEERING BELT
13511R
A
B
C
T
13510R
Crankshaft
Alternator
Tension wheel
Bolt A: alternator belt tension

Bolt B: power assisted steering belt tension
NOTE : Tighten the nuts of bolts (A) and (B) after
adjusting the tension.
Tension
(US=SEEM unit)
Alternator
belt,
multitooth
Power assisted
steering belt,
multitooth
Fitting
101 6
106 6
Minimum
operating
52
59
13363R1
07-9
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VALUES AND SETTINGS

F8Q
ENGINE
07
Mot.
1273
ALTERNATOR BELT
ALTERNATOR AND POWER ASSISTED STEERING

BELT
13512R
A
B
C
T
13509R
Crankshaft
Alternator
Tension wheel
Tension
(US=SEEM unit)
Alternator
belt,
multitooth
Power assisted
steering belt,
multitooth
Fitting
115 5
116 6
Minimum
operating
70
68
07-10
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VALUES AND SETTINGS

Timing belt tension
Tensioning process
07
E7J engine
Engine cold (ambient temperature).

Fit the new belt.
Position the sensor of Mot. 1273.
Turn the wheel of the sensor until it disengages
(three "CLICKS").
Tension the belt until the recommended fitting
value is displayed on Mot. 1273.
Lock the tensioner, check it and adjust the value.
Turn the crankshaft over at least three times .
Check that the tension value is within the fitting
tension tolerance ( 10%), otherwise readjust it,
repeating the operations described above.
13361R
NOTE :
Belt tension (in SEEM units)
- For the F8Q engine, remove the pin Mot 1054

before fitting the sensor of tool Mot 1273 and
press hard on the section of belt between the
intermediate shaft sprocket (or idle sprocket)
and the tension wheel, then make the measurement.
Fitting: 30 U.S.
Minimum operating : 26 U.S.
F8Q engine
- Never refit a belt which has been removed.

- Replace the belt if the tension is below the minimum operating tension.
D7F engine
There are special features for tensioning the timing belt: refer to section 11.
13094R
Belt tension (in SEEM units)

Fitting : 29 U.S.
Minimum operating : 25 U.S.
07-11
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VALUES AND SETTINGS

07
METHOD FOR TIGHTENING THE CYLINDER HEAD

REMINDER:
In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the
cylinder head mounting holes.
All the cylinder head bolts must be systematically renewed after removal.
There is no cylinder head retightening operation.
Using engine oil, lubricate the threads and under the heads of the bolts.
D7F ENGINE
E7J ENGINE
Preseating the gasket
Tighten all the bolts to 2 daN.m, then angle tighten to 90 in the order shown below.
Tighten all the bolts to 2 daN.m, then angle tighten to 97 2 in the order shown below.
10
10
90775S
90775S
Wait 3 minutes settling time.
Tightening the cylinder head:
- The cylinder head tightening is carried out in

stages and the following procedure is applied
successively to bolts 1-2 then 3-4, 5-6, 7-8 and 9
-10.

successively to bolts 1-2 then 3-4, 5-6, 7-8 and 9
-10.
- Slacken bolts 1-2 until they are completely free.
- Tighten bolts 1-2 to 2 daN.m, then turn

through an angle of 200.
- Tighten bolts 1-2 to 2 daN.m, then turn

through an angle of 97 2.
- Repeat the slackening and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10.
- Repeat the slackening and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10
07-12
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VALUES AND SETTINGS

F8Q ENGINE

Tighten all the bolts to 3 daN.m then angle tighten to 80 4 in the order shown below.
10
90775S

successively to bolts 1-2, then 3-4, 5-6, 7-8 and
9-10.
- Tighten bolts 1-2 to 2.5 daN.m, then angle tighten to 213 7.
- Repeat the slackening and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10.
07-13
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07
VALUES AND SETTINGS

Tyres and wheels
Vehicle
Wheel rim
Tyres
07
Cold inflation pressure
(in bars) (1)
Front
Rear
5 B 13
165/70 R 13 C 88/86
2.8
3.6
5 B 13
165/70 R 13 83 (2)
2.6
2.9
5.5 J 14
165/70 R 14
2.4
3.0
FC0X
KC0X
(1) Fully laden and motorway use.

Tightening torque of wheel nuts : 9 daN.m
Rim run-out: 1.2 mm
(2) Reinforced tyre.
07-14
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VALUES AND SETTINGS

Brakes
07
Drum diameters or disc thicknesses (in mm)

Max. disc run-out
(in mm)
Vehicle
Front
Normal
Rear
Min.
FC0X
20
Normal
Max. (1)
normal
payload
203.2
normal
payload
204.45
increased
payload
228.3
increased
payload
229.5
17.7
KC0X
Front
Rear
0.07
(1) Drum: maximum wear diameter
Lining thicknesses (in mm) (including backing)

Vehicle
Front
Brand new
Rear
Minimum
Brand new
Brake fluid
Minimum
With ABS
4.6 (1)
3.15 (2)
FC0X
17.8
5.5
KC0X
2
No ABS
SAE J1703
DOT 4
4.2 (1)
2.8 (2)
With ABS
4.8
FC0X (3)
17.8
KC0X (3)
5.5
2
No ABS
4.5
(1) Leading brake shoe.
(2) Trailing brake shoe.
(3) Increased payload.
07-15
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SAE J1703
DOT 4
VALUES AND SETTINGS

Brake limiter
07
BRAKING PRESSURE
Vehicle
Test pressure (1) (in bars)
Fuel tank
(driver on board)
Front
Rear
FC0X
KC0X
normal payload
100
35.4
FC0X
KC0X
increased payload
100
38
90966S
(1) The test is performed using two pressure gauges in an X arrangement.
07-16
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+8
0
+8
0
VALUES AND SETTINGS

Underbody heights
Vehicle
At the front
H1 - H2 = ... mm
07
At the rear
H4 - H5 = ... mm
Dimension X (in mm)

R-H and L-H
- 60.5 (1)
402 (1)
- 54.1 (2)
430 (2)
FC0X
73.5
KC0X
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 higher.
Any adjustment of the underbody height means that the brake limiter and the headlights must be adjusted.
(1) Increased payload.

(2) Standard payload.
07-17
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VALUES AND SETTINGS

Underbody heights
07
MEASUREMENT POINTS
12333R3
Dimension H5 is measured from the axis of the

suspension bar.
88636-4R
07-18
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VALUES AND SETTINGS

Underbody heights
88576R
88637R
07-19
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07
VALUES AND SETTINGS

Values for checking the front axle geometry
ANGLES
POSITION OF
FRONT AXLE
VALUES
07
ADJUSTMENT
CASTOR
355
325
255
225
30
H5 - H2
H5 - H2
H5 - H2
H5 - H2
= 97 mm
= 117 mm
= 137 mm NOT ADJUSTABLE
= 157 mm
H1 - H2
H1 - H2
H1 - H2
H1 - H2
=
7 mm
= 74 mm
NOT ADJUSTABLE
= 98 mm
= 164 mm
H1 - H2
H1 - H2
H1 - H2
H1 - H2
=
7 mm
= 74 mm NOT ADJUSTABLE
= 98 mm
= 164 mm
Maximum right/left
difference = 1
93012-1S
CAMBER
112
- 015
- 029
- 013
30
Maximum right/left
difference = 1
93013-1S
KINGPIN
805
1025
1101
1156
30
Maximum right/left
difference = 1
93014-1S
PARALLELISM
UNLADEN
Adjustable by
rotating track
rod sleeves
1 turn= 30
(3 mm)
UNLADEN
(For 2 wheels)
toe-out
+ 010 10
+ 1 mm 1 mm
93011-1S
RUBBER BUSHES
81603S1
07-20
http://vnx.su
VALUES AND SETTINGS

Values for checking the rear axle geometry
ANGLES
VALUES
07
POSITION OF
REAR AXLE
ADJUSTMENT
UNLADEN
NOT ADJUSTABLE
UNLADEN
NOT ADJUSTABLE
UNLADEN
CAMBER
- 050 15
93013-2S
PARALLELISM
(For 2 wheels)
Toe-in
- 15 10
- 1,5 mm 1 mm
93011-2S
RUBBER BUSHES
81603S1
07-21
http://vnx.su
Fault finding
LUCAS DIESEL INJECTION
INJECTION
ELECTRONICALLY CONTROLLED HYDRAULIC
SYSTEMS
IMMOBILISER
AIRBAG - SEAT BELT PRETENSIONERS

77 11 194 235
JULY 1997
Edition Anglaise

Renault.

Renault 1997
http://vnx.su
Fault finding
Contents
Page
BATTERIE
DIESEL
PROJECTEURS
INJECTION
13 LUCAS
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Aid
Checking conformity
Customer complaints
Fault charts
Page
BATTERIE PROJECTEURS
(cont)
17 INJECTION
13-1
13-2
13-5
13-31
13-32
13-37
13-38
D7F 710 engine - 55 tracks

Introduction
XR25 fiche
Status and parameter checks
Status and parameter interpretation
Customer complaints
Fault charts
Aid
Checking conformity
17-147
17-152
17-155
17-175
17-181
17-201
17-202
17-207
17-208
17 INJECTION
E7J 780 engine
Introduction
XR25 fiche
Status and parameter
interpretation
Customer complaints
Fault charts
Aid
Checking conformity
D7F 710 engine - 35 tracks

Introduction
XR25 fiche
Customer complaints
Fault charts
Aid
Checking conformity
17-1
17-6
17-9
17-30
ELECTRONICALLY CONTROLLED
38 HYDRAULIC SYSTEMS
17-36
17-56
17-57
17-62
17-63
17-75
17-80
17-83
17-103
17-109
17-128
17-129
17-134
17-135
http://vnx.su
Introduction
XR25 fiche
Checking conformity
Aid
Customer complaints
Fault charts
38-1
38-2
38-4
38-18
38-19
38-20
38-21
Fault finding
Contents
Page
82 IMMOBILISER
Introduction
XR25 fiche
Customer complaints (petrol
version)
Fault charts (petrol version)
Customer complaints (diesel
version)
Fault charts (diesel version)
Checking conformity
Aid
88
82-1
82-2
82-4
82-14
82-15
82-25
82-26
82-34
82-39
AIRBAG - PRETENSIONERS
Introduction
Wiring
XR25 fiche
Checking conformity
Checking the pretensioners
Aid
http://vnx.su
88-1
88-2
88-5
88-7
88-22
88-23
88-24
F8Q 630/662 ENGINE

FAULT FINDING
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
..............................................................
05
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
Checking conformity
.........................................................................
32
Customer complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
http://vnx.su

Fault finding - Introduction
F8Q
630 / 662
13
CONDITIONS FOR APPLYING THE TESTS DESCRIBED IN THIS FAULT FINDING DOCUMENT
The tests described in this fault finding section should only be applied to the vehicle if the title of the fault
treated corresponds exactly to the display noted on the XR25 when the ignition is switched on.
If a bargraph is interpreted when flashing, the conditions for confirming the presence of an actual fault (and
the necessity of applying the fault finding) are shown in the "Notes" section or at the start of the bargraph
interpretation.
If a bargraph is only interpreted if it is permanently illuminated, the application of these tests recommended
in the fault finding document when the bargraph is flashing will not allow the cause of the memorised fault
to be determined. In this case, only checking of the wiring and connections of the faulty component should
be carried out (the fault is simply memorised as it was not present at the moment of testing).
NOTE :
The ignition should be switched off before the XR25 is used.
SPECIAL TOOLING REQUIRED FOR OPERATIONS ON THE DPC DIGITAL INJECTION SYSTEM
- XR25 test kit.

- XR25 cassette N 17 minimum.
- 25 track bornier El. 1332 for testing using the computer connector.
DPCF01 1.0
13-1
http://vnx.su

Fault finding - XR25 fiche
13
PRESENTATION OF FICHE XR25 N 60 SIDE 1/2
FI21760-1
DPCF01 1.0
13-2
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13
FI21760-2
DPCF01 1.0
13-3
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13
BARGRAPH SYMBOLS
FAULTS (always on a coloured background)
If illuminated, there is a fault with the product tested. The associated text
defines the fault.
The bargraph may be :
- Permanently illuminated
: fault present.
- Flashing
: fault memorised
- Extinguished
: no fault or not diagnosed
STATUS (always on a white background)
Bargraph always at the top right hand side.

If illuminated dialogue has been established with the computer for the product.
If it remains extinguished:
- The code does not exist.
- There is a fault with the tool, the computer or the XR25 / computer connection.
The representation of the following bargraphs indicates their initial status:
Initial status: (ignition on, engine stopped, no operator action)
or
Indefinite
- illuminated when the function or condition on the fiche is met.
Extinguished
Illuminated - extinguishes when the function or condition on the fiche is no

longer met
ADDITIONAL NOTES
Certain bargraphs have a *. The *.. command, when the bargraph is illuminated,
allows additional information on the type of fault or status to be displayed.
DPCF01 1.0
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13
Fault finding - Interpretation of XR25 bargraphs
Fiche n 60 1/2
Bargraph 1 RH extinguished
Code present
NOTES
Use bornier El. 1332 for any operations on the computer connector.
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on another vehicle. If the XR25 is not the cause of the fault and dialogue is not established with another computer on the same vehicle, a faulty computer may be causing interference on the K and L fault finding lines.
Disconnect connections successively to determine which computer is at fault.
Check the ISO selector is on position S8, that you are using the latest XR25 cassette and the correct access
code (D34).
Check the battery voltage and carry out any necessary operations to ensure the correct voltage (U battery
> 10.5 volts).
Check the 15 Amp fuses on the engine connection unit have not blown (positions 3 and 4).
Check the connection and condition of the connections on the computer connector and the connection
R67 engine / dashboard.
Check the computer is correctly fed:
- Earth on track 2 of the computer connector (check the condition and tightness of the engine earth
strap and the engine earth MH near to the gearbox housing).
- + after ignition feed on track 1 of the computer connector.
Check the diagnostic socket is correctly fed:

- Earth on track 5.
- + before ignition feed on track 16.
Check and ensure the continuity and insulation of the lines in the connection diagnostic socket/
computer:
- Between track 10 of the computer connector and track 15 of the diagnostic socket.
If fault finding is not established after these operations, replace the computer (consult the "Aid" section
for this operation).
AFTER REPAIR
When communication is established, deal with any fault bargraphs which may be
illuminated.
DPCF01 1.0
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13
Fiche n 60 1/2
Bargraph 1 LH illuminated
Computer
NOTES
None
Replace the computer (consult the "Aid" section for this operation).
AFTER REPAIR
Erase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
DPCF01 1.0
13-6
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13
Coolant temperature sensor circuit

XR25 aid:
NOTES
co.1
Fiche n 60 1/2
*02 :
co.1 : Open circuit or short circuit to 12 volts

cc.0 : Short circuit or short circuit to earth
NOTES
If bargraphs 2RH and 3LH are also illuminated, look for a CO of the sensor earth (track 3 of the computer connector)
Also check the condition and tightness of the engine earth strap and
the gearbox engine earth.
Ensure the continuity and insulation in relation to + 12 volts of the following connection :
- Between track 25 on the computer connector and track 2 on the coolant temperature sensor
connector.
Ensure the continuity of the following connection :
- Between track 3 on the computer connector and track 1 on the coolant temperature sensor connector.
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the coolant temperature sensor then erase the computer memory.
If the "coolant temperature sensor circuit" fault reappears, replace the computer (consult the "Aid"
section for this operation).
cc.0
NOTES
None
Ensure insulation from earth of the following connection :

- Between track 25 on the computer connector and track 2 on the coolant temperature sensor
connector.
Check to see if the sensor circuit (or the sensor) is in short circuit (resistance at 60C = 1.2 Kohms).
If the fault persists after these tests, replace the coolant temperature sensor then erase the computer memory.
If the "coolant temperature sensor circuit" fault reappears, replace the computer (consult the "Aid"
AFTER REPAIR
test.
DPCF01 1.0
13-7
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13
Bargraph 2 RH illuminated
Air temperature sensor circuit

XR25 aid:
NOTES
co.1
Fiche n 60 1/2
*22 :

cc.0 : Short circuit or short circuit to earth
NOTES
If bargraphs 2LH and 3LH are also illuminated, look for a CO of the
common sensor earth (track 3 of the computer connector)
Ensure the continuity and insulation in relation to + 12 volts of the following connection :
- Between track 24 on the computer connector and track 2 of the air temperature sensor connector.
Ensure the continuity of the following connection :
If the fault persists after these tests, replace the air temperature sensor then erase the computer memory.
If the "air temperature sensor circuit" fault reappears, replace the computer (consult the "Aid" section
cc.0
NOTES
None
Ensure insulation from earth of the following connection :

Check to see if the sensor circuit (or the sensor) is in short circuit (resistance at 20C = 3.5 Kohms).
If the fault persists after these tests, replace the air temperature sensor then erase the computer memory.
If the "air temperature sensor circuit" fault reappears, replace the computer (consult the "Aid" section
AFTER REPAIR
test.
DPCF01 1.0
13-8
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13
Load potentiometer circuit

XR25 aid:
NOTES
co.0
Fiche n 60 1/2
*03 :
co.0 : Open circuit or short circuit to earth

cc.1 : Short circuit to 5 volts or to 12 volts
dEF : Sensor feed fault
NOTES
None
Ensure the continuity and insulation in relation to earth of the connection between track 23 on the
computer connector and track 3 on the pump connector (10 tracks).
Also ensure the insulation of this connection in relation to the connection between track 3 on the computer connector and track 5 on the pump connector (potentiometer earth).
Also ensure the continuity of the connection between track 4 on the computer connector and track 4 on
the pump connector.
Look for a possible potentiometer short circuit (between tracks 4 and 5 on the 10 track connector) or a
short circuit in its feed.
If the fault persists after these tests, replace the load potentiometer ( consult the "Aid" section for this
operation).
If the "load potentiometer circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
If BG2LH and 2RH are also illuminated, look for a CO on the sensor
earth (track 3 of the computer connector).
Ensure insulation from 5 volts and from 12 volts of the connection between track 23 on the computer
connector and track 3 on the pump connector (10 tracks).
Also ensure the insulation of this connection in relation to the connection between track 4 on the
computer connector and track 4 on the pump connector(+ 5 volts potentiometer).
Ensure the continuity of the connection between track 3 on the computer connector and track 5 on the
pump connector.
operation).
this operation).
AFTER REPAIR
test.
DPCF01 1.0
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13
CONT
dEF
NOTES
None
Ensure the insulation (+12 Volts and earth) of the following connection :
- Between track 4 on the computer connector and track 4 of the pump connector (10 tracks).
operation).
this operation).
AFTER REPAIR
test.
DPCF01 1.0
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13
NOTES
Bargraph 3 RH flashing
Fiche n 60 1/2
Engine speed sensor circuit
The engine speed sensor circuit fault is present if the bargraph illuminates when
the engine is running.
Measure the resistance of the flywheel signal sensor at its connector. Replace the sensor if the resistance
is not approximately 250 ohms.
Ensure the continuity and insulation of the following lines:
- Between track 8 on the computer connector and track B on the flywheel signal sensor connector.
- Between track 3 on the computer connector and track A on the flywheel signal sensor connector.
Also check the insulation between these two connections.
Carry out a visual inspection of the general condition of the wiring and its routing for possible
interference.
Check the positioning and condition of the sensor.
Check the condition of the target (deformation, mounting, noise....).
Check the conformity of the target: 2 gaps at 180.
If the fault persists after these tests, replace the flywheel signal sensor.
If the "engine speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
test.
DPCF01 1.0
13-11
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13
Bargraph 4 LH flashing
Vehicle speed sensor circuit

XR25 aid:
NOTES
cc.0
Fiche n 60 1/2
*04 :
cc.0 : Short circuit to earth

The vehicle speed sensor circuit fault is present if the bargraph illuminates during a road test. Use bornier El. 1332 for any operations on the computer
connector.
NOTES
None
Ensure the insulation from earth of the connection between track 12 on the computer connector and
track B1 on the vehicle speed sensor connector.
Also ensure the insulation of this connection in relation to the connection between track 3 on the computer
connector and track B2 on the vehicle speed sensor connector.
Check the vehicle speed sensor feed:
- +after ignition feed on track A of the sensor connector
- Earth on track B2 of the sensor connector.
If the fault persists after these tests, replace the vehicle speed sensor, then erase the computer memory.
If the "vehicle speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
co.1
NOTES
None
Ensure the continuity and insulation in relation to 12 volts of the connection between track 12 on the
computer connector and track B1 on the vehicle speed sensor connector.
Also ensure the insulation of this connection in relation to the vehicle speed sensor+ after ignition feed line
(track A of the sensor connector).
Check the vehicle speed sensor feed:
- +after ignition feed on track A of the sensor connector
- Earth on track B2 of the sensor connector.
If the fault persists after these tests, replace the vehicle speed sensor, then erase the computer memory.
If the "vehicle speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
AFTER REPAIR
test.
DPCF01 1.0
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NOTES
13
Fiche n 60 1/2
Atmospheric pressure sensor circuit
None
Replace the computer (consult the "Aid" section for this operation).
AFTER REPAIR
test.
DPCF01 1.0
13-13
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13
Fiche n 60 1/2
Needle lift sensor circuit
NOTES
The needle lift sensor circuit fault is present if the bargraph illuminates when the
engine is running. Use bornier El. 1332 for any operations on the computer
connector.
Measure the resistance of the needle lift sensor at its connector.

Replace the injector with the sensor if the resistance is not approximately 105 ohms.
Ensure the continuity of the following connections:
- Between track 7 on the computer connector and track 1 on the needle lift sensor connector.
- Between track 3 on the computer connector and track 2 on the needle lift sensor connector.
Ensure the insulation of the connection between track 7 on the computer connector and track 1 on the
needle lift sensor connector .
Also ensure the insulation between the 2 lines on the needle lift sensor.
Also check the condition of the wiring between the sensor connector and the sensor.
The "needle lift sensor circuit" fault may be connected to absence of injection at the cylinder with the
sensor.
Check the condition of the injector and its fuel supply.
If the fault persists after these tests, replace the injector with the sensor.
If the "needle lift sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
AFTER REPAIR
test.
DPCF01 1.0
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13
Bargraph 5 RH illuminated (co.0) or flashing (cc.1)
Altimetric corrector control circuit

XR25 aid:
NOTES
co.0
*25 :
Fiche n 60 1/2

cc.1 : Short circuit to 12 volts
NOTES
None
Measure the resistance of the altimetric corrector relay coil (position H on engine connection unit).
Ensure the continuity and the insulation from earth of the connection between track 15 of the computer
connector and terminal 2 of the corrector relay mounting.
Ensure the presence of + after ignition feed on track 1 of the corrector relay mounting.
Test the connections on the computer connector and the relay mounting.
If the fault persists after these tests, replace the altimetric corrector relay.
If the "altimetric corrector circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
Even if present at the moment of testing, this fault is declared by a

flashing BG 5RH side. To confirm its presence and the necessity of
following the fault finding below, erase the computer memory
then start command mode G19*.
The fault is present if the bargraph flashes again.
Measure the resistance of the altimetric corrector relay coil (position H on engine connection unit).
Replace the relay if the resistance is not approximately 85 ohms.
Ensure the insulation from +12 volts of the connection between track 15 on the computer connector
and terminal 2 on the corrector relay mounting.
If the fault persists after these tests, replace the altimetric corrector relay.
If the "altimetric corrector circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
test.
DPCF01 1.0
13-15
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13
Bargraph 6 LH illuminated (co.0/cc.1) or flashing (1.dEF)
Advance corrector circuit

XR25 aid:
NOTES
co.0
*06 :
Fiche n 60 1/2

1 . d E F : Pump hydraulic control
NOTES
None
Measure the resistance of the advance corrector at the 10 track pump connector (between tracks 2 and
7). Replace the advance corrector if the resistance is not approximately 12 ohms.
Ensure the continuity of the connection between track 6 on the computer connector and track 7 on the
pump connector.
Ensure the presence of + after ignition feed on track 2 of the corrector connector, wiring side.
Ensure the insulation from earth of the connection between track 6 on the computer connector and track 7
on the pump connector.
If the fault persists after these tests, replace the advance corrector .
If the "advance solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
None
Measure the resistance of the advance corrector at the 10 track pump connector (between tracks 2 and
7). Replace the advance corrector if the resistance is not approximately 12 ohms.
Ensure the insulation from +12 volts of the connection between track 6 on the computer connector and
track 7 on the pump connector.
If the fault persists after these tests, replace the advance corrector .
If the "advance solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
test.
DPCF01 1.0
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13
CONT
1.dEF
NOTES
The fault is present if the bargraph is illuminated when the engine is

running.
This fault indicates that the advance corrector is seized, the injection pump has been incorrectly set or
there is a fuel supply fault.
It is taken into account when the advance noted by the needle lift sensor differs by more than 5 from the
advance value requested by the computer.
NOTE : If there is a fault where the advance corrector is seized, there will be a characteristic noise when
the ignition is switched on (irregular clicking of the corrector).
- Check the condition of the fuel supply to the pump and the injectors (filter blocked, pipe kinked, air
leak, ...).
Check the type of diesel fuel used in extreme cold weather (a "summer " type diesel fuel may cause
this fault at -15 C).
- Check the pump timing and check the tightness of the pump pulley.
- If the fuel supply and the pump timing are correct, replace the advance corrector.
AFTER REPAIR
test.
DPCF01 1.0
13-17
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13
Fast idle solenoid valve circuit

XR25 aid:
NOTES
co.0
*26 :
Fiche n 60 1/2

NOTES
None
Measure the resistance of the fast idle solenoid valve at its connector. Replace the fast idle solenoid valve
if the resistance is not approximately 45 ohms.
Ensure continuity of the connection between track 16 on the computer connector and track 1 on the fast
idle solenoid valve connector.
Ensure the presence of + after ignition feed on track 2 on the fast idle solenoid valve connector, wiring side.
on the fast idle solenoid valve connector.
If the fault persists after these tests, replace the fast idle solenoid valve.
If the "fast idle solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
NOTES
Even if present at the moment of testing, this fault is still declared

by a flashing BG 6RH side. To confirm its presence and the necessity
of following the fault finding below, erase the computer memory
Measure the resistance of the fast idle solenoid valve at its connector. Replace the fast idle solenoid valve
if the resistance is not approximately 45 ohms.
Ensure insulation from +12 volts of the connection between track 16 on the computer connector and
track 1 on the fast idle solenoid valve connector.
If the fault persists after these tests, replace the fast idle solenoid valve.
If the "fast idle solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
AFTER REPAIR
test.
DPCF01 1.0
13-18
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13
EGR solenoid valve circuit

XR25 aid:
NOTES
co.0
*27 :
Fiche n 60 1/2

NOTES
None
Measure the resistance of the EGR solenoid valve at its connector. Replace the EGR solenoid valve if the
resistance is not approximately 45 ohms.
Ensure continuity of the connection between track 5 on the computer connector and track 1 of the EGR
solenoid valve connector.
Ensure the presence of + after ignition feed on track 2 of the EGR solenoid valve connector, wiring side.
of the EGR solenoid valve connector.
If the fault persists after these tests, replace the EGR solenoid valve.
If the "EGR solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
cc.1
NOTES

of following the fault finding below, start the engine.
The fault is present if the bargraph illuminates when the engine is
running.
Measure the resistance of the EGR solenoid valve at its connector. Replace the EGR solenoid valve if the
resistance is not approximately 45 ohms.
Ensure insulation in relation to +12 volts of the connection between track 5 on the computer connector and
track 2 of the EGR solenoid valve connector.
If the fault persists after these tests, replace the EGR solenoid valve.
If the "EGR solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
AFTER REPAIR
test.
DPCF01 1.0
13-19
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13
Bargraph 8 LH illuminated (co.0) or flashing (cc.1)
Preheating relay N 1 control circuit

XR25 aid:
NOTES
co.0
*08 :
Fiche n 60 1/2

None
NOTES
Ensure the continuity and insulation in relation to earth of the connection between track 14 on the
computer connector and track B1 on the relay unit connector.
Ensure the presence of + after ignition feed on track A1 on the relay unit connector.
If the fault persists after these tests, replace the relay unit.
If the "preheating relay No. 1 control circuit" fault reappears, replace the computer (consult the "Aid"
cc.1
NOTES

by a flashing BG 8LH side. To confirm its presence and the necessity
then start command mode G10*1*.
Ensure insulation in relation to 12 volts of the connection between track 14 on the computer connector
and track B1 on the relay unit connector.
If the fault persists after these tests, replace the relay unit.
If the "preheating relay No. 1 control circuit" fault reappears, replace the computer (consult the "Aid"
AFTER REPAIR
test.
DPCF01 1.0
13-20
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13
PAS pump assembly relay control circuit

XR25 aid:
NOTES
co.0
*29 :
Fiche n 60 1/2

NOTES
None
Measure the resistance of the PAS pump assembly relay coil (position C on the engine connection unit).
Replace the relay if its resistance is not approximately 65 ohms.
Ensure the continuity and insulation from earth of the connection between track 20 on the computer
connector and terminal 2 on the pump assembly relay mounting.
Ensure the presence of + after ignition feed at terminal 1 of the pump assembly relay mounting.
Check the connections on the computer connector and the relay mounting.
If the fault persists after these tests, replace the PAS pump assembly relay.
If the "PAS pump assembly relay control circuit" fault reappears, replace the injection computer (consult
the "Aid" section for this operation).
cc.1
NOTES

Measure the resistance of the PAS pump assembly relay coil (position C on the engine connection unit).
Replace the relay if its resistance is not approximately 65 ohms.
Ensure the insulation from + 12 Volts of the connection between track 20 of the computer connector
and terminal 2 on the pump assembly relay mounting.
If the fault persists after these tests, replace the PAS pump assembly relay.
If the "PAS pump assembly relay control circuit" fault reappears, replace the injection computer (consult
AFTER REPAIR
test.
DPCF01 1.0
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13
10
Fault warning light circuit

XR25 aid:
NOTES
Fiche n 60 1/2
*10 :
Even if present at the moment of testing, this fault is still declared by a flashing
BG 10LH side. To confirm its presence and the necessity of following the fault finding below, erase the computer memory then start command mode G21*1*.
cc.1
NOTES
None
Ensure insulation in relation to 12 volts of the connection between track 18 of the computer connector
and the instrument panel warning light (track 6 on connector MA).
Test at the warning light bulb (bulb in short circuit).
AFTER REPAIR
test.
DPCF01 1.0
13-22
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13
10
Bargraph 10 RH illuminated (Co.0) or flashing (cc.1)
Preheating warning light circuit

XR25 aid:
NOTES
co.0
*30 :
Fiche n 60 1/2
cc.0 : Open circuit or short circuit to earth

NOTES
None
Check the condition of the preheating warning light bulb then the presence of +after ignition feed at
the warning light.
Ensure the continuity and insulation in relation to earth of the connection between track 9 of the
computer connector and the instrument panel preheating warning light (track 5 on CY connector).
Test the connections on the computer connector.
cc.1
NOTES

then start command mode G21*2*.
Ensure insulation in relation to 12 volts of the connection between track 9 of the computer connector
and the instrument panel preheating warning light (track 5 on connector CY).
Test at the preheating warning light bulb (bulb in short circuit).
AFTER REPAIR
test.
DPCF01 1.0
13-23
http://vnx.su
13
12
Battery voltage
XR25 aid:
NOTES
Fiche n 60 1/2
*12 :
1 . d E F : Battery voltage low

2 . d E F : Battery voltage too high
Carry out a complete check of the charging circuit using the Optima 5800 diagnostic station.
Carry out the operations required to ensure correct voltage feed to the computer:
8 volts < correct voltage< 16 volts.
- Check the battery charge.
- Check the charging circuit.
- Check the tightness and condition of the battery terminals.
- Check the computer earth.
Ensure the presence of + after ignition feed on track 1 of the computer connector.
AFTER REPAIR
test.
DPCF01 1.0
13-24
http://vnx.su
13
12
NOTES
Fiche n 60 1/2
Full load or no load not programmed
None
Programme the full load position of the accelerator pedal using command G31* (do not adjust the load
lever directly).
Enter code G31* on the XR25 (engine speed zero).
- Press the accelerator pedal when the display flashes "PF".
The display then shows "bon", "Fin" then "6/7.dIE" when the procedure has been completed correctly. Bargraph 12 RH side must be extinguished.
- Switch off the ignition.
AFTER REPAIR
test.
DPCF01 1.0
13-25
http://vnx.su
13
13
Bargraph 13 LH flashing (cc.1)
Air conditioning cut out information circuit

XR25 aid:
NOTES
Fiche n 60 1/2
*13 :
None
cc.1
NOTES

by a flashing BG 13LH side. To confirm its presence and the necessity
then start the engine. The fault is present if the bargraph flashes
when the engine is running.
Ensure insulation in relation to 12 volts of the connection between track 19 on the computer connector
and track 18 on the air conditioning computer connector.
Test the connections on the 2 connectors (+ intermediate connection engine / dashboard).
If the fault persists after these tests, replace the air conditioning control module.
If the "air conditioning cut out information "fault reappears, replace the diesel injection computer (consult
AFTER REPAIR
test.
DPCF01 1.0
13-26
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13
Bargraphs 2 RH and LH sides and bargraph 3 RH side
Solenoid valve control
Fiche n 60 2/2
NOTES
None
These bargraphs visualise the control of the various solenoid valves:

- Advance solenoid valve (bargraph 2 LH side is always illuminated).
- Fast idle solenoid valve .
- EGR solenoid valve.
Bargraph 4 LH side
Erase stored faults

XR25 aid :
NOTES
AFTER REPAIR
BG 4LH is illuminated if command mode G0** to erase the memory

has been used since the last XR25 dialogue began.
None
Bargraph 4 RH side
Fiche n 60 2/2
Preheating prevented
XR25 aid :
NOTES
Fiche n 60 2/2
BG 4RH is illuminated if command mode G59*1* to prevent control

of the heater plugs has been used since the last XR25 dialogue began.
None
Ensure the bargraphs operate correctly

DPCF01 1.0
13-27
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Bargraphs 5 and 6 RH and LH sides
13
Fiche n 60 2/2
Relay control
NOTES
None
These bargraphs visualise the control of the various relays:

- Preheating relay N 1.
- Preheating relay N 2 (not used).
- Power assisted steering pump assembly relay (for AC + PAS).
- Altimetric corrector relay.
Bargraphs 9 RH and 9 LH side
Air conditioning
XR25 aid :
NOTES
10
AFTER REPAIR
BG 9LH illuminated if AC requested

BG 9RH illuminated if AC authorised
If BG 9LH is extinguished when AC is requested, ensure the continuity and insulation of the connection between track 11 of the diesel computer connector and
track 20 of the AC computer connector.
Bargraph 10 LH side
Fiche n 60 2/2
Warning light control

XR25 aid :
NOTES
Fiche n 60 2/2
BG 10LH is illuminated if the warning light on the instrument panel

is controlled. This bargraph is normally illuminated; it extinguishes
when the engine is running if there is no fault.
None

DPCF01 1.0
13-28
http://vnx.su

10
Bargraph 10 RH side
11
11
Bargraph 11 LH side
AFTER REPAIR
Fiche n 60 2/2
Load information output

This bargraph allows visualisation of the emission of the load lever
position information (this information is not used for this application). It is permanently illuminated.
None
Bargraph 11 RH side
Fiche n 60 2/2
Engine speed information output

XR25 aid :
NOTES
BG 10RH illuminated during the preheating phase
None
XR25 aid :
NOTES
Fiche n 60 2/2
Preheating warning light control

XR25 aid :
NOTES
13
This bargraph allows visualisation of the emission of engine speed

information (this information is not used for this application). It is
permanently illuminated.
Fiche n 60 2/2
None

DPCF01 1.0
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18
13
Bargraphs 18 and 19 RH and LH
Computer configuration for with and without air conditioning/

with and without power assisted steering pump assembly
19
NOTES
Vehicles fitted with power assisted steering but without air conditioning must
be configured to "without PAS".
These bargraphs show the computer configuration for the air conditioning and pump assembly power
assisted steering options.
Computers sold by the Parts Department are systematically configured for vehicles with air conditioning
and with the PAS pump assembly.
If the vehicle does not have air conditioning, use the command mode G50*4* to reverse the computer
configuration (the opposite command exists for configuring to "with AC": G50*3*).
If the vehicle is not fitted with a PAS pump assembly (vehicle without air conditioning), use command
mode G50*9* to reverse the computer configuration (the opposite command exists for configuring to
"with PAS": G50*8*).
NOTE : Vehicles fitted with power assisted steering but without air conditioning must be configured to
"without PAS".
AFTER REPAIR
test.
DPCF01 1.0
13-30
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Fault finding - Aid
13
REPLACING THE COMPUTER
A) On these computers it is necessary to programme the load lever full load position (this value is required to
replace and adjust the load lever position potentiometer).
Programming procedure:
Enter code G31* on the XR25 (engine speed zero)
Press the accelerator pedal until the display flashes "PF".
The display then shows "bon", "Fin" then "6/7.dlE" when the procedure has been carried out correctly.
Bargraph 12 RH side must be extinguished.
Switch off the ignition.
B) Lucas digital DPC injection computers are sold pre-configured to "with air conditioning".
If the vehicle does not have air conditioning, use command G50*4* on the XR25 to programme "without
air conditioning".
Lucas digital DPC injection computers are sold pre-configured to "with power assisted steering" (with power assisted steering pump assembly).
If the vehicle does not have a power assisted steering pump assembly (vehicle without air conditioning),
use command G50*9* on the XR25 to programme "without power assisted steering".
Vehicles fitted with power assisted steering but without air conditioning must be configured to "without
power assisted steering".
REPLACING THE LOAD LEVER POSITION POTENTIOMETER
The load lever position potentiometer may only be replaced in After Sales if the full load position has been
programmed into the computer before the fault with the potentiometer.
Procedure for replacing and adjusting the load lever position potentiometer:
Fit the new potentiometer into position without locking the mounting bolts.
Connect the potentiometer and set up the XR25 (S8 code D34).
Start command G32* on the XR25, keep the accelerator pedal fully depressed (do not touch the load lever
directly) and turn the potentiometer until the display on the XR25 shows a value other than H.L (outside limits). Adjust the setting by turning the potentiometer to obtain 0 on the display.
Tighten the mounting bolts with the potentiometer in this position then press * to complete the adjustment procedure.
DPCF01 1.0
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Fault finding - Checking conformity
NOTES
Order of
operations
13
Engine cold, ignition on
Function to check
Action
Dialogue with XR25
D34
(selector on
S8)
Bargraph
Display and notes
6. dlE
Use fiche n 60
fault test side
1
Fault test
Interpretation of
normally illuminated
bargraphs
1
Code present
7. dlE
3
Change to status test

mode
Interpretation of
bargraphs
G01*
Use fiche n 60
status test side
1
Code present
2
Advance corrector fed
4
Illuminated if command mode
G0** has been used since the
last dialogue took place
10
Fault warning light fed
10
Illuminated in preheating
phase
11
Injection computer may give
load lever position to other
computers (not used)
11

engine speed information to
other computers (not used)
DPCF01 1.0
13-32
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NOTES
Order of
operations
13
Engine cold, ignition on
Function to check
Action
Bargraph
Computer
configuration
Display and notes
18
With AC
G50*3*
19
With AC
With PAS with pump
G50*8*
18
Without AC
G50*4*
Without AC
19
With conventional PAS
G50*9*
Absolute pressure
sensor
#16
Coolant temperature
sensor
#02
X = Ambient temperature
5 C
Air temperature
sensor
#03
5 C
EGR solenoid valve
X = local atmospheric pressure
X=0
#24
DPCF01 1.0
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NOTES
13
Engine warm at idle speed after at least one operation of the engine cooling fan
assembly (air conditioning not selected).
Order of
operations
Function to check
Action
G01*
Bargraph
Display and notes
7. dlE
Use fiche n 60
status test side
20
2
No faults
Battery voltage
Ensure this bargraph is not

flashing, otherwise enter
G02* and turn the fiche over.
Repair the faulty component
then erase the memory (G0**)
and return to status testing
(G01*)
13 volts < X < 14.5 volts
#04
DPCF01 1.0
13-34
http://vnx.su

NOTES
Order of
operations
13
Function to check
Interpretation of
bargraphs
Action
Bargraph
Display and notes
Code present
2
Advance corrector fed
2
Illuminated if fast idle solenoid
valve is fed
3
Illuminated for 40 seconds at

idle speed after starting phase
Illuminated if command mode

G0** has been used since the
last dialogue took place
5
Illuminated for post heating
Illuminated if altimetric
corrector is fed
Illuminated if vehicle has a PAS

pump assembly
(AC version only)
11
load lever position to other
computers (not used)
11

engine speed information to
other computers (not used)
DPCF01 1.0
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NOTES
13
Order of
operations
Function to check
Action
Bargraph
Display and notes
EGR solenoid valve
After starting
phase for
40 seconds
EGR solenoid valve fed
X = 82
#24
After
40 seconds
3
X=0
#24
Computer
configuration
18
G50*3*
With AC
With AC
19
G50*8*
With PAS with pump
18
G50*4*
Without AC
Without AC
19
G50*9*
With conventional PAS
DPCF01 1.0
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Fault finding - Customer complaints
NOTES
13
Only consult these customer complaints after a complete check using the XR25.
No dialogue from the computer to the XR25.
Chart 1
Idle speed too high (when air conditioning not requested)
Chart 2
No fast idle when air conditioning requested
Chart 3
Starting fault (engine will not start or is difficult to start).
Chart 4
Warning light illuminates with no fault shown by the XR25.
Chart 5
Vehicle produces black smoke at altitude
Chart 6
DPCF01 1.0
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Fault finding - Fault charts
Chart 1
NOTES
13
NO DIALOGUE FROM THE COMPUTER TO THE XR25.
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on another vehicle. If the XR25 is not the cause of the fault and dialogue is not established with another computer on the same vehicle, a faulty computer may be causing interference on the K and L fault finding lines.
Disconnect connections successively to determine which computer is at fault.
Check the ISO selector is on position S8, that you are using the latest XR25 cassette and the correct access
code (D34).
Check the battery voltage and carry out any necessary operations to ensure the correct voltage (U battery
> 10.5 volts).
Check the 15 Amp fuses on the engine connection unit have not blown (positions 3 and 4).
Check the connection and condition of the connections on the computer connector and the connection
R67 engine / dashboard.
Check the computer is correctly fed:
- Earth on track 2 of the computer connector (check the condition and tightness of the engine earth
strap and the engine earth on the gearbox housing).
- + after ignition feed on track 1 of the computer connector.
Check the diagnostic socket is correctly fed:

- Earth on track 5.
- + before ignition feed on track 16.
Check and ensure the continuity and insulation of the lines in the connection diagnostic socket/
computer:
If fault finding is not established after these operations, replace the computer (consult the "Aid" section
AFTER REPAIR
Carry out a road test then check using the XR25.

Deal with any illuminated fault bargraphs.
DPCF01 1.0
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Chart 2
NOTES
13
IDLE SPEED TOO HIGH (WHEN AIR CONDITIONING NOT

REQUESTED)
Only consult this customer complaint after a complete check using the XR25.
This fault may be connected to fast idle operation.

Check the condition of the pneumatic circuit for the fast idle solenoid valve.
Look for a short circuit to + 12 volts of the connection between track 11 on the injection computer and
track 20 on the BE connector for the air conditioning computer ("AC Inj. / fast idle" information).
AFTER REPAIR

DPCF01 1.0
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Chart 3
NOTES
13
NO FAST IDLE WHEN AIR CONDITIONING REQUESTED
Look for an open circuit or a short circuit to earth on the connection between track 11 on the injection
computer and track 20 on the BE connector for the air conditioning computer ("AC Inj. / fast idle" information).
This fault causes the absence of illumination of bargraph 9 LH side "air conditioning requested".
AFTER REPAIR

DPCF01 1.0
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Chart 4
NOTES
13
STARTING FAULT (ENGINE WILL NOT START OR IS DIFFICULT TO

START) (warning light extinguished).
If no fault is shown by the XR25, ensure that the fault is not caused by a faulty immobiliser system.
Check the operation of the preheating system:

Start command mode G10*1* and check for a voltage at the plugs.
If the plugs are not fed, check the connection of the 3 track connector on the relay unit and the condition
of the 70 Amp fuse on the engine connection unit.
If the fault persists, check the fuel supply circuits (for the pump and the injectors).
If necessary, carry out a complete check of the engine (starter drive speed, pump timing, condition of
injectors, rocker arm clearances, compression, .....).
AFTER REPAIR

DPCF01 1.0
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Chart 5
NOTES
13
WARNING LIGHT ILLUMINATES WITH NO FAULT SHOWN BY THE

XR25.
If no fault is shown by the XR25, look for a short circuit to earth of the heater plug feed wiring or a plug
short circuit fault.
AFTER REPAIR

DPCF01 1.0
13-42
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Chart 6
NOTES
13
VEHICLE PRODUCES BLACK SMOKE AT ALTITUDE
Measure the resistance of the altimetric corrector at the 10 track pump connector (between tracks 1 and
6).
Replace the altimetric corrector if the resistance is not approximately 15 ohms.
Ensure the continuity of the connection between track 1 on the pump connector, wiring side, and track 5
on the altimetric connector control relay (position H on the relay plate in the engine connection unit).
Ensure the presence of earth on track 6 of the pump connector, wiring side.
AFTER REPAIR

DPCF01 1.0
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E7J 780 ENGINE
MULTIPOINT INJECTION
FAULT FINDING
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
06
..............................................................
09
..................................................................
30
...........................................................
36
56
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
Checking conformity
63
.........................................................................
http://vnx.su
INJECTION
Fault finding- Introduction
E7J 780
engine
17
SETTING UP DIALOGUE BETWEEN THE XR25 AND THE COMPUTER
Connect the test kit to the diagnostic socket.
Put the selector on S8
Switch on the ignition.
Enter D13
9.NJ
COMPUTER IDENTIFICATION
The computer is not identified by reading a fault code but by reading the Part Number directly from the
computer. After having set up a dialogue with the computer:
ENTER
G70*
7700
XXX
XXX
The Part Number will then appear on the central display in three sequences.
Each sequence is displayed for approximately two seconds. The display is repeated twice .
ERASING THE MEMORY (ignition on)
After an operation on the injection system the computers memory can be erased by using the code G0** .
JF5111.0
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E7J 780
engine
INJECTION
17
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier Sus.
1228.
97434S
Bornier Sus. 1228 is a 55 track base with a printed circuit on which are 55 copper coated surfaces, numbered
from 1 to 55.
Using the wiring diagrams, the tracks connecting the components to be tested can be easily identified.
IMPORTANT :
All tests using bornier Sus. 1228 must be carried out with the battery disconnected.
The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 Volts be
applied to the test points.
JF5111.0
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INJECTION
E7J 780
engine
17
DESCRIPTION OF THE FAULT-FINDING PHASES
The process described below is to be carried out in all cases of faults.

XR25 FAULT-CHECKING
This phase is the essential starting point for any intervention on the vehicle.
There are several constraints to the treatment of the bargraphs :
- A priority in the order of treatment when several bargraphs are illuminated.
- The interpretation of a bargraph depending on whether it is constantly illuminated or flashing .
1 - Order of priority
A series of illuminated bargraphs corresponding to the sensors with the same 12 V or having the same
earth, indicates a fault in this source. These priorities are dealt with in the "NOTES" section of the
fault-finding of the bargraph concerned.
2 - Input / output fault bargraphs

a) Illuminated :
The fault is present : treat the fault following the method described in the "INTERPRETATION OF XR25
BARGRAPHS" section.
b) Flashing :
Note the bargraphs displayed on the XR25.
Erase the memory of the computer and attempt to re-illuminate the bargraph: ignition on, idle speed
(or at starter speed) or by means of a road test (the "NOTES" section in the fault finding for the
bargraph concerned may help to determine the conditions under which the bargraph will illuminate).
If the bargraph has re-illuminated (fixed or flashing) :
The fault is present once again. In this case, treat the fault bargraph.
If the bargraph has not re-illuminated, check :
-
the electrical lines which correspond to the flashing fault,

the connectors of these lines (for rust, bent pins...).
the resistance of the component found to be faulty.
the cleanliness of the wires (insulation melted or cut, friction..).
NOTE : If the customer complaint does not correspond to the fault bargraph which is flashing
(example : Air temperature sensor fault bargraph flashing, but no customer complaint) ignore
this memorised fault and erase it.
3 - No bargraphs illuminated
If no bargraphs are illuminated on the XR25, carry out a status and parameter check. This may help in
detecting a problem.
JF5111.0
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E7J 780
engine
INJECTION
17
XR25 CHECKING STATUSES AND PARAMETERS
The status and parameter check is aimed at checking the statuses and parameters which do not illuminate
any fault bargraphs if they are outside of permitted tolerance values . This phase allows :
- Faults to be found without the illumination of fault bargraphs which may correspond to a customer
complaint (example : absence of no load information causing an unstable idle speed).
- The correct operation of the injection to be checked and the risk of faults appearing shortly after the
repair to be eliminated.
This section contains fault-finding for statuses and parameters, under their test conditions
(example : fault finding for # 01 ignition on and fault finding for # 01 engine running).
If a status does not operate normally or a parameter is outside of permitted tolerance values, consult the
fault-finding page indicated in the "Fault-finding" column.
XR25
CHECK CORRECT
If the XR25 check is correct, but the customer complaint persists, the problem must be dealt with through
customer complaints.
Treatment of customer complaints
This section has fault charts, which suggest a series of possible causes of the problem.
These lines of enquiry must only be used in the following cases :
- No fault bargraph appears on the XR25.
- No faults are detected during the checking of statuses and parameters.
- The vehicle is not operating correctly
POST-REPAIR CHECK
This operation is a simple check of the repair (by a command, or by an XR25 command mode ...).
This makes it possible to check that the system upon which the intervention has been carried out is correct
electrically.
It is an introduction to the road test.
ROAD TEST
A road test is essential in order to guarantee the correct operation of the vehicle and to test the quality of the
repair. Its role is to make sure that no faults occur (or will occur) when driving.
In order to be significant, the road test is subject to special driving conditions.
JF5111.0
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INJECTION
E7J 780
engine
17
Driving conditions for programming the adaptive variables:

During the road test, the engine speed must be stabilised for a few moments between:
220
then 340
then 470
then 600
then 730
<
<
<
<
<
# 01
# 01
# 01
# 01
# 01
<
<
<
<
<
340 mbars
470 mbars
600 mbars
730 mbars
870 mbars
Do not exceed an engine speed of 4800 rpm

The engine must be warm (coolant temperature > 75 C).
For this test, start from a fairly low engine speed, in 3rd or 4th gear, and apply progressive acceleration to
stabilise at the pressure required for 10 seconds in each zone.
The test must then be continued by driving normally, in a varied manner for 3 to 6 miles (5 to 10 km).
JF5111.0
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E7J 780
engine
INJECTION
17
PRESENTATION OF XR25 FICHE N 27 SIDE 1/2
FI21727-1
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E7J 780
engine
PRESENTATION OF XR25 FICHE
INJECTION
17
N 27 SIDE 2/2
FI21727-2
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INJECTION
E7J 780
engine
17
REPRESENTATION OF THE BARGRAPHS
Illuminates when a dialogue has been established with the product computer. If it remains
extinguished:
- the code does not exist,
- there is a fault in the tool, the computer or the line
REPRESENTATION OF THE FAULTS (always on a coloured background)
If illuminated, indicates a fault on the tested product, the associated text defines the fault.
If extinguished, indicates that the fault has not been found on the tested product.
REPRESENTATION OF THE STATUSES (always on a white background)

Engine off, ignition on, no operator action
The status bargraphs on the fiche are represented as the status which they should have when the engine is
off, the ignition is on and there is no operator action
- If on the fiche the bargraph is represented as
the test kit should give as

information

information
the test kit should give as information
either
or
Engine running
Extinguishes when the function or condition given on the fiche is no longer performed.
Illuminates when the function or condition given on the fiche is performed
Fiche n 27 is a generic fiche used for several engines.

The different engines do not use all the bargraphs. To find out the bargraphs dealt with by the injection
computer, after having set up a dialogue with the computer, press the V and 9 buttons simultaneously.
The bargraphs dealt with will:
-
illuminate permanently for non memorisable fault bargraphs or status bargraphs,

flash for memorisable fault bargraphs.
To return to fault finding mode, press button D.
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INJECTION
E7J 780
engine
17
Bargraph 1 RH side extinguished
XR25 CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
No connection, CO, CC-, CC+
This bargraph must be illuminated for fault finding
Test the XR25 on another vehicle.

Check:
- the injection, engine and passenger compartment fuses,
- the connection between the XR25 and the diagnostic socket,
- the position of the ISO selector (S8),
- the conformity of the cassette.
Repair if necessary.
Check:
- the presence of + 12 V on track 16 and earth on track 5 of the diagnostic socket,
- that the XR25 cable is in good condition.
Connect the bornier in place of the computer and check the insulation and continuity of the line:
Computer
Computer
Computer
Computer
Computer
Computer
2
3
11
38
24
32
Earth
Earth
7 Diagnostic socket
15 Diagnostic socket
Fuse F6
15 A
Fuse F3
5A
Repair.
AFTER REPAIR
Erase the computer memory using G0**.

Try to start the engine. Switch the ignition on, then deal with the other faults.
Remember to carry out a status and parameter check.
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INJECTION
E7J 780
engine
17
Bargraph 2 LH side illuminated
COMPUTER CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
Computer faulty
None
The computer is incorrect or faulty.

Replace the computer.
AFTER REPAIR

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INJECTION
E7J 780
engine
17
Bargraph 2 RH side illuminated
IMMOBILISER CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
*22 = 1 dEF CO, CC- or CC+ line 37 on the computer

*22 = 2 dEF Refer to the immobiliser fault finding
Ignore this bargraph if the vehicle is not fitted with an immobiliser.
Connect the bornier in place of the computer and check the insulation, continuity and that there is no
interference resistance on the wiring on track 37 of the computer.
If the fault persists, refer to the immobiliser fault finding.
AFTER REPAIR

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INJECTION
E7J 780
engine
17
AIR TEMPERATURE SENSOR CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+line 20 or 46
If BG 6RH is also illuminated, check line 46 of the computer.
Computer
Computer
20
46
2
1
Air temperature sensor

Check the resistance of the sensor. Replace it if necessary.
The fault persists! Replace the injection computer.
IMPORTANT: The computer has probably been damaged by an electric shock. The cause of the damage
must be found before fitting a new computer.
AFTER REPAIR

JF5111.0
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INJECTION
E7J 780
engine
17
Bargraph 3 RH side illuminated or flashing
OXYGEN SENSOR CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+line 17
If BG 3RH is flashing, increase the engine speed to 2500 rpm for 5 minutes
If BG3RH becomes permanently illuminated, deal with the fault.
Check the connection and the condition of the connector on the oxygen sensor.
Check, ignition on during the timed phase, for :
- earth on track B of the oxygen sensor,
- + 12 V after the fuel pump relay on track A of the oxygen sensor.
Computer
17
C
Oxygen sensor
The fault persists. Replace the oxygen sensor.
AFTER REPAIR
Turn the engine, switch the ignition on and erase the computer memory using
G0**. Try to start the engine. Switch the ignition on, then deal with the other
faults. Remember to carry out a status and parameter check.
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INJECTION
E7J 780
engine
17
COOLANT TEMPERATURE SENSOR CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
If BG 6LH or BG 5LH is also illuminated, check line 44 of the computer.
Computer
44
B1 Coolant temperature sensor
Computer
15
AFTER REPAIR

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INJECTION
E7J 780
engine
17

Fiche n 27 side 1/2
VEHICLE SPEED CIRCUIT

XR25 aid:
NOTES
CO, CC- or CC+ line 12
Carry out a road test if BG 4RH is flashing
Check on the vehicle speed sensor for:

- earth on track B2,
- + 12 after ignition feed on track A.
Check the sensor is correctly positioned.
interference resistance on the line:
Computer
12
B1
Vehicle speed sensor
The fault persists! Replace the sensor.
AFTER REPAIR

JF5111.0
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INJECTION
E7J 780
engine
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
PRESSURE SENSOR CIRCUIT

CO, CC- or CC+ line 45, 44 or 16
If BG 6RH is also illuminated, check line 45 on the computer.

If BG 6LH or BG 4LH is also illuminated, check line 44 on the computer.
Check that the pressure sensor is connected correctly both electrically and pneumatically.
Check the conformity of the pressure sensor pipe (it must not be holed or blocked...).
Computer
45
C Pressure sensor
Computer
44
A Pressure sensor
Computer
16
B Pressure sensor
AFTER REPAIR

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INJECTION
E7J 780
engine
17

5
FLYWHEEL SIGNAL CIRCUIT

XR25 aid:
NOTES
*25 = CO.0
*25 = CC.0
Fiche n 27 side 1/2
*25 = CO.0
*25 = CC.0
*25 = In
=>
=>
=>
CO or CC- line 33 or 34
CC- line 33 or 34 on the computer
sensor incorrectly connected
If BG 5RH is flashing, erase the computer memory using G0**.

Try to start the vehicle.
If BG 5RH becomes permanently illuminated or flashes, deal with this fault.
Check the condition of the flywheel, especially if it has been removed.

Connect the bornier in place of the computer and check the insulation,
continuity and that there is no interference resistance on the line:
Computer
33
B Target sensor
Computer
34
A Target sensor
IMPORTANT: The computer has probably been damaged by an electric shock.
The cause of the damage must be found before fitting a new
computer.
*25 = In
Check the target sensor has been correctly connected (the sensor connector must
not be inverted).
AFTER REPAIR

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INJECTION
E7J 780
engine
17
Bargraph 6 LH side illuminated or flashing
PINKING SENSOR CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 8 or 44
If BG 6LH is flashing, erase the computer memory using G0**. Run the engine at
3000 rpm for 3 min. If BG 6LH becomes permanently illuminated or flashes, deal
with this fault. If BG 4LH or BG 5LH is also illuminated, check line 44 on the
computer.
Computer
8
2 Pinking sensor
Computer
44
1 Pinking sensor
Computer
31
Pinking sensor screening
The fault persists! Replace the pinking sensor in question.
AFTER REPAIR

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INJECTION
E7J 780
engine
17
THROTTLE POTENTIOMETER CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
If BG 5LH is also illuminated, check line 45 on the computer.

If BG 3LH is also illuminated, check line 46 on the computer.
Computer
Computer
Computer
19
45
46
2
1
3
Throttle potentiometer
Check the resistance of the throttle potentiometer.
The fault persists! Replace the throttle potentiometer.
AFTER REPAIR

JF5111.0
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INJECTION
E7J 780
engine
17

8
FUEL PUMP CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
*08 = ignore this information

CO line 52
If BG 8LH is flashing, erase the computer memory using G0**. Try to start the
engine. If BG 6LH is now permanently illuminated or flashing, deal with this fault. In
certain cases, BG 13RH is illuminated, which must be ignored if ADAC is not present.
Enter the fuel pump relay command mode : G10*.

Does the fuel pump relay click?
The fuel pump
relay does not
click
Check the presence of 12 volts on track L1 on the fuel pump relay mounting.
If necessary, repair the line to the 15 A fuse.
Check the insulation, continuity and that there is no interference resistance on the line:
Computer
48
L2
Fuel pump relay
If the fuel pump relay still does not click, replace the fuel pump relay.

computer.
The fuel pump

relay clicks
Check the presence of 12 volts on track L3 on the fuel pump relay mounting.
If necessary, repair the line to the 30 A fuse.
Check the insulation and continuity of the line:

Computer
52
L5 Fuel pump relay
NOTE : If there is a short circuit on this line, check all the users of this feed.
If the fault persists, replace the fuel pump relay.

computer.
AFTER REPAIR

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INJECTION
E7J 780
engine
17
11
INJECTOR CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
*11 = XX.CO
*11 = XX.CC
=> CO or CC- line 30 or 4 on the computer

=> CC+ line 30 or 4 on the computer
XX = 14 => Cylinder 1 or 4 line 30 on the computer

engine. If BG 11LH is now permanently illuminated or flashing, deal with this fault.
When the ignition is switched on and during the timed phase, check for 12 V on track 1 of the faulty
injector.
If necessary, repair the line from track 1 injector to track L5 fuel pump relay.
Connect the bornier in place of the computer and check the insulation and continuity of the line :
Computer
Computer
30
4
2
2
Injectors 1 and 4
Injectors 2 and 3
The fault persists! Replace the faulty injector.
NOTE : Check the insulation and continuity of the lines for the other injectors and also check the
resistance of these injectors.
AFTER REPAIR
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INJECTION
E7J 780
engine
17
11
AT
XR25 aid:
NOTES
Fiche n 27 side 1/2
INJECTION CIRCUIT
None
None
Ignore the illumination of this bargraph as the vehicle does not have an automatic transmission.
AFTER REPAIR

JF5111.0
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INJECTION
E7J 780
engine
17
13
MEMORY CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
Loss of computer feed
None
This bargraph only illuminates when the computer feed has been cut (disconnection of the battery, the
computer, ...).
Check the computer feed hygiene:
Computer
24
Fuse
15 A
F6
Computer
32
Fuse
5A
F3
Turn the engine.
Switch the ignition off.
Switch the ignition on.
Enter dialogue with the computer.
NOTE : memorised faults are erased. It would therefore be useful to carry out a road test to check there
are no faults on the injection system.
AFTER REPAIR

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INJECTION
E7J 780
engine
17

13
Fiche n 27 side 1/2
ADAC CIRCUIT
XR25 aid:
False diagnosis by computer for vehicles not fitted with ADAC
This vehicle is not fitted with ADAC at the moment.

If another bargraph is illuminated, refer to the fault finding for that bargraph.
NOTES
If your vehicle has ADAC,

this method of fault finding will not be of use for this fault.
This bargraph is often illuminated or flashing in the following cases:

- Air conditioning compressor command mode G12*.
- Fault on fuel pump relay circuit.
- Other cases, which have not yet been noted, may well exist.
AFTER REPAIR

JF5111.0
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INJECTION
E7J 780
engine
17
14
IDLE SPEED REGULATION CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 40 or 35 or 9 or 36 on the computer
engine (if the engine will not start, keep trying with the starter motor). If BG 14LH
becomes permanently illuminated or flashes, deal with this fault.
Computer
40
B idle speed regulation stepping motor
Computer
35
A idle speed regulation stepping motor
Computer
9
D idle speed regulation stepping motor
Computer
36
C idle speed regulation stepping motor
NOTE : This operation can be carried out without having to remove the throttle body.
Check the resistance of the idle speed regulation stepping motor.
Check the idle speed regulation valve if necessary.
AFTER REPAIR

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INJECTION
E7J 780
engine
17
14
CANISTER BLEED CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 42 of the computer
If BG 14RH is flashing, erase the computer memory using G0**. Start the engine. If
BG 14RH becomes permanently illuminated when the engine is running, deal with
this fault.
Check the resistance of the canister bleed valve.

Replace the valve if necessary.
Check, ignition on and during the timed phase, for 12 V on track A of the canister bleed.
Computer
42
Canister bleed valve
AFTER REPAIR
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INJECTION
E7J 780
engine
17
15
COMPUTER
XR25 aid:
NOTES
Fiche n 27 side 1/2
AC CONNECTION CIRCUIT
CC + 12 V line 51 on the computer
Check that the vehicle has air conditioning and if it is not fitted with air
conditioning, deal with the other bargraphs first.
Engine running, select the air conditioning function.
Connect the bornier in place of the computer and check the insulation and continuity of line 51 on the
computer.
If the fault persists, refer to the air conditioning fault finding.
AFTER REPAIR

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INJECTION
E7J 780
engine
17

15
Fiche n 27 side 1/2
EGR CIRCUIT
XR25 aid:
None
None
NOTES
Ignore the illumination of this bargraph as the vehicle is not fitted with EGR.
AFTER REPAIR

JF5111.0
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INJECTION
E7J 780
engine
17
16
COMPUTER
XR25 aid:
NOTES
Fiche n 27 side 1/2
MPA CONNECTION CIRCUIT

=> CO line 28 or 29 on the computer
=> CC+ or CC- line 28 or 29 on the computer
*16 = XX.CO
*16 = XX.CC

NOTE : If there is an open circuit, it is possible for *16 = XX.CC instead of *16 =
XX.CO .
Check the + after ignition feed to the coil concerned on track 2.

Check the resistance of the faulty coil.
Replace the coil if necessary.
Check the hygiene of the anti-interference condenser on track 1 of the coil.
Computer
Computer
29
28
3
3
Coil 2-3
Coil 1-4
AFTER REPAIR
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E7J 780
engine
INJECTION
Fault finding - Status and parameter checks
Engine stopped, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue
with XR25
D13
(selector on
S8)
Bargraph
Display and notes
Fault finding
1
Fault test
9.NJ
Use fiche 27
1
Deal with
fault
bargraph
Code present
Change to
status test
10.NJ
None
G01*
Status test
Battery
voltage
11.8 < X < 13.2 V
# 04
19
Computer
configuration
Immobiliser
19
Ignition on
Computer configured to
manual gearbox
automatic transmission
This status bargraph must

be extinguished when
the ignition is on to
indicate that the
immobiliser is not active.
DIAG 1
See Fiche
"Reminder C"
to configure
vehicle
DIAG 12
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E7J 780
engine
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Fault finding
2
No load
# 17
Throttle
position
potentiometer
.
Accelerator
pedal
slightly
depressed
16 < X < 50
2
DIAG 2
2
Full load
# 17
Pressure sensor
Coolant
temperature
sensor
Air
temperature
sensor
185 < X < 243
X =Atmospheric pressure
# 01
DIAG 9
# 02
X = Engine temperature
5 C
DIAG 3
# 03
X = Temperature under
bonnet 5 C
DIAG 4
DIAG 17
10
Fan assembly
G17*
Fan must operate
11
Fault warning
light
Switch
ignition on
Fault warning light must

illuminate then
extinguish
DIAG 19
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E7J 780
engine
INJECTION
17
Carry out the actions below if the engine does not start.
NOTES
Otherwise, refer to the following pages.
Order of
operations
Function to be
checked
Flywheel signal
sensor
Action
Bargraph
Ignition
Fuel pressure
Fault finding
3
Starter
Illuminated if TDC
information is detected
DIAG 5
G10*
Fuel pump should be

heard to operate
DIAG 6
Connect
Optima
Station
Starting test.
Complete guide on
Optima Station
Fuel pump
2
Display and notes
Connect
pressure
gauge to
fuel inlet
and activate
starter
motor
Pressure gauge must

show
2.5 bars
Injector
command
Starter
Fuel must come out of

the injector
Engine
compression
Connect
Optima
Station
Complete guide on
Optima Station
Flywheel
Connect
Optima
Station
Oscilloscope.
Complete guide on
Optima Station
Use Optima
5800 Station
Fuel pressure,
see Workshop
Repair
Manual or
section
DIAG 11
Use Optima
5800 Station
Use Optima
5800 Station
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E7J 780
engine
INJECTION
Carry out the actions below (engine warm, at idle speed, no consumers)
if the engine starts.
Otherwise refer to the previous pages.
NOTES
Order of
operations
Function to be
checked
Action
Charging
circuit
# 04
Throttle
potentiometer
No load
Idle speed
regulation
Bargraph
Anti-pinking
circuit
Pressure circuit
X = atmospheric pressure
# 35
6
0 < X < 255

X varies around 128
50 X 900 mb
# 05
Fuel pressure
DIAG 2
DIAG 7
DIAG 8
300 X 400 mb
# 16
DIAG 1
700 < X < 800 rpm
X variable and not zero
# 01
Fault finding
- 2.4 % < X < 6.2 %
# 13 (at
3500 rpm,
no load)
Richness
regulation
Illuminated (does not

flash!)
2 % < X < 15 %
# 12
# 21
Display and notes
13 < X < 14.5 V
# 06
3
17
Connect a
pressure
gauge to the
gallery and
activate the
starter
motor
Pressure gauge must

show
2.5 bars
DIAG 9
DIAG 10
See also
DIAG 15
Fuel pressure,
see Workshop
Repair
Manual or
section
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E7J 780
engine
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Fault finding
9
AC selected
Illuminated when AC
selected
10
Illuminated when AC
requests compressor
operation
DIAG 16
AC
10
Illuminated when
injection authorises
operation of compressor
# 06
830 < X < 930 rpm
Power assisted
steering
pressostat
13
Turn wheels
to full lock
Illuminated when wheels

turned to full lock
DIAG 18
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E7J 780
engine
INJECTION
17
Check during road test.
NOTES
Order of
operations
Function to be
checked
Vehicle speed
information
Action
Bargraph
# 18
Display and notes
Fault finding
X = speed read on
speedometer in km/h
DIAG 13
Programming
2
Adaptive
richness
# 30
64 X 192
# 31
64 X 192
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
0.97 < < 1.03
2500 rpm
after driving
3
Emission of
pollutants
At idle
speed, wait
for
stabilisation
DIAG 14
DIAG 15
see also
DIAG 10
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
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E7J 780
engine
INJECTION
Fault finding - Status and parameter interpretation
17
Fiche n 27
BATTERY VOLTAGE
DIAG 1
NOTES
XR25 aid:
Battery voltage, ignition on, Minimum < # 04 < Maximum

Battery voltage, idle speed, Minimum < # 04 < Maximum
No fault bargraphs should be illuminated.

No consumers
Ignition on
If # 04 < Minimum, the battery is discharged:

Check the charging circuit to determine the cause of this fault.
If # 04 > Maximum, the battery may be overcharged:
Check the charging voltage is correct with and without consumers.
At idle speed
If # 04 < Minimum, the charging voltage is too low:

If # 04 > Maximum, the charging voltage is too high:
The alternator regulator is faulty. Repair this fault and check the electrolyte level in the battery.
NOTE:
The battery and the charging circuit may be checked using the OPTIMA 5800 station (measurement does
not require the battery to be disconnected, which retains the memories of the computers).
AFTER REPAIR
Start the status and parameter check again from the beginning.
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INJECTION
E7J 780
engine

THROTTLE POTENTIOMETER
XR25 aid:
DIAG 2
NOTES
17
Fiche n 27
# 17 outside tolerances
# 17 does not vary when throttle moves
Status BG 2LH or 2RH, incorrect illumination

Ignition on or engine running.
Status bargraph 2RH

incorrect illumination
None
NOTES

Computer
Computer
Computer
19
45
46
2
1
3
If the fault is still present, replace the throttle potentiometer.
# 17 is fixed
NOTES
None
Check the resistance of the throttle potentiometer when the throttle butterfly is moved.
If the resistance varies, check the electrical lines of the sensor.
If the resistance does not vary, check that the sensor is connected mechanically to the throttle.
If necessary, replace the sensor.
NOTES
None
Check the upper and lower stops of the throttle butterfly.

Check the accelerator control (points of resistance and friction).
Repair.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
COOLANT TEMPERATURE
DIAG 3
NOTES
XR25 aid:
# 02 = Engine temperature 5 C
If the value read is incoherent, check the sensor is correctly following the standard table of values for
"resistance as a function of temperature".
Replace the sensor if the values are incorrect (NOTE : If a sensor is incorrect, this is often due to an electric
shock).
Check the insulation, continuity and that there is no interference resistance on the electrical line :
Computer
15
Computer
44
Repair.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
AIR TEMPERATURE
DIAG 4
NOTES
XR25 aid:
# 03 = Temperature under the bonnet 5 C
shock).
Computer
20
2
Computer
46
1
Repair.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
TDC DETECTION
DIAG 5
NOTES
XR25 aid:
Status BG 3LH, incorrect illumination

When the starter motor is activated.
Check the sensor is correctly mounted.

Check the condition of the target (if it has been removed).
Computer
33
B
Flywheel signal sensor
Computer
34
A
Repair. If necessary, replace the sensor.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
FUEL PUMP
DIAG 6
The command mode should cause the fuel pump to operate
XR25 aid:
NOTES
Check the impact sensor is correctly clipped in.

Check the 30A fuel pump fuse.
Check the insulation and continuity of the wiring:
Fuel pump fuse
L3 Fuel pump relay
Fuel pump relay
Impact sensor
L5
Impact sensor
C1 Fuel pump
Check the hygiene and presence of earth on track C2 of the fuel pump.
If + 12 V is not reaching the fuel pump, replace the fuel pump relay.
If + 12 V is reaching the fuel pump, replace the fuel pump.
AFTER REPAIR
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E7J 780
engine
INJECTION
17

IDLE SPEED REGULATION
XR25 aid:
Fiche n 27
Engine speed , Minimum < # 06 < Maximum
DIAG 7
NOTES

Computer
9
D
Idle speed regulation motor
Computer
35
A
Computer
40
B
Computer
36
C
Repair if necessary and continue fault finding using the value for # 06.
# 06 < Minimum
NOTES
The idle speed is too low
Idle speed regulation is not maintaining the idle speed.

- Clean the air supply circuit (throttle body, idle regulation valve), since it is probably contaminated.
- Check the engine oil level (too high ---> splashing).
- Check and ensure correct fuel pressure.
- Using the OPTIMA 5800 station, check the engine compression.
- Check the valve clearances and the timing.
If all these points are correct, replace the idle regulation motor.
# 06 > Maximum
NOTES
The idle speed is too high
An air leak may be affecting the idle speed regulation programming.

- Check the connections on the manifold.
- Check the hygiene of the pipes on the manifold.
- Check the pneumatically controlled solenoid valves.
- Check the manifold gaskets.
- Check the throttle body gaskets.
- Check the sealing of the brake servo.
- Check the restrictions are present in the oil vapour rebreathing circuit.
- Check the fuel pressure.
If all these points are correct, replace the idle speed regulation motor.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
ANTI-PINKING CIRCUIT
DIAG 8
NOTES
XR25 aid:
# 13 is not zero and variable for fast idle or under load
The pinking sensor should give a signal which is variable and not zero, to prove that it is recording the
mechanical vibrations of the engine.
If the signal is zero:
- Check the sensor is correctly screwed in.
- Check the insulation and continuity of the wiring:
Computer
8
2
Pinking sensor
Computer
44
1
Pinking sensor
Computer
2
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
PRESSURE CIRCUIT
DIAG 9
XR25 aid:
NOTES
# 01 not coherent
ignition on
# 01 < Minimum at idle
speed
# 16 not coherent
Ignition on # 01 not coherent

At idle speed # 01 < Minimum or # 01 > Maximum
# 16 not coherent
Check the insulation, continuity and that there is no interference resistance

on the line:
Computer
45
C
Pressure sensor
Computer
44
A
Pressure sensor
Computer
16
B
Pressure sensor
If all these points are correct, replace the sensor.
A vacuum pump with a pressure gauge may be used to check coherence with
# 01 and to show a faulty sensor.
# 01 > Maximum at idle

speed
The manifold pressure is often a sign of incorrect engine operation. Check

- the sealing of the pipe between the manifold and the sensor,
- the valve clearances,
- the canister bleed valve which should be closed at idle speed,
- cylinder compression using the OPTIMA 5800 station.

AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
RICHNESS REGULATION
DIAG 10
Richness regulation faulty
XR25 aid:

Ignition correct (a check may be made using the OPTIMA 5800 station).
No other status bargraph should show a fault.
NOTES
Check the connection and condition of the oxygen sensor connector.

Ignition on, during the timed phase, check for:
- earth on track B of the oxygen sensor.
Computer
17
Oxygen sensor
Check the sealing of the canister bleed valve (a leak can disrupt the richness considerably).
Check the sealing of the exhaust pipe upstream from the oxygen sensor.
Check the sealing of the inlet manifold.
If the vehicle has only been driven in town, the sensor is contaminated (try driving under load).
Check the fuel pressure.
If the idle speed is unstable, check the valve clearances.
Check the injectors (flow and shape of the jet).
If necessary, replace the oxygen sensor.
AFTER REPAIR
JF5111.0
17-45
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E7J 780
engine
INJECTION
17
Fiche n 27
INJECTOR
DIAG 11
NOTES
XR25 aid:
CO or CC - line 30 of the computer for injectors 1 and 4

Check the resistance of the faulty injector. Replace it if necessary.

injectors 1 and 4
Computer 30
injectors 2 and 3
Computer
4
2 injectors
2 injectors
During command mode operation, check for + 12 Volts on track 1 of the faulty injector.
Repair.
AFTER REPAIR
JF5111.0
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E7J 780
engine
INJECTION
17
Fiche n 27
IMMOBILISER
DIAG 12
NOTES
XR25 aid:
Status BG 3RH illuminated, ignition on
Check the insulation and continuity of the wiring for track 37 on the injection computer.
AFTER REPAIR
JF5111.0
17-47
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E7J 780
engine
INJECTION
17
Fiche n 27
VEHICLE SPEED
DIAG 13
NOTES
XR25 aid:
# 18 = Speed read on speedometer in km/h

Check on a road test.
if the value read is incoherent:

- Check that the sensor is correctly mounted and supplied:
+12 V on A1
Earth on B2
- Check the insulation, continuity and that there is no interference resistance on the line:
Computer
12
B1 vehicle speed sensor
NOTE : Check the different functions that use this information.
Repair.
The fault persists! Replace the speed sensor.
AFTER REPAIR
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17-48
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E7J 780
engine
INJECTION
17
Fiche n 27
ADAPTIVE RICHNESS
DIAG 14
NOTES
XR25 aid:
Minimum < # 30 < Maximum


Carry out the programming operations.
Ensure the canister bleed valve is sealed.

Erase the computer memory.
Engine warm , running at idle speed, check the values for # 30 and # 31.
- If # 30 or # 31 is at a MAXIMUM, there is not enough fuel .
- If # 30 or # 31 is at a MINIMUM, there is too much fuel.
Ensure the hygiene, cleanliness and correct operation of :
- filter.
- fuel pump.
- fuel circuit.
- fuel tank.
AFTER REPAIR
JF5111.0
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INJECTION
E7J 780
engine
17
Fiche n 27
EMISSION OF POLLUTANTS
DIAG 15
NOTES
0.97 1.03
at 2500 rpm.
XR25 aid:
None
NOTES
The oxygen sensor loops correctly at 2500 rpm.
If CO > 0.3 % at 2500 rpm.

The catalytic converter is faulty.
NOTE : it is vital to determine the cause of the catalytic converter damage to
avoid a new converter also being damaged.
If < 0.97 or > 1.03 at idle speed

Check the sensor earth and heating.
Check there is no air leak at the manifold.
0.97 1.03
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm.
There is a fault with the injection or the sensor.
AFTER REPAIR
JF5111.0
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INJECTION
E7J 780
engine
17
Fiche n 27
DIAG 15
CONT
NOTES
> 1.03
at 2500 rpm.
NOTES
None

Check there is no leak at the exhaust.
Check that an injector has not seized.
Check the fuel pressure is not too low.

Check there is not an injection fault.
Check there is not an ignition fault.
Check the sensor is not faulty.
< 0.97
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm. CO >
0.3 % at 2500 rpm.
Check the pressure sensor.

Check the sensor.
Check that an injector is not faulty.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
AIR CONDITIONING
DIAG 16
NOTES
XR25 aid:
Status BG 9LH, 10LH or 10 RH, incorrect illumination
Check the insulation and continuity of the lines for track 5 and track 51 on the injection computer.
Refer to the fault finding for the air conditioning.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
ANTIPERCOLATION RELAY
DIAG 17
NOTES
The antipercolation relay

does not click when its
command mode is used
XR25 aid:
The fan assembly must operate when command mode G17* is used.
Ignition on, check for 12 V on track 1 of the fan assembly relay.
There is not 12 V
on track 1
There is 12 V
on track 1
Check the line for track 1 of the relay to the fuse.
Connect the bornier in place of the computer and

check the insulation and continuity of the line:
Bornier 14
2
Relay
Repair.
The fault persists, replace the relay.
The fault persists!
Replace the injection computer.

does click when its
Fan assembly relay in place, check, during operation of the command mode,
for 12 V on track 5 of the fan assembly relay.
There is not 12 V
on track 5
Check the insulation and continuity of line 3 on the

relay to the fuse.
The fault persists, replace the fan assembly relay.
There is 12 V
on track 5

Relay
5
2 Fan assembly
Fan assembly
1
Earth
Repair.
If the fan assembly still does not operate, replace the
fan assembly.
AFTER REPAIR
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E7J 780
engine
INJECTION
17
Fiche n 27
POWER ASSISTED STEERING PRESSOSTAT
DIAG 18
NOTES
XR25 aid:
None
Check the correct operation of the power assisted steering (oil level, ...).
Check the insulation and continuity of the line for track 13 on the injection computer.
Check the power assisted steering pressostat is correctly connected.
If all these points are correct, replace the power assisted steering pressostat.
AFTER REPAIR
JF5111.0
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E7J 780
engine
INJECTION
17
Fiche n 27
FAULT WARNING LIGHT CIRCUIT
DIAG 19
NOTES
XR25 aid:
None
Check the condition of the warning light and its feed.

Computer
43
6
Instrument panel
Repair.
AFTER REPAIR
JF5111.0
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E7J 780
engine
NOTES
INJECTION
17
Only refer to this customer complaint after a complete check using the XR25.
STARTING FAULTS
Chart 1
IDLE SPEED FAULTS
Chart 2
BEHAVIOUR WHILE DRIVING
Chart 3
JF5111.0
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E7J 780
engine
Chart 1
NOTES
INJECTION
17
STARTING FAULTS
Check the fuel
Check there is fuel present

(fuel gauge faulty).
Check the fuel is of the correct type.
Check the hoses
Check no hoses are pinched

(especially after a removal operation).
Check the injectors
Check no injectors are in open circuit.
Check the canister bleed
Disconnect the pipe connecting the canister bleed solenoid valve

to the inlet manifold.
Plug the pipe to prevent an air leak.
If there is no other effect, the canister bleed is faulty.
Check the engine

compression
Connect the OPTIMA 5800 station to carry out the compression

test and follow the instructions.
Check the flywheel
Connect the OPTIMA 5800 station to carry out the flywheel test
and follow the instructions.
Check the idle speed

regulation valve
Tap gently to release the valve.
AFTER REPAIR
Erase the computer memory using G0** and carry out a road test.
JF5111.0
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INJECTION
E7J 780
engine
Chart 2
NOTES
17
IDLE SPEED FAULTS
Check the fuel

Check the hoses

Check the oil level
Use the dipstick to check if the

oil level is too high.
Check the injectors
Check no injectors are in open circuit.
Check the flywheel

regulation valve
Check the manifold
Check the condition of the manifold gaskets.
AFTER REPAIR
JF5111.0
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INJECTION
E7J 780
engine
17
Chart 2
CONT
NOTES
Check the injectors
Check, after removal, that the injectors do not drip.
Check the throttle body
Check the throttle body is not contaminated.
Check the brake servo
Check the brake servo is not leaking (noise).
Check the engine

compression


AFTER REPAIR
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INJECTION
E7J 780
engine
Chart 3
NOTES
17
Check the air filter
Check the air filter is not deformed.
Check the fuel

Check the hoses

Check the oil level

Check the inlet

manifold
Check the exhaust

manifold
Check the exhaust manifold is not leaking.
Check the injectors
AFTER REPAIR
JF5111.0
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INJECTION
E7J 780
engine
17
Chart 3
SUITE
NOTES
Check the flywheel
Check the axle assemblies
Check the calipers, drums and bearings are not seized.

Check that the tyres are not under-inflated.
Check the cooling
Check that cooling is not insufficient.
AFTER REPAIR

JF5111.0
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INJECTION
Fault finding -Aid
E7J 780
engine
17
For further details, refer to section 12

Injector resistance
14.5
Idle regulation stepping

motor resistance
A-D
= 52
B - C = 52
Canister bleed valve resistance
35
Ignition coil resistance
Primary
1-3 ; 2-3 = 1
1-2
= 0.5
Secondary
10 k
Oxygen sensor heating resistance
3 to 15
Throttle potentiometer resistance
no load 1-2 = 5440

1-3 = 4500
2-3 = 2160
Flywheel signal resistance
220
Fuel pressure
3 bars ignition on/ 2.5 bars at idle speed
CO
0.3 % maximum
HC
100 ppm maximum
CO2
14.5 % minimum
Lambda
0.97 < < 1.03
Value for:
full load
1-2 = 2200
1-3 = 4460
2-3 = 5340
Sensor resistance
Temperature in C
20
40
80
90

Resistance in ohms
7470
to
11970
3060
to
4045
1315
to
1600
Coolant temperature sensor

Resistance in ohms
6700
to
8000
2600
to
3000
1100
to
1300
270
to
300
200
to
215
JF5111.0
17-62
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INJECTION
E7J 780
engine
Engine cold, ignition on.
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue with XR25
D13
(selector on
S8)
Bargraph
Display and notes
9.NJ
Use fiche n 27
fault test side
1
Fault test
Interpretation of
bargraphs
1
Code present
2
3
Immobiliser
If the vehicle does not have an

immobiliser, this bargraph
should be illuminated.
10.NJ
G01*
Use fiche n 27
status test side
JF5111.0
17-63
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INJECTION
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Interpretation of
bargraphs
Code present
2
No load recognition
3
Illuminated if immobiliser
active
4
+ after ignition information
received
12
Illuminates after erasing the

memory to indicate that the
operation has been carried out
correctly
Computer configured for:

19
manual gearbox (G50*2*)
19
(G50*1*)
JF5111.0
17-64
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INJECTION
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
2
6
Throttle position
potentiometer
No load
# 17
16 < X < 50
Accelerator
pedal slightly
depressed
Full load
# 17
185 < X < 243
Absolute pressure
sensor
# 01
X = Local atmospheric
pressure
Coolant temperature
sensor
# 02
5 C
Air temperature
sensor
# 03
5 C
10
Idle speed regulation

stepping motor
# 12
11
12
Engine speed
Canister bleed
The value read is variable

depending on the coolant
temperature :
7 % X 100 %
# 06
X = 0 rpm
# 23
X = 0.7 %
JF5111.0
17-65
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INJECTION
E7J 780
engine
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once (air
conditioning not selected).
Order of
operations
Function to be
checked

mode
Action
Bargraph
Display and notes
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Battery voltage

G02* and turn over the fiche.
IMPORTANT : This bargraph
may flash if the vehicle has no
immobiliser. Ignore this
bargraph if fault bargraph 2 RH
side is illuminated and *22 = 2
dEF.
the erase the memory (G0**)
and return to the status test
(G01*)
# 04
if in # 04
X < 12.7 volts

Engine speed < X < 930
rpm nominal
then # 06
JF5111.0
17-66
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INJECTION
E7J 780
engine
NOTES
Order of
operations
17
Function to be
checked
Interpretation of
bargraphs
Action
Bargraph
Display and notes
Code present
2
No load recognition
3
Engine speed information
received
4
received
6
Idle speed regulation active
6
Richness regulation active
7
Fuel pump active
JF5111.0
17-67
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INJECTION
E7J 780
engine
NOTES
Order of
operations
4
(cont)
17
Function to be
checked
Interpretation of
bargraphs (cont)
Action
Bargraph
12
Display and notes

correctly

19
19
Idle speed
(G50*1*)
Without air
conditioning
operating
# 06
X = 750 50 rpm
# 12
2 % < X < 15 %
9
Air
conditioning
selected
10
Illuminated depending on
status of air conditioning
X = 880 50 rpm
# 06
if AC requests fast idle speed

13
PAS pressostat
X = 850 50 rpm
# 06
JF5111.0
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INJECTION
E7J 780
engine
NOTES
Order of
operations
17
Engine warm, at idle speed, after fan assembly has operated at least once.
Function to be
checked
Anti-pinking noise
measurement
Manifold pressure
Richness regulation
Action
Bargraph
# 13
(3500 rpm, no
load)
Display and notes
X variable or not zero
X is variable and
approximately 350 50 mb
(this pressure varies with
altitude)
# 01
no consumers
Stable engine
speed of 2500
rpm then idle
speed
Adaptive idle speed

correction
# 05
X varies in the range from 50 to

900 mV approximately
# 35
X is close to 128 and varies

slightly
with a maximum of 255
and minimum of 0
- 2.4 % < X < 6.2 %
(average value after erasing
the memory: 0)
# 21
7
10
Canister bleed
# 23
11
PAS pressostat
# 06
Canister bleed is prevented.

The solenoid valve remains
closed. X = 0.7 %
13
X = 850 rpm
JF5111.0
17-69
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INJECTION
E7J 780
engine
NOTES
Order of
operations
17
Checks to be carried out during a road test.
Function to be
checked
Action
Bargraph
Display and notes
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Canister bleed
# 23
Vehicle speed
information
# 18
Pinking sensor
11

dEF.
(G01*)
Canister bleed is authorised

X = variable and > 0.7
X = vehicle speed read on

speedometer
Vehicle under
load and
engine speed
2000 rpm
X = variable and not zero
# 13
0X7
(if there is a sensor fault, the
advance is retarded
systematically by 3 , which is
not visible using # 15 )
# 15
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E7J 780
engine
NOTES
INJECTION
17
Order of
operations
Function to be
checked
Adaptive richness
Action
Bargraph
After
programming
phase
# 30
Display and notes
64 X 192
the memory: 128)
# 31
64 X 192
the memory: 128)
JF5111.0
17-71
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D7F 710
engine 35 tracks
INJECTION
17
Enter D13
9.NJ
ENTER
G70*
7700
XXX
XXX
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier MS
1048.
89024S3
Bornier MS 1048 is a 35 track base with a printed circuit on which are 35 copper coated surfaces, numbered
from 1 to 35.
IMPORTANT :
All tests using bornier MS 1048 must be carried out with the battery disconnected.
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17

XR25 FAULT-CHECKING

a) Illuminated :
BARGRAPHS" section.
b) Flashing :
-

JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
XR25
CHECK CORRECT
POST-REPAIR CHECK
electrically.
ROAD TEST
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17

260
then 385
then 510
then is 635
then 760
<
<
<
<
<
# 01
# 01
# 01
# 01
# 01
<
<
<
<
<
385 mbars
510 mbars
635 mbars
760 mbars
970 mbars

JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
FI21727-1
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
FI21727-2
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
extinguished:


information

information
either
or
Engine running

-

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D7F 710
engine 35 tracks
INJECTION
17
XR25 CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2

Check:
Check:
Check, ignition on, for 12 V on track:
- 1 on the main relay,
- 1 on the fuel pump relay.
Computer
Computer
Computer
Computer
Computer
Computer
Computer
Computer
4
16
34
9
10
18
26
20
Earth
Earth
Earth
7 Diagnostic socket
5 Main relay
2 Main relay
2 Fuel pump relay
Ignition on, check for 12 V on track 5 of the main relay:

- If there is 12 V on track 5 of the main relay: replace the fuel pump relay.
- If there is not 12 V on track 5 of the main relay: replace the main relay.
AFTER REPAIR

JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
COMPUTER CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
Computer faulty
None

AFTER REPAIR

JSA051.0
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D7F 710
engine 35 tracks
INJECTION
17
IMMOBILISER CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
*22 = 1 dEF CO, CC- or CC+ line 30 on the computer

*22 = 2 dEF Refer to the immobiliser fault finding
AFTER REPAIR

JSA051.0
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D7F 710
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INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
For certain faults BG 6RH may be flashing

If BG 4LH or BG 5LH or BG 6LH or BG 6RH are also illuminated,check line 15 on the
computer.
Computer
Computer
2
15
2
1

AFTER REPAIR

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D7F 710
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INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+line 22

CO line 4
If BG 3RH is flashing, increase the engine speed to 2500 rpm for 5 minutes
If BG 3RH becomes permanently illuminated, deal with the fault.
Check for the presence of earth on track 4 on the injection computer.
Computer
22
C
Oxygen sensor
AFTER REPAIR
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D7F 710
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INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
If BG 3LH or BG 5LH or BG 6LH or BG 6RH is also illuminated, check line 15 on the

computer. For certain faults, BG 4LH is only permanently illuminated when the
engine is running.
Computer
15
1
Computer
6
2
AFTER REPAIR

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D7F 710
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INJECTION
17

Fiche n 27 side 1/2

XR25 aid:
NOTES
Carry out a road test if BG 4RH is flashing

- + 12 after ignition feed on track A.
Computer
B1
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
If BG 6RH is also illuminated, check line 5 on the computer.

If BG 4LH or BG 3LH or BG 6LH or BG 6RH is also illuminated, check line 15 on the
computer.
Check the conformity of the pressure sensor pipe (it must not be holed or blocked...).
Computer
5
C Pressure sensor
Computer
15
A Pressure sensor
Computer
23
B Pressure sensor
AFTER REPAIR

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D7F 710
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INJECTION
17

5

XR25 aid:
NOTES
*25 = CO.0
*25 = CC.0
Fiche n 27 side 1/2
*25 = CO.0
*25 = CC.0
*25 = In
=>
=>
=>
CO or CC- line 13 or 31
CC- line 13 or 31 on the computer
Try to illuminate BG 5RH when the starter is activated.

BG 5RH often seen to flash if *25 = dEF as its permanent illumination is very quick.
In certain cases, BG 5RH may illuminate then extinguish.
Check the resistance of the target sensor.

Replace the sensor if necessary.
Computer
13
B Target sensor
Computer
31
A Target sensor
computer.
*25 = In
not be inverted).
AFTER REPAIR

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D7F 710
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INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 1 or 15
For certain faults BG 6LH will only illuminate permanently at 3000 rpm. for 1
minute. If BG 4LH or BG 5LH or BG 3LH or BG 6RH is also illuminated, check line 15
on the computer.
Computer
1
2 Pinking sensor
Computer
15
1 Pinking sensor
Computer
16
The fault persists! Replace the pinking sensor.
AFTER REPAIR

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D7F 710
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INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
If BG 6RH is flashing and BG 3LH is fixed, deal with BG 3G. If BG 5LH is also
illuminated, check line 5 on the computer. If BG 4LH or BG 5LH or BG 6LH or BG
3LH is also illuminated, check line 15 on the computer .

Replace the throttle potentiometer if necessary.
Computer
Computer
Computer
3
5
15
C
B
A
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
FUEL PUMP CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
Just detection of CC+
CO or CC- on line 20 of the computer prevents dialogue with the computer.
Check the insulation from 12 V of line :

Computer
20
2 Fuel pump relay
The fault persists! Replace the fuel pump relay.
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
11
INJECTOR CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
*11 = XX.CO
*11 = XX.CC
=> CO or CC- line 32 or 33 of the computer

=> CC+ line 32 or 33 of the computer
XX = 14 => Cylinder 1 or 4 line 33 of the computer

Check the resistance of the valve for the two faulty injectors.
Replace the injector/s if necessary.
injector.
If necessary, repair the line from track 1 injector to track 5 fuel pump relay.
Computer
Computer
33
32
2
2
Injectors 1 and 4
Injectors 2 and 3
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
11
AT
XR25 aid:
NOTES
Fiche n 27 side 1/2
INJECTION CIRCUIT
None
None
Ignore the illumination of this bargraph with this computer.
AFTER REPAIR

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D7F 710
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INJECTION
17

12

XR25 aid:
NOTES
Fiche n 27 side 1/2
None

Computer
19
Instrument panel
Repair.
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
13
MEMORY CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
Loss of computer feed
None
computer, ...).
Computer
Main relay
18
3
5 Main relay
Fuse
Computer
Main relay
26
1
2 Main relay
Fuse
Computer
Fuel pump relay
20
1
2 Fuel pump relay

Fuse
Turn the engine.
Switch the ignition off and wait for the loss of dialogue between the XR25 and the computer.
NOTE : memorised faults are erased. It would therefore be useful to carry out a road test to check there
are no faults on the injection system.
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
14

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 11 or 12 or 28 or 29 on the computer
None

Computer
11
Computer
12
Computer
28
Computer
29
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
14

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 24 on the computer
None

Check, ignition on , for 12 V on track A of the canister bleed.
Computer
24
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
15
COMPUTER
XR25 aid:
NOTES
Fiche n 27 side 1/2
None
None
Ignore the illumination of this bargraph with this computer.
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
17
16
COMPUTER
XR25 aid:
NOTES
Fiche n 27 side 1/2
*16 = XX.CO
*16 = XX.CC



Check the resistance of the coil.
Computer
Computer
17
35
2
1
Coil
Coil
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue
with XR25
D13
(selector on
S8)
Bargraph
Display and notes
Fault finding
1
Fault test
9.NJ
1
1
Use fiche 27
Code present
Change to
status test
G01*
10.NJ
Deal with
fault
bargraph
None
Status test
Battery
voltage
11.8 < X < 13.2 V
# 04
DIAG 1
19
manual gearbox
4
Computer
configuration
19
Immobiliser
(if option)
Ignition on

indicate that the
See Fiche
"Reminder C"
to configure
vehicle
DIAG 12
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Fault finding
2
No load
# 17
Throttle
position
potentiometer
.
Accelerator
pedal
slightly
depressed
10 < X < 50
2
DIAG 2
2
Full load
# 17
10
11
Pressure sensor
Coolant
temperature
sensor
Air
temperature
sensor
Fan assembly
Fault warning
light
185 < X < 245
X =Atmospheric pressure
# 01
# 02
5 C
# 03
bonnet 5 C
G17*
Fan must operate
Switch
ignition on
Fault warning light must

illuminate then
extinguish
DIAG 9
DIAG 3
DIAG 4
DIAG 16
DIAG 18
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
Order of
operations
Function to be
checked
Flywheel signal
sensor
Action
Bargraph
Ignition
Fuel pressure
Fault finding
3
Starter
Illuminated if TDC
information is detected
DIAG 5
G10*
Fuel pump should be

heard to operate
DIAG 6
Connect
Optima
Station
Starting test.
Complete guide on
Optima Station
Fuel pump
2
Display and notes
Connect
pressure
gauge to
fuel inlet
and activate
starter
motor
Pressure gauge must

show
2.5 bars
Injector
command
Starter

the injector
Engine
compression
Connect
Optima
Station
Complete guide on
Optima Station
Flywheel
Connect
Optima
Station
Oscilloscope.
Complete guide on
Optima Station
Use Optima
5800 Station
Fuel pressure,
see Workshop
Repair
Manual or
section
DIAG 11
Use Optima
5800 Station
Use Optima
5800 Station
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
Function to be
checked
Charging
circuit
Throttle
potentiometer
Idle speed
regulation
Anti-pinking
circuit
Pressure circuit
Action
Bargraph
# 06
Illuminated (does not

flash!)
DIAG 1
DIAG 2
690 < X < 790 rpm

DIAG 7
# 12
4 % < X < 14 %
# 13 (at
3500 rpm,
no load)
DIAG 8
270 X 430 mb
# 35
6
0 < X < 255

X varies around 128
50 X 900 V
# 05
Fuel pressure
Fault finding
2
No load
# 16
Richness
regulation
Display and notes
13 < X < 14.5 V
# 04
# 01
17
Connect a
pressure
gauge to the
fuel inlet
and activate
the starter
motor
Pressure gauge must

show
2.5 bars
DIAG 9
DIAG 10
See also
DIAG 15
Fuel pressure,
see Workshop
Repair
Manual or
section
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D7F 710
engine 35 tracks
INJECTION
NOTES
17
Order of
operations
Function to be
checked
Action
Power assisted
steering
pressostat
Turn wheels
to full lock
Bargraph
13
Display and notes
Fault finding

turned to full lock
DIAG 17
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D7F 710
engine 35 tracks
INJECTION
17
NOTES
Order of
operations
Function to be
checked
Vehicle speed
information
Action
Bargraph
# 18
Display and notes
Fault finding
X = speed read on
speedometer in km/h
DIAG 13
Programming
2
Adaptive
richness
Emission of
pollutants
# 30
106 X 150
# 31
106 X 150
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
0.97 < < 1.03
2500 rpm
after driving
DIAG 14
DIAG 15
see also
DIAG 10
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
At idle
speed, wait
for
stabilisation
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
BATTERY VOLTAGE
DIAG 1
NOTES
XR25 aid:
Battery voltage, ignition on, Minimum < # 04 < Maximum

Battery voltage, idle speed, Minimum < # 04 < Maximum

No consumers
Ignition on

At idle speed

NOTE:
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
XR25 aid:
DIAG 2
NOTES
17
Fiche n 27

Status bargraph 2RH

None
NOTES

Computer
Computer
Computer
3
5
15
C
B
A
# 17 is fixed
NOTES
None
Check the resistance of the throttle potentiometer when the throttle butterfly is moved.
NOTES
None
Check the upper and lower stops of the throttle butterfly.

Repair.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
COOLANT TEMPERATURE
DIAG 3
NOTES
XR25 aid:
# 02 = Engine temperature 5 C
shock).
Computer
6
2
Computer
15
1
Repair.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
AIR TEMPERATURE
DIAG 4
NOTES
XR25 aid:
# 03 = Temperature under the bonnet 5 C
shock).
Computer
2
2
Computer
15
1
Repair.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
TDC DETECTION
DIAG 5
NOTES
XR25 aid:
Status BG 3LH, incorrect illumination

Check the resistance of the TDC sensor.

Computer
13
B
Computer
31
A
Repair.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
FUEL PUMP
DIAG 6
The command mode should cause the fuel pump to operate
XR25 aid:
NOTES

Fuel pump fuse
Fuel pump relay
Fuel pump relay
Impact sensor
Impact sensor
C1 Fuel pump
AFTER REPAIR
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D7F 710
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INJECTION
17

XR25 aid:
Fiche n 27
Engine speed , Minimum < # 06 < Maximum
DIAG 7
NOTES

Replace the idle speed regulation valve if necessary.
Computer
11
D
Computer
12
A
Computer
28
B
Computer
29
C
# 06 < Minimum
NOTES

- Clean the air supply circuit (throttle body, idle regulation valve), since it is probably contaminated.
# 06 > Maximum
NOTES

- Check the throttle body gaskets.
AFTER REPAIR
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D7F 710
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INJECTION
17
Fiche n 27
DIAG 8
NOTES
XR25 aid:
# 13 is not zero and variable for fast idle or under load
Computer
1
2
Pinking sensor
Computer
15
1
Pinking sensor
Computer
16
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
PRESSURE CIRCUIT
DIAG 9
XR25 aid:
NOTES
# 01 not coherent
ignition on
speed
# 16 not coherent

# 16 not coherent
Check the insulation, continuity and that there is no interference resistance

on the line:
Computer
5
C
Pressure sensor
Computer
15
A
Pressure sensor
Computer
23
B
Pressure sensor

speed


AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
RICHNESS REGULATION
DIAG 10
NOTES
XR25 aid:

AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
INJECTOR
DIAG 11
NOTES
XR25 aid:

Check the resistance of the faulty injector.

Replace it if necessary.
Repair.
injectors 1 and 4
Computer 33
injectors 2 and 3
Computer 32
2 injectors
2 injectors
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
Fiche n 27
IMMOBILISER
DIAG 12
NOTES
XR25 aid:
17
Status BG 3RH, incorrect illumination
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
VEHICLE SPEED
DIAG 13
NOTES
XR25 aid:

Check on a road test.

- Check that the sensor is correctly mounted and supplied:
+12 V on A1
Earth on B2
Computer
8
B1 vehicle speed sensor
Repair.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27 side 2/2
ADAPTIVE RICHNESS
DIAG 14
NOTES
XR25 aid:


Carry out the programming operations.

- If # 30 or # 31 is at a MAXIMUM, there is not enough fuel .
- filter
- fuel pump
- fuel circuit
- fuel tank.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
DIAG 15
NOTES
0.97 1.03 at 2500

rpm
XR25 aid:
None
NOTES
If CO > 0.3 % at 2500 rpm


0.97 1.03
at 2500 rpm
NOTES
There is a fault with the injection or the sensor.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
DIAG 15
CONT
NOTES
> 1.03
at 2500 rpm
NOTES
None


< 0.97
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm., CO >
0.3 % at 2500 rpm.

Check the sensor.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
DIAG 16
NOTES

XR25 aid:
There is not 12 V
on track 1
There is 12 V
on track 1

Bornier 27
2
Relay
Repair.
The fault persists!

does click when its
There is not 12 V
on track 5

relay to the fuse.
There is 12 V
on track 5

Relay
5
1 Fan assembly
Fan assembly
2
Earth
Repair.
fan assembly.
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
DIAG 17
NOTES
XR25 aid:
None
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
17
Fiche n 27
DIAG 18
NOTES
XR25 aid:
None

Computer
19
6
Instrument panel
Repair.
AFTER REPAIR
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D7F 710
engine 35 tracks
NOTES
INJECTION
17
STARTING FAULTS
Chart 1
IDLE SPEED FAULTS
Chart 2
Chart 3
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D7F 710
engine 35 tracks
INJECTION
17
STARTING FAULTS
Chart 1
NOTES
Check the fuel

Check the hoses


Check the engine

compression

Check the flywheel

regulation valve
AFTER REPAIR
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D7F 710
engine 35 tracks
INJECTION
Chart 2
NOTES
17
IDLE SPEED FAULTS
Check the fuel

Check the hoses

Check the oil level

Check the flywheel

regulation valve
Check the manifold
Check the injectors
AFTER REPAIR
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D7F 710
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INJECTION
17
Chart 2
CONT
NOTES
Check the
engine
compression

AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
Chart 3
NOTES
17
Check the fuel

Check the hoses

Check the oil level

Check the inlet

manifold
Check the exhaust

manifold
Check the injectors
AFTER REPAIR
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D7F 710
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INJECTION
17
Chart 3
CONT
NOTES
Check the flywheel

Check that the tyres are not under-inflated.
Check the cooling
AFTER REPAIR

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D7F 710
engine 35 tracks
INJECTION
Fault finding -Aid
17

Injector resistance
14.5

motor resistance
A - D= 100
B - C = 100
35
Primary
1-4 ; 1-3 ; 2-3 ; 2-4

3-4
Secondary
8 k
= 1.5
= 0.6
3 to 15
no load A-B
A-C
B-C
220
Fuel pressure
CO
0.3 % maximum
HC
100 ppm maximum
CO2
14.5 % minimum
Lambda
0.97 < < 1.03
Value for:
= 1300
= 1360
= 2300
full load
A-B= 1300
A-C= 2350
B-C = 1260
Sensor resistance
Temperature in C
20
40
80
90

Resistance in ohms
5000
to
7000
1700
to
3300
500
to
1550

Resistance in ohms
6700
to
8000
2600
to
3000
1100
to
1300
270
to
300
200
to
215
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue with XR25
D13
(selector on
S8)
Bargraph
Display and notes
9.NJ
Use fiche n 27
fault test side
1
Fault test
Interpretation of
bargraphs
1
Code present
2
3
Immobiliser

10.NJ
G01*
Use fiche n 27
status test side
JSA051.0
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Interpretation of
bargraphs
Code present
2
No load recognition
3
active
4
received
5
Locking relay control effective
12
correctly
12
19
(G50*1*)
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
2
6
Throttle position
potentiometer
No load
# 17
10 < X < 50
2
Accelerator
pedal slightly
depressed
2
Full load
# 17
185 < X < 245
Absolute pressure
sensor
# 01
Coolant temperature
sensor
# 02
5 C
Air temperature
sensor
# 03
5 C
10
11
12

stepping motor
Engine speed
Canister bleed
X = Local atmospheric pressure

temperature :
11 % X 100 %
# 12
# 06
X = 0 rpm
# 23
X = 0.7 %
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D7F 710
engine 35 tracks
INJECTION
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once
Order of
operations
Function to be
checked

mode
Action
Bargraph
Display and notes
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present
Battery voltage

dEF.
(G01*)
# 04
if in # 04
X < 12.7 volts

rpm nominal
then # 06
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Interpretation of
bargraphs
Action
Bargraph
Display and notes
Code present
2
No load recognition
3
received
4
received
6
6
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
4
(cont)
17
Function to be
checked
Interpretation of
bargraphs (cont)
Action
Bargraph
Display and notes
Fuel pump active
12

correctly

19
19
(G50*1*)
Idle speed
# 06
4 % < X < 14 %
# 12
Anti-pinking noise
measurement
X = 740 50 rpm
# 13
(3500 rpm, no
load)
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D7F 710
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INJECTION
NOTES
Order of
operations
Function to be
checked
Action
Bargraph
Manifold pressure
# 01
no consumers
Richness regulation
Stable engine
speed of 2500
rpm then idle
speed
17
Adaptive idle speed

correction
Display and notes
X is variable and is
approximately
270 X 430 mb
altitude)
6
# 05

# 35

slightly
and minimum of 0
- 4.3 % < X < 3.9 %
the memory: 0)
# 21
11
10
Canister bleed

closed. X = 0.7 %
# 23
13
11
PAS pressostat
X = 800 rpm
# 06
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D7F 710
engine 35 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
10.NJ
G01*
Use fiche n 27
status test side
20
No fault present
2
Canister bleed
# 23
Vehicle speed
information
# 18
Pinking sensor
11

dEF.
(G01*)


speedometer
Vehicle under
load and
engine speed
2000 rpm

0X6
advance is retarded
# 13
# 15
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D7F 710
engine 35 tracks
NOTES
INJECTION
17
Order of
operations
Function to be
checked
Adaptive richness
Action
Bargraph
Display and notes
After
programming
phase
# 30
106 X 150
the memory: 128)
# 31
106 X 150
the memory: 128)
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D7F 710 ENGINE - 55 tracks
MULTIPOINT INJECTION
FAULT FINDING
CONTENTS
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152
..............................................................
155
..................................................................
175
...........................................................
181
201
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
202
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
207
Checking conformity
208
.........................................................................
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D7F 710
engine 55 tracks
INJECTION
17
Enter D13
9.NJ
ENTER
G70*
7700
XXX
XXX
JSA052.0
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D7F 710
engine 55 tracks
INJECTION
17
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier Sus
1228.
97434S
Bornier Sus 1228 is a 55 track base with a printed circuit on which are 55 copper coated surfaces, numbered
from 1 to 55.
IMPORTANT :
All tests using bornier Sus 1228 must be carried out with the battery disconnected.
JSA052.0
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D7F 710
engine 55 tracks
INJECTION
17

XR25 FAULT-CHECKING

a) Illuminated :
BARGRAPHS" section.
b) Flashing :
-

JSA052.0
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D7F 710
engine 55 tracks
INJECTION
17
XR25
CHECK CORRECT
POST-REPAIR CHECK
electrically.
ROAD TEST
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D7F 710
engine 55 tracks
INJECTION
17

260
then 385
then 510
then is 635
then 760
<
<
<
<
<
# 01
# 01
# 01
# 01
# 01
<
<
<
<
<
385 mbars
510 mbars
635 mbars
760 mbars
970 mbars

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D7F 710
engine 55 tracks
INJECTION
17
FI21727-1
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D7F 710
engine 55 tracks
INJECTION
17
FI21727-2
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D7F 710
engine 55 tracks
INJECTION
17
extinguished:


information

information
either
or
Engine running

-

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D7F 710
engine 55 tracks
INJECTION
17
XR25 CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2

Check:
Check:
Check, ignition on, for 12 V on track:
- 1 on the fuel pump relay.
Computer
Computer
Computer
Computer
Computer
Computer
Computer
Computer
18
2
3
11
38
1
40
48
Earth
Earth
Earth
7 Diagnostic socket
5 Main relay
2 Main relay
2 Fuel pump relay
Ignition on, check for 12 V on track 5 of the main relay:

- If there is 12 V on track 5 of the main relay: replace the fuel pump relay.
- If there is not 12 V on track 5 of the main relay: replace the main relay.
AFTER REPAIR

JSA052.0
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D7F 710
engine 55 tracks
INJECTION
17
Bargraph 2 LH side illuminated.
Fiche n 27 side 1/2
COMPUTER CIRCUIT
XR25 aid: computer faulty
NOTES
None

AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
Bargragh 2 RH side illuminated
IMMOBILISER CIRCUIT
XR25 aid:
NOTES
Fiche n 27 side 1/2
*22 = 1 dEF CO, CC- or CC+ line 37 of the computer

*22 = 2 dEF Refer to the immobiliser fault finding section
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+line 20 or 46 of the computer
Connect the bornier in place of the computer and check the insulation and continuity of the line.
Computer
Computer
20
46
2
1

Check the resistance of the sensor. Replace if necessary.
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
Fiche n 27 side 1/2

XR25 aid:
NOTES
CO, CC- or CC+line 17 of the computer

CO line 18 of the computer
If BG 3RH is flashing, increase the engine speed to 2500rpm for 5 minutes.

If BG 3RH becomes permanently illuminated, deal with the fault.
Check for the presence of earth on track 18 of the injection computer.
Computer 17
C Oxygen sensor
AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
17
Fiche n 27 side 1/2

XR25 aid :
NOTES
CO, CC- or CC+line 44 or 15 of the computer
If BG 6LH or BG 5LH is also illuminated , check line 44 of the computer. For certain
faults, BG 4LH is only permanently illuminated when the engine is running.
Computer 44
1 Coolant temperature sensor
Computer 15
AFTER REPAIR

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D7F 710
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INJECTION
17

Fiche n 27 side 1/2

XR25 aid:
NOTES
Carry out a road test if the BG 4RH is flashing.

-+ 12 after ignition feed on track A.
Computer
12
B1
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
Bargraph 5LH side illuminated

XR25 aid :
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 45, 44 or 16 of the computer

If BG 6LH or BG 4LH is also illuminated, check line 44 of the computer.
Check the conformity of the pressure sensor pipe (it must not be pierced or blocked...).
Computer
45
C Pressure sensor
Computer
44
A Pressure sensor
Computer
16
B Pressure sensor
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17

5

XR25 aid:
NOTES
*25 = CO.0
*25 = CC.0
Fiche n 2 side 1/2
*25 = CO.0
*25 = CC.0
*25 = In
=>
=>
=>
CO or CC- line 33 or 34 of the computer

CC- line 33 or 34 of the computer
Try to illuminate BG 5RH when the starter is activated.

BG 5RH is often seen to flash if *25 = dEF as its permanent illumination is very
quick. In certain cases, BG 5RH may illuminate then extinguish.
Check the resistance of the target sensor.

Computer
33
B Target sensor
Computer
34
A Target sensor
computer.
*25 = In
not be inverted).
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17

XR25 aid:
NOTES
Fiche n 2 side 1/2
CO, CC- or CC+ line 54 or 44 of the computer
For certain faults BG 6LH will only illuminate permanently at 3000 rpm. for 1
minute. If BG 4LH or BG 5LH is also illuminated, check line 44 of the computer.
Computer
54
2 Pinking sensor
Computer
44
1 Pinking sensor
Computer
2
The fault persists! Replace the pinking sensor.
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
Fiche n 27 side 1/2

XR25 aid:
NOTES
CO, CC- or CC+ line 19, 45 or 46 of the computer
If BG 5LH is also illuminated, check line 45 of the computer.

If BG 3LH is also illuminated, check line 46 of the computer.

Computer
Computer
Computer
19
45
46
C
B
A
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
FUEL PUMP CIRCUIT

XR25 aid:
NOTES
Fiche n 27 side 1/2
Only detection of CC+ on line 48 of the computer
CO or CC- on line 48 of the computer prevents dialogue with the computer.
Check the insulation from 12 V of line :

Computer
48
2 Fuel pump relay
The fault persists! Replace the fuel pump relay.
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
11
Fiche n 27 side 1/2
INJECTOR CIRCUIT
XR25 aid:
NOTES
*11 = XX.CO
*11 = XX.CC


Check the resistance of the value for the two faulty injectors.
Replace the injector/s if necessary.
injector.
If necessary, repair the line from track 1 injector to track 5 fuel pump relay.
Computer
Computer
30
4
2
2
Injectors 1 and 4
Injectors 2 and 3
AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
17

11
AUTOMATIC TRANSMISSION
XR25 aid:
Fiche n 27 side 1/2
INJECTION CIRCUIT
None
None
NOTES
Ignore this bargraph, as this vehicle is not fitted with automatic transmission.
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17

12

XR25 aid:
NOTES
Fiche n 27 side 1/2
None

Connect the bornier in place of the computer and check the insulation and continuity of the line.
Computer
43
Instrument panel
Repair.
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17

13
Fiche n 27 side 1/2
MEMORY CIRCUIT
Loss of computer feed.
XR25 aid:
NOTES
None
computer, ...).
Computer
Main relay
1
3
Computer
Main relay
40
Computer
Fuel pump relay
48
1
5 Main relay
Fuse
2 Main relay
Fuse
2 Fuel pump relay
Fuse
Run the engine.
Switch the ignition off and wait for the loss of dialogue between the XR25 and the computer.
NOTE :
Memorised faults are erased. It would therefore be useful to carry out a road test to check
there are no faults on the injection system.
AFTER REPAIR

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D7F 710
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INJECTION
17
14
Bargraph 14LH side illuminated

XR25 aid:
NOTES
Fiche n 27 side 1/2
CO, CC- or CC+ line 8 or 35 or 9 or 36 of the computer
None

Computer
8
Computer
35
Computer
9
Computer
36
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
17
14
Bargraph 14RH side illuminated

XR25 aid:
NOTES
Fiche n 27 side 1/2
None

Check, ignition on , for 12 V on track A of the canister bleed valve.
Computer
42
AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
17
15
COMPUTER
XR25 aid:
NOTES
Fiche n 27 side 1/
CC + 12 V line 51 of the computer
Check that the vehicle has air conditioning, if not, ignore this bargraph.
Connect the bornier in place of the computer and check the insulation and continuity of line 51 of the
computer.
If the fault persists, consult the air conditioning fault finding section.
AFTER REPAIR

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D7F 710
engine 55 tracks
INJECTION
16
COMPUTER
XR25 aid:
NOTES
17
Fiche n 27 side 1
*16 = XX.CO
*16 = XX.CC



Check the resistance of the coil.
Computer
Computer
29
28
2
1
Coil
Coil
AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue
with XR25
D13
(selector
on S8)
Bargraph
Display and notes
Fault finding
1
Fault test
9.NJ
Use fiche 27
1
Deal with
fault
bargraph
Code present
Change to
status test
10.NJ
None
G01*
Status test
Battery
voltage
11.8 < X < 13.2 V
# 04
19
Computer
configuration
Immobiliser
(if option)
19
Ignition on
3
manual gearbox

indicate that the
DIAG 1
See Fiche
Reminder C
to configure
the vehicle
DIAG 12
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Fault finding
2
No load
# 17
Throttle
position
potentiometer
.
Accelerator
pedal
slightly
depressed
10 < X < 50
2
DIAG 2
Pressure sensor
Coolant
temperature
sensor
Air
temperature
sensor
10
Fan assembly
11
Fault warning
light
Full load
# 17
185 < X < 245
# 01
X = Atmospheric
pressure
DIAG 9
# 02
5 C
DIAG 3
# 03
bonnet 5 C
DIAG 4
G17*
The fan must operate
DIAG 17
Switch
ignition on
The fault warning light

must illuminate then
extinguish
DIAG 19
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D7F 710
engine 55 tracks
INJECTION
17
NOTES
Order of
operations
Function to be
checked
Flywheel signal
sensor
Action
Bargraph
Display and notes
Fault finding
Fuel pump
Ignition
Fuel pressure
Starter
Illuminated if TDC
information detected
DIAG 5
G10*
Fuel pump should be

heard to operate
DIAG 6
Connect
Optima
Station
Starting test, complete

guide on Optima Station
Connect
pressure
gauge to
fuel inlet
and activate
starter
motor
Injection
command
Starter
Engine
compression
Connect
Optima
Station
Flywheel
Connect
Optima
Station
The pressure gauge must

show 2.5 bars

the injector
Complete guide on
Optima Station
Oscilloscope.
Complete guide on
Optima Station
Use Optima
5800 Station
Fuel pressure,
see Workshop
Repair
Manual or
section
DIAG 11
Use Optima
5800 Station
Use Optima
5800 Station
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
Function to be
checked
Action
Charging
circuit
# 04
Throttle
potentiometer
Idle speed
regulation
Anti-pinking
circuit
Pressure circuit
Bargraph
No load
# 21
- 4.3 % < X < 3.9 %
# 13 (at
3500 rpm,
no load)
Fuel pressure
# 35
# 05
Connect a
pressure
gauge to the
fuel gallery
and activate
the starter
motor
Fault finding
DIAG 1
DIAG 2
690 < X < 790 rpm

4 % < X < 14 %
# 16
Richness
regulation
Illuminated(does not
flash!)
# 12
# 01
Display and notes
13 < X < 14.5 V
# 06
3
17
DIAG 7
DIAG 8
270 X 430 V
DIAG 9
0 < X < 255

X varies around 128
50 X 900 V
Pressure gauge must

show
2.5 bars
DIAG 10
See also DIAG

15
Fuel pressure,
see Workshop
Repair
Manual or
section
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
Function to be
checked
17
Action
Bargraph
Display and notes
Fault finding
9
Extinguished if fast idle is
not active
AC selected
10
10
Air
conditioning
# 06
Illuminated if the air

conditioning requests
compressor operation
Illuminated if the
injection authorises
compressor operation
DIAG 16
690 X 790 rpm
# 44
300 X 4000 W
9
800 X 900 rpm
# 06
Power assisted
steering
prestostat
# 44
10
Turn wheels
to full lock
13
300 X 4000 W

turned to full lock
DIAG 18
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D7F 710
engine 55 tracks
INJECTION
17
NOTES
Order of
operations
Function to be
checked
Vehicle speed
information
Action
Bargraph
Display and notes
Fault finding
X = speed read on the

speedometer in km/h
DIAG 13
# 30
106 X 150
DIAG 14
# 31
106 X 150
# 18
Programming
2
Adaptive
richness
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
0.97 < < 1.03
2500rpm
after driving
3
Emission of
pollutants
At idle
speed, wait
for
stabilisation
DIAG 15
see also
DIAG 10
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
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D7F 710
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INJECTION
DIAG 1
NOTES
BATTERY VOLTAGE
XR25 aid: Battery voltage ignition on, Minimum< # 04 < Maximum
Battery voltage idle speed, Minimum< # 04 < Maximum
17
Fiche n 27

No consumers
Ignition on

At idle speed

NOTE:
AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
DIAG 2
NOTES
XR25 aid:# 17 outside tolerances
17
Fiche n 27

Status bargraph 2RH

NOTES
None

Check the insulation and the continuity of the line:
Computer 19
C Throttle potentiometer
Computer 45
B Throttle potentiometer
Computer 46
A Throttle potentiometer
# 17 is fixed
NOTES
None
Check the resistance of the throttle potentiometer when the throttle is activated.
NOTES
None
Check the upper and lower stops of the throttle.

Repair.
AFTER REPAIR
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D7F 710
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INJECTION
DIAG 3
17
COOLANT TEMPERATURE
XR25 aid:# 02 = Engine temperature 5 C
NOTES
If the value read is inconsistent, check the sensor correctly follows the standard table of values for
shock).
Computer 15
Computer 44
Repair.
AFTER REPAIR
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D7F 710
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INJECTION
DIAG 4
17
Fiche n 27
AIR TEMPERATURE
XR25 aid:# 03 = Temperature under the bonnet 5 C
NOTES
If the value read is incoherent, check the sensor correctly follows the standard table of values for
shock).
Computer
20
2 Air temperature sensor
Computer
46
1 Air temperature sensor
Repair.
AFTER REPAIR
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INJECTION
DIAG 5
17
Fiche n 27
TDC DETECTION
XR25 aid:Status BG 3LH, incorrect illumination
NOTES

Check the resistance of the TDC sensor.

Computer
33
B Flywheel signal sensor
Computer
34
A Flywheel signal sensor
Repair.
AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
DIAG 6
Fiche n 27
FUEL PUMP
XR25 aid:
17
The command mode should cause the fuel pump to operate.
NOTES

Fuel pump fuse

Fuel pump relay 5
Impact sensor
Fuel pump relay
Impact sensor
C1 Fuel pump
AFTER REPAIR
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INJECTION
DIAG 7
17
Fiche n 27
XR25 aid: Engine speed , Minimum < # 06 < Maximum
NOTES

Replace the idle speed regulation valve if necessary.
Computer
8
D Idle speed regulation motor
Computer
35
A Idle speed regulation motor
Computer
9
B Idle speed regulation motor
Computer
36
C Idle speed regulation motor
# 06 < Minimum
NOTES

- Clean the air supply circuit (throttle body, idle speed regulation valve), since it is probably
contaminated.
# 06 > Maximum
NOTES

- Check the throttle body seals.
AFTER REPAIR
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INJECTION
17
DIAG 8
Fiche n 27
XR25 aid:# 13 is not zero and variable for fast idle or under load
NOTES
Computer
54
2 Pinking sensor
Computer
44
1 Pinking sensor
Computer
2
AFTER REPAIR
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INJECTION
17
DIAG 9
XR25 aid:
NOTES
# 01 not coherent
ignition on
speed
# 16 not coherent
Fiche n 27
PRESSURE CIRCUIT

# 16 not coherent
Check the insulation, the continuity and that there is no interference on the
line:
Computer
45
C Pressure sensor
Computer
44
A Pressure sensor
Computer
16
B Pressure sensor


speed


AFTER REPAIR
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INJECTION
DIAG 10
NOTES
Fiche n 27
RICHNESS REGULATION
XR25 aid:
17

AFTER REPAIR
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D7F 710
engine 55 tracks
INJECTION
DIAG 11
NOTES
17
INJECTOR
Fiche n 27
XR25 aid : CO or CC - line 30 of the computer for injectors 1 and 4
CO or CC - line 4 of the computers for injectors 2 and 3
Check the resistance of the faulty injector.

Replace it if necessary.
Repair.
injectors 1 and 4 Computer 30
2 injectors
injectors 2 and 3 Computer 4
2 injectors
AFTER REPAIR
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D7F 710
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INJECTION
DIAG 12
17
Fiche n 27
IMMOBILISER
XR25 aid : Status BG 3RH, illuminated when ignition switched on
NOTES
AFTER REPAIR
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D7F 710
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INJECTION
DIAG 13
17
Fiche n 27
VEHICLE SPEED
XR25 aid:
NOTES
No fault bargraphs should be illuminated. Check with a road test.

- Check that the sensor is correctly mounted and fed:
+12 V on A1
Earth on B2
Computer 12
B1vehicle speed sensor
Repair.
AFTER REPAIR
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INJECTION
17
Fiche n 27 side 2/2
DIAG 14
ADAPTIVE RICHNESS
XR25 aid:Minimum < # 30 < Maximum
NOTES
No fault bargraphs should be illuminated.Carry out the programming operations.

- If # 30 or # 31 is at a MAXIMUM, there is not enough fuel.
- filter
- fuel pump
- fuel circuit
- fuel tank.
AFTER REPAIR
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D7F 710
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INJECTION
17
DIAG 15
Fiche n 27
XR25 aid:
None
NOTES
0.97 1.03 at 2500

rpm
NOTES
If CO > 0.3 % at 2500 rpm


0.97 1.03 at 2500

rpm
NOTES
It is an injection or sensor fault.
AFTER REPAIR
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D7F 710
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INJECTION
DIAG 15
17
Fiche n 27
Cont.
NOTES
> 1.03 at 2500 rpm
NOTES
None


< 0.97
at 2500 rpm.
NOTES
The oxygen sensor does not loop correctly at 2500 rpm, CO >
0.3 % at 2500 rpm.

Check the sensor.
AFTER REPAIR
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D7F 710
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INJECTION
DIAG 16
17
Fiche n 27
AIR CONDITIONING
XR25 aid:Status BG 10LH or 10RH incorrect illumination
NOTES
Check the insulation and continuity of lines track 5 and track 51 of the injection computer.Repair if
necessary.Consult the air conditioning fault finding.
AFTER REPAIR
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D7F 710
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INJECTION
17
DIAG 17
Fiche n 27
XR25 aid:
NOTES

There is not 12 V
on track 1
There is 12 V
on track 1

Bornier 10
2 Relay
Repair.

The fault persists!

does click when its
There is not 12 V
on track 5

relay to the fuse.
There is 12 V
on track 5

Relay
5
1 Fan assembly
Fan assembly
2
Earth
Repair.
fan assembly.
AFTER REPAIR
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INJECTION
DIAG 18
17
Fiche n 27
XR25 aid :None.
NOTES
AFTER REPAIR
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INJECTION
DIAG 19
17
Fiche n 27
XR25 aid:None
NOTES

Computer
43
6 Instrument panel
Repair.
AFTER REPAIR
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INJECTION
17
NOTES
STARTING FAULTS
Chart 1
IDLE SPEED FAULTS
Chart 2
Chart 3
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INJECTION
17
STARTING FAULTS
Chart 1
NOTES
Check the fuel

Check the hoses


Check the engine

compression

Check the flywheel

regulation valve
AFTER REPAIR
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INJECTION
17
IDLE SPEED FAULTS
Chart 2
NOTES
Check the fuel

Check the hoses

Check the oil level

Check the flywheel

regulation valve
Check the manifold
Check the injectors
AFTER REPAIR
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INJECTION
17
Chart 2
CONT
NOTES
Check the engine

compression


AFTER REPAIR
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INJECTION
17
Chart 3
NOTES
Check the fuel

Check the hoses

Check the oil level

Check the inlet manifold
Check the exhaust manifold
Check the injectors
AFTER REPAIR
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INJECTION
17
Chart 3
CONT
NOTES
Check the flywheel

Check that the tyres are not under inflated.
Check the cooling
AFTER REPAIR

If there is no other effect, the canister bleed is faulty..
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D7F 710
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INJECTION Fault finding - Aid
17

Injector resistance
14.5

motor resistance
A-D
B-C
35
Primary =
1-4 ; 1-3 ; 2-3 ; 2-4

3-4 = 0.6
Secondary
= 100
= 100
= 1.5
8 k
3 to 15
no load A-B= 1300

A-C= 1360
B-C = 2300
220
Fuel pressure
CO
0.3 % maximum
HC
100 ppm maximum
CO2
14.5 % minimum
Oxygen
0.97 < < 1.03
Value for:
full load
A-B= 1300
A-C= 2350
B-C = 1260
Sensor resistance
Temperature in C
Resistance in ohms
Resistance in ohms
20
40
80
90
5000
to
7000
1700
to
3300
500
to
1550
6700
to
8000
2600
to
3000
1100
to
1300
270
to
300
200
to
215
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engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Dialogue with XR25
D13
(selector on
S8)
Bargraph
Display and notes
9.NJ
Use fiche n 27
fault test side
1
Fault test
Interpretation of
bargraphs
1
Code present
2
3
Immobiliser

10.NJ
G01*
Use fiche n 27
status test side
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engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
Interpretation of
bargraphs
Code present
2
No load recognition
3
active
4
received
5
9
Always illuminated if air
conditioning option available
12
19

correctly

Manual gearbox (G50*2*)
19
Automatic
transmission(G50*1*)
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engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
2
6
Throttle position
potentiometer
No load
# 17
10 < X < 50
Accelerator
pedal slightly
depressed
Full load
# 17
185 < X < 245
X = Local atmospheric
pressure
Absolute pressure
sensor
# 01
Coolant temperature
sensor
# 02
5 C
Air temperature
sensor
# 03
5 C
10

stepping motor
# 12
11
12
Engine speed
Canister bleed

temperature : : 11 % X
100 %
# 06
X = 0 rpm
# 23
X = 0.7 %
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D7F 710
engine 55 tracks
INJECTION
NOTES
17
Engine warm, at idle speed, after fan assembly has operated at least once(air
conditioning not selected)
Order of
operations
Function to be
checked
Action
G01*
Bargraph
Display and notes
10.NJ
Use fiche n 27
status test side
20
2
No fault present
Battery voltage

IMPORTANT: This bargraph
dEF.
(G01*)
# 04
if in # 04
X < 12.7 volts

rpm nominal
then # 06
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Engine warm, at idle speed, after fan assembly has operated at least once(air
Function to be
checked
Interpretation of
bargraphs
Action
Bargraph
Display and notes
Code present
2
No load recognition
3
received
4
received
5
6
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
4
(cont)
17
Function to be
checked
Interpretation of
bargraphs (cont)
Action
Bargraph
Display and notes
Fuel pump active

9
Always illuminated if air

conditioning option available
12
correctly

19
Manual gearbox (G50*2*)
19
Automatic
transmission(G50*1*)
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D7F 710
engine 55 tracks
INJECTION
NOTES
17
Order of
operations
Function to be
checked
Engine idle speed
Action
Bargraph
Display and notes
6
Without air
conditioning
# 06
X = 740 50 rpm
# 12
4 % < X < 14 %
# 44
X 300 W
With air
conditioning
and without
fast idle
request
10
# 06
# 44
X = 740 50 rpm
With air
conditioning
and fast idle
request
300 X 4000 W
9
# 06
10
# 44
X = 850 50 rpm
300 X 4000 W
Anti-pinking noise
measurement
# 13
(3500 rpm, no
load)
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
Function to be
checked
Manifold pressure
Richness regulation
17
Adaptive idle speed

correction
Action
Bargraph
X is variable and is
approximately
270 X 430 mb
altitude)
# 01
no consumers
Stable engine
speed of 2500
rpm then idle
speed
Display and notes
# 05

# 35

slightly
and minimum of 0
- 4.3 % < X < 3.9 %
the memory : 0)
# 21
11
10
Canister bleed

closed. X = 0.7 %
# 23
13
11
PAS pressostat
X = 800 rpm
# 06
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D7F 710
engine 55 tracks
INJECTION
NOTES
Order of
operations
17
Function to be
checked
Action
Bargraph
Display and notes
10.NJ
G01*
Use fiche n 27
status test side
20
2
No fault present

IMPORTANT: This bargraph
dEF.
(G01*)
Canister bleed
# 23
Vehicle speed
information
# 18
Pinking sensor
11


speedometer
Vehicle under
load and
engine speed
2000 rpm
# 13
0X6
advance is retarded
# 15
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engine 55 tracks
NOTES
INJECTION
17
Order of
operations
Function to be
checked
Adaptive richness
Action
Bargraph
Display and notes
After
programming
phase
# 30
106 X 150
the memory : 128)
# 31
106 X 150
the memory : 128)
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ABS BOSCH 5.3
FAULT FINDING
CONTENTS
Pages
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
.............................................................
04
.........................................................................
18
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Checking conformity
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ABS BOSCH
5.3
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
38
CONDITIONS FOR APPLICATION FOR THE TESTS DEFINED IN THIS FAULT FINDING
The tests described in this fault finding are only to be applied when the wording of the fault corresponds
exactly to the display on the XR25 kit.
If a fault is dealt with because there is a flashing bargraph, the conditions for confirming the existence of an
actual fault (and the need to apply the fault finding ) can be found in the "Notes" or at the beginning of the
bargraph interpretation.
If a bargraph is only interpreted when it is permanently illuminated, the application of the recommended
tests in the fault finding when the bargraph is flashing will not allow you to determine the origin of the
memorisation of this fault. In this case, only a test of the wiring and the connections of the component in
question must be carried out (the fault is simply memorised as it was not present at the time of testing).
NOTE : The ignition must have been switched off before the XR25 kit is used.
INDISPENSABLE TOOLING REQUIRED FOR OPERATIONS ON THE ABS SYSTEM
- XR25 kit.
-
XR25 cassette n 16 minimum.
Reminders : When there is intermittent fault memorisation, the ABS warning light will illuminate the next
time the vehicle is used until the car reaches 7.5mph (12 km/h). When the fault is memorised, a
counter relating to the fault is set at 40 . This value is reduced by one each time the ignition is
turned on if the fault is not present when the vehicle exceeds 7.5mph (12 km/h). When the
reading on the counter is equal to 1, it remains at 1 and the fault is not erased.
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ABS BOSCH
5.3
PRESENTATION OF

XR25
38
FICHE N 53
FI21753
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ABS BOSCH
5.3
Fault finding- Fiche XR25
38
SYMBOLISATION OF THE BARGRAPHS
- Of faults (always on coloured background) :

If illuminated, signals a fault on the product tested. The associated text
describes the fault.
This bargraph may be:
- Illuminated
: fault present.
- flashing
: fault memorised.
- Extinguished
: fault absent or not found.
- Of status (always on white background) :
Bargraph is always on the upper right hand side

If illuminated, this signals the establishment of dialogue with the product computer
If it remains extinguished :
- There is a fault in the XR25, the computer or the XR25/computer connection.
The representation of the following bargraphs indicates their initial status:
Initial status : (ignition on, engine stopped, without operator action).
or
Indefinite
illuminated when the function or condition specified on the fiche is
met
Extinguished
Illuminated
extinguished when the function or condition specified on the fiche is

no longer met.
- Supplementary information:
Certain bargraphs have a *. Command*.., when the bargraph is illuminated, allows supplementary
information on the type of fault or status arising to be displayed.
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 1, right hand side extinguished
Code present
NOTES
None.
Check that the XR25 kit is not the cause of the fault by trying to communicate with the computer of
another vehicle. If the XR25 kit is not at fault and it will not communicate with any other computer in the
same vehicle, it is possible that a faulty computer is corrupting fault finding lines K and L . Locate this
computer by disconnecting the lines one by one.
Check that the ISO interface is correctly in position S8 and that you are using the most recent XR25
cassette and the correct access code.
Check the battery voltage and carry out the necessary operations to obtain the correct voltage(9.4Volts<
U battery<17.4Volts)
Check the presence and condition of the ABS fuse on the connection unit of the passenger compartment
(10A).
Check the connection of the computer connector and the condition of its connection.
Check the connection and condition of the connection at the R36 dashboard / ABS connection.
Check the ABS earth wires (tighten the two earth screws above the ABS assembly).
Check that the computer is correctly fed :
- earth on track 19 of the 31 track connector,
- + after ignition feed on track 15 of the 31track connector.
Check that the diagnostic socket is correctly fed :

- + before ignition feed on track 16,
- earth on track 5.
Check the continuity and insulation of the lines in the diagnostic socket / ABS computer connection:
- between track 12 of the computer connector and track 15 of the diagnostic socket,
- between track 11 of the computer connector and track 7 of the diagnostic socket.
If dialogue is still not established after these tests, replace the ABS computer.,
AFTER REPAIR
When communication is established, deal with any fault bargraphs which may be
illuminated.
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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 1 left hand side illuminated
Power supply/computer
NOTES
None.
Check the condition and position of the 60A ABS fuse in the engine connection unit (white mounting).
Ensure continuity between this fuse and tracks 17 and 18 of the computer connector (presence of positive
before ignition feed on both tracks). Check the tightness and condition of the battery terminals.
Check the connections on the 31 track connector of the ABS computer.
Check the ABS earths (above the hydraulic assembly) and visually check all the ABS wiring.
Erase the computer memory, exit the fault finding (G13*) and switch off the ignition.
Carry out a new XR25 test. If the "power supply / computer" fault persists, replace the ABS computer.
AFTER REPAIR
After replacing the computer, carry out another XR25 test.

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ABS BOSCH
5.3

38
Fiche n 53
2-3-4-5
Bargraphs 2, 3, 4 or 5 right or left hand side flashing
Solenoid valve circuit
Even if present at time of testing, these faults will always be declared by a

flashing bargraph.
NOTES
To confirm their presence and therefore the need to apply the fault finding
described below start command G20*. The fault is present if the bargraph
appears illuminated at the end of the command.
If bargraph 11 left hand side is also illuminated, deal with bargraph 11 left hand
side as a priority.
Check the ABS earths (tightening of the two screws above the hydraulic assembly).
Check the condition and position of the 60A ABS fuse in the engine connection unit (white mounting).
Check the connection and condition of the connections on the 31 track connector of the computer.
Erase the computer memory, exit the fault finding mode(G13*) switch off the ignition.
Switch on the ignition and carry out a new test with the XR25 kit, using command G20*.
If the fault "solenoid valve circuit"reappears, replace the ABS computer.
AFTER REPAIR
Erase computer memory(GO**).

Carry out a road test followed by a check with the XR25 kit.
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ABS BOSCH
5.3
38
Fiche n 53
Front left wheel sensor circuit
NOTES
None.
Check the connection and condition of the sensor connections.

If the connector is correct, check the resistance of the sensor at its connector..
Replace the sensor if its resistance is not approximately 1.6 Kohms (1,6 Kohms 320 ohms).
If the resistance is correct, check and ensure the continuity of the connection between the sensor
connector and the computer connector:
- between one track of the sensor connector and track 7 of the computer connector,
- between the other track of the sensor connector and track 6 of the computer connector.
Also check the insulation between these connections.
Carry out a visual inspection of the sensor wiring and check the quality of the connection on the 31 track
computer connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor then erase the computer
memory.
Exit fault finding mode(G13*) and switch off the ignition.
Switch the ignition on and replace the sensor if the fault reappears.
If the fault reappears after replacing the sensor, replace the computer.
AFTER REPAIR

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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 6 Right hand side illuminated
Front right wheel sensor circuit
NOTES
None.

If the connector is correct, check the resistance of the sensor at its connector.
Replace the sensor if its resistance is not approximately 1.6 Kohms (1.6 Kohms 320 ohms).
If the resistance is correct , check and ensure the continuity of the connections between the sensor
connector and the computer connector :
- between one track of the sensor connector and track 3 of the computer connector,
- between the other track of the sensor connector and track 5 of the computer connector.
Carry out a visual inspection of the sensor wiring and check the quality of the connections on the 31
track computer connector.
If all the checks are correct, reconnect the computer and the wheel speed sensor, then erase the
computer memory.
Exit the fault finding mode(G13*) and switch off the ignition.
Switch the ignition on and replace the sensor if the fault reappears .
AFTER REPAIR

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ABS BOSCH
5.3
38
Fiche n 53
Rear left wheel sensor circuit
NOTES
None.

Check the connections at the intermediate connection under the body (R101).
If the connector is correct, check the resistance of the sensor at its connector. Replace the sensor if the
resistance is not approximately 1.6 Kohms (1.6 Kohms 320 ohms).
If the resistance is correct, check and ensure the continuity of the connections between the sensor
- between one track of the sensor connector and track 8 of the computer connector (via track B of the
connector under the body R101),
- between the other track of the sensor connector and track 9 of the computer connector (via track A of
the connector under the body R101).
Carry out a visual inspection of the sensor wiring and check the quality of the connections on the 31 track
computer connector.
If all checks are correct, reconnect the computer and wheel speed sensor, then erase the computer
memory.
Switch on the ignition and replace the sensor if the fault reappears.
AFTER REPAIR

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ABS BOSCH
5.3
38
Fiche n 53
Bargraph 7 Right hand side illuminated
Rear right wheel sensor circuit
NOTES
None.

Check the connections at the intermediate connector under the body (R101).
If the connector is correct , check the resistance of the sensor at its connector.
If the resistance is correct, check and ensure the continuity of the connections between the sensor
- between one track of the sensor connector and track 1 of the computer connector (via track D of the
connector under the body R101),
-between the other track of the sensor connector and track 2 of the computer connector (via track C of
the connector under the body R101).
Carry out a visual inspection of sensor wiring and check the quality of the connections on the 31 track
computer connector.
If all checks are correct, reconnect the computer and the wheel speed sensor, then erase the computer
memory.
Switch on the ignition and replace the sensor if the fault reappears.
AFTER REPAIR

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ABS BOSCH
5.3
38

Fiche n 53
8
Bargraph 8 right or left hand side
flashing
Front right or front left wheel sensor signal
NOTES
Even if they are present at time of testing, these faults will always be declared by
BG 8 flashing on the left or right hand side.
To confirm their presence and therefore the need to apply the fault finding below, carry out a road test. The fault is present if the bargraph illuminates during
the test.
If bargraphs 6 and 8 left hand side are both illuminated, deal with bargraph 6
first.
If bargraphs 6 and 8 right hand side are both illuminated, deal with bargraph 6
first.
Check the quality of the wheel speed sensor mounting (its position and that it is tightened to
recommended torque).Check the sensor / target air gap over one wheel revolution : 0.13 mm < air
gap< 1.96 mm. Check conformity of the target (condition, number of teeth=26)

computer connector.
memory.
Leave fault finding mode(G13*) and carry out a road test. Replace the sensor if the fault reappears.
If the fault reappears after replacing the sensor, it may be caused by an operating fault on a solenoid
valve and it is therefore necessary to carry out the hydraulic check of the solenoid valves with the XR25 kit
with command G03* or G04* (consult the section "Aid"). If the ten unlocking/locking cycles do not occur
on one of the wheels, replace the hydraulic assembly.
If the hydraulic assembly is not at fault, replace the computer.
AFTER REPAIR

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ABS BOSCH
5.3
38

Fiche n 53
9
Bargraph 9 right or left hand side flashing
Signals to rear right or rear left wheel sensor
NOTES
Even if present at time of test, these faults will always be declared by BG9 flashing on the left or right hand side.
To confirm their presence and therefore the need to apply the fault finding below, carry out a road test.The fault is present if the bargraph illuminates during
the test.
If bargraphs 7 and 9 left hand side are both illuminated, deal with bargraph 7
first.
If bargraphs 7 and 9 right hand side are both illuminated, deal with bargraph 7
first.
Check the quality of the wheel speed sensor mounting (position and torque tightening).
Check the connections at the intermediate connector under the body R101.
computer connector.
memory. Leave fault finding mode(G13*) and carry out a road test.
If the fault reappears, check the sensor/target air gap over one wheel rotation :
0.03 mm < air gap< 2.4 mm (test only possible on vehicle with 4 bar rear axle).
Check conformity of the target:condition, number of teeth = 26.
If all checks are correct, leave fault finding mode(G13*) and carry out a road test.
Replace the sensor if the fault reappears.
If the fault reappears after replacing sensor, it could be caused by a solenoid valve operating fault. It is
therefore necessary to carry out a hydraulic test of the solenoid valves with the XR25 kit with command
G05* or G06* (consult section"Aid"). If the ten unlocking/locking cycles do not occur on one of the
wheels, replace the hydraulic assembly.
If the hydraulic assembly is not at fault, replace the computer.
AFTER REPAIR

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ABS BOSCH
5.3
Bargraph 10 right hand side illuminated or flashing
10
38
Fiche n 53
Pump motor circuit

XR25 aids: * 30
NOTES
1.dEF
NOTES
1.dEF
2.dEF
: Permanent signal or CO earth.

: Motor not turning over.
If bargraph 10 RH is flashing, confirm the presence of the fault and therefore the
need to apply fault finding below, using command G20* on the XR25 kit.
The fault is present if the bargraph re-illuminates at the end of the command.
Replace the computer if the pump motor is operating permanently.
Check the ABS earths (tightening of the two earth bolts above the hydraulic assembly).
Check/ ensure continuity between the ABS earth and track 16 of the computer connector.
Check locking of the two-track connector of the pump motor.
If all checks are correct, reconnect the computer and erase the memory with command G0**.
Leave fault finding mode(G13*) and carry out a road test.
Replace the computer if the fault reappears.
2.dEF
NOTES
None.
Replace the hydraulic assembly (mechanical locking of the pump, ...).
AFTER REPAIR

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ABS BOSCH
5.3
38
11
Fiche n 53
Solenoid valve power supply fault
NOTES
None.
Carry out operations necessary for obtaining correct voltage between tracks 19 and 17/18 of the 31-track
ABS computer connector (9.4 volts < correct voltage < 17.4 volts) :
- Check tightness and condition of battery terminals.
- Check the 60A fuse in the engine connection unit (white base).
- Ensure continuity between the 60A fuse and tracks 17 and 18 of the computer connector.
- Check the ABS earths (tightening of the two earth bolts above the hydraulic assembly).
- Check/ ensure continuity between the ABS earth and track 19 of the computer connector.
If all the checks are correct, reconnect the computer then erase its memory with command G0**.
Leave fault finding mode(G13*) and carry out a road test. Replace the computer if the fault reappears.
AFTER REPAIR

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ABS BOSCH
5.3
12
38
Fiche n 53
Bargraph 12 left hand side illuminated or flashing
Brake light circuit

NOTES
None.
Press the brake pedal while observing right and left bargraph 13.
Are the positions "pedal released" and "pedal depressed" registered?
YES
Check the two brake light bulbs and the earth of the rear light units (no
earthing of track 14 across the bulbs when pedal is not depressed ).
NO
Apply the fault finding described in the interpretation of bargraph 13 right

and left hand side for "Bargraph 13 left hand side extinguished, brake pedal
depressed".
AFTER REPAIR

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ABS BOSCH
5.3
12
38
Fiche n 53
Bargraph 12 right hand side flashing
Target of one of the wheels
NOTES
Even if present at moment of testing, this fault will always be declared by BG 12

RH side flashing.
To confirm its presence and therefore the need to apply the fault finding below,
carry out a road test. The fault is present if the bargraph illuminates during the
test.
Check the quality of wheel speed sensor mountings (position and that they are tightened to the
recommended torque).
Check the conformity of the targets :condition, number of teeth= 26.
AFTER REPAIR

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ABS BOSCH
5.3
38
13
Fiche n 53
Bargraph 13 right and left
Brake pedal
NOTES
Illuminated on left hand side if pedal depressed.

Illuminated on right hand side if pedal not depressed.
Carry out checks only if illumination of the bargraph is not consistent with the
pedal position.
Bargraph 13 left hand side extinguished, brake pedal depressed
BG 13 right remains permanently illuminated.

If brake lights are operating :
- Ensure continuity between dashboard / rear left R2 connector on track 7 and track 14 of the ABS
computer connector .
Dashboard / ABS R36 intermediate connector (track 8).
If brake lights are not operating :
- Check condition and adjustment of brake light switch as well as the 15A fuse for the brake lights (in
the passenger compartment connection unit). Replace if necessary.
- Disconnect the brake light switch, then check / ensure presence of + after ignition feed on track A3
of the connector
- Check operation of brake light switch (closed contact between tracks A3 and B1).
- Check and ensure continuity between track B1 of the brake light switch connector and the dashboard
/ rear left hand side R2 connector on track 7.
Bargraph 13 permanently illuminated on left hand side
- Check the condition and adjustment of the brake light switch. Replace if necessary.
- Check the operation of the brake light switch contact (closed contact between tracks A3 and B1).
Replace the brake light switch if there is permanent continuity between the two tracks.
- Check and ensure insulation from 12 volts of the connection between track B1 of the brake light
switch connector and track 14 of the ABS computer connector .
Intermediate connectors :
Dashboard / ABS R36 on track 8.
Dashboard / rear left hand side R2 on track 7.
AFTER REPAIR
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ABS BOSCH
5.3
NOTES
Fault finding - Conformity Check
38
Only carry out this conformity check after a complete XR25 check.
Order of
operations
Function to be checked
Action
XR25 dialogue
D11
(selector on
S8)
Bargraph
Display and Comments
#12
2
Computer conformity
Operation of ABS warning

light- computer
initialisation check
Acknowledgement that
brake pedal is not
pressed
Acknowledgement that
brake pedal is pressed
Two second illumination of

warning light when ignition is
switched on (consult fault
finding if it remains illuminated
or if it does not illuminate)
Ignition
13
Press brake
pedal
13
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ABS BOSCH
5.3
Fault finding - Aid
38
Use of command modes:
Solenoid valve control for hydraulic inspection: G03* to G06*

Lift vehicle so that the wheels can be turned and check that they turn freely.
Keep the brake pedal pressed down so that the wheel being tested cannot be turned by hand (do
not press the brake too hard to ensure you are at the releasing limit).
Enter G0X*
Ten cycles of unlocking/locking must be noted for the wheel concerned.
Pump motor control : G08*

Enter G08* and apply brake
Pump operation must be noted for 2 seconds.
Pump motor and solenoid valve control : G20*

Enter G20* and apply brake
Brief motor and solenoid valve operation must be noted.
Bleeding of hydraulic circuits : G15*3* front left / G15*4* front right / G15*5* rear left / G15*6* rear
right
Apply the procedure described in the section "Bleeding the circuits" in the Workshop Repair Manual.
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ABS BOSCH
5.3
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM
NOTES
Fault finding - Customer Complaints
38
Only consult this section after a complete check with the XR25 kit.
WARNING LIGHT FAULTS
ABS warning light does not illuminate for 3 seconds after ignition switched on.
Chart 1
Permanent illumination of ABS warning light .
Chart 2
ABS warning light illuminates again after engine starts.
Chart 3
Temporary illumination of ABS warning light when driving.
Chart 3
FAULTS NOTED WHEN BRAKING WITH ABS REGULATION
Locking of one or more wheels.
Chart 4
Pulling.
Chart 5
Wandering.
Chart 6
Unexpected ABS operation at low speed and little force applied to brake.
Chart 7
Unexpected ABS operation on poor road surface.
Chart 8
Unexpected ABS operation when using special equipment

(mobile phone,CB...).
Chart 9
Extension of brake pedal travel following a regulation phase

(with an irregular pedal when regulation begins).
Chart 10
Spongy pedal.
Chart 11
Brake pedal vibration.
Chart 12
Noise from pump, pipes or hydraulic assembly .
Chart 13
ABS warning light does not illuminate, computer disconnected.
Chart 14
No communication with ABS computer.
Chart 15
OTHER CASES
AFTER REPAIR
Carry out a road test, then a check with the XR25 kit.
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ABS BOSCH
5.3
Fault finding - Fault chart
38
ABS WARNING LIGHT DOES NOT ILLUMINATE FOR 3

SECONDS WHEN IGNITION SWITCHED ON
Fault chart 1
NOTES
Check the 15A instrument panel fuse on the

passenger compartment connection unit
(if the problem affects all instrument panel
operations).
Turn off the ignition.

Disconnect the computer, then switch on
the ignition again.
Does the warning light illuminate?
yes
Carry out an inspection of the connections

on the 31 track connector.
Replace the computer if the fault persists.
no
Check condition of ABS warning light bulb

and its power supply.
Ensure continuity of connection between
track 21 of the computer connector and the
warning light (track 3 of the black
instrument panel connector).
If fault persists, check the instrument panel
operation.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
38
ABS WARNING LIGHT PERMANENTLY ILLUMINATED

WHEN IGNITION SWITCHED ON (no fault declared by
XR25)
Fault chart 2
NOTES
Disconnect the computer and check the

shunt positioning in the 31 track connector
(between track 19 and track 21).
Ensure on the computer side that a shunt
opening pin is present between tracks 19
and 21 of the computer connector.
Reconnect the computer.

Check that there is continuity between
track 10 of the R36 connector on the engine
compartment side, and earth.
Is continuity ensured ?
yes
Look for a fault in the shunt or a short

circuit to earth of the connection between
track 21 of the computer connector and R36
on track 10.
no
Look for a short circuit to earth of the

connection between track 10 of the R36
connector and the ABS warning light (track
3 of the black instrument panel connector).
AFTER REPAIR
B76531.0
38-22
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ABS BOSCH
5.3
Fault chart 3
NOTES
38
REILLUMINATION OF WARNING LIGHT AFTER STARTING THE ENGINE

TEMPORARY ILLUMINATION OF ABS WARNING LIGHT WHEN DRIVING
Check the voltage of the computer power supply : 9.5 volts < correct voltage < 17.5 volts.
If necessary, carry out the following operations :
- Check the battery charge (check the charging circuit if necessary).
- Check the ABS earths (tightness of two earth bolts above the ABS assembly).
Disconnect the computer and check the condition and the positioning of the shunt in the 31 track
connector (between track 19 and track 21).
Check on the computer side, the condition of the shunt opening pin.
AFTER REPAIR
B76531.0
38-23
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ABS BOSCH
5.3
Fault chart 4
NOTES
38
LOCKING OF ONE OR MORE WHEELS
Wheel locking on a vehicle equipped with ABS, or tyre squeal, considered by the customer
as locking, can be linked to a normal reaction of the system and should not be systematically
considered as a fault :
- locking is allowed below 3.75 mph ( 6 km/h) (the system will not provide regulation).
- Braking with ABS regulation under very bad road conditions (high degree of tyre squeal).
- -----------------------------------------
REMINDER:
On the other hand, if there really is wheel locking on one or more wheels, lift the vehicle so the wheels can
be turned, and check :
- a possible incorrect connection in the speed sensor connection.
Use operations #01, #02, #03 and #04 while turning the appropriate wheel and ensure the consistency of the results obtained .
If the value measured is zero, turn the other wheels to confirm a bad electrical connection of the sensors and repair the wiring.
- A possible incorrect connection of the hydraulic assembly pipes.
Use operations G03*, G04*, G05* and G06* while applying the brake and check for the ten cycles of
unlocking/locking on the wheel concerned (consult section "Aid").
If the ten cycles do not occur on the wheel tested, (wheel remains locked), see if they occur on another wheel (if a bad connection is confirmed: repair).
If the ten cycles do not occur on a wheel and the pipes are correctly connected, replace the hydraulic
assembly.
Check the condition of the ABS targets and that they conform.
Also check the sensor/target air gap by rotating each of the wheels :
Front 0.13 mm < air gap over one rotation < 1.96 mm.
Rear 0.03 mm < air gap over one rotation < 2.4 mm (check only possible on vehicles with four-bar
rear axles).
If the fault persists after these checks, replace the hydraulic assembly.
AFTER REPAIR
B76531.0
38-24
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ABS BOSCH
5.3
Fault chart 5
38
PULLING
NOTES
Remove the 10A ABS fuse on the passenger

compartment connection unit and carry out
a road test with the ABS non-operational.
Does the fault persist under these
conditions?
yes
If the pedal travel is relatively long, bleed

the brake circuit.
If it is normal, check the tyre pressure, the
front axle assembly
or possibly for leaks in the circuit.
no
Lift the vehicle so the wheels can be turned

and check for :
- a possible incorrect connection in the
speed sensors,
- a possible incorrect connection of the
hydraulic assembly piping.
For these two checks, consult and apply the
methods defined in Fault Chart 4.Check the
condition of the ABS targets and that they
conform. Also check the sensor/ target air
gap by rotating each wheel.
If the fault persists, replace the hydraulic
assembly.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 6
38
WANDERING
NOTES
Remove the 10A ABS fuse in the passenger

compartment connection unit and carry out
a road test with ABS non-operational.
Does the fault persist under these
conditions?
yes
Handling fault not linked to ABS system.

Check the condition and conformity of
brake linings, check tyre pressures, front
axle assembly, ...
no
Normal behaviour linked to system

operation in the regulation phase
essentially because of asymmetrical grip or
poor road surface.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 7
NOTES
38
UNEXPECTED ABS OPERATION AT LOW SPEEDS AND

WHEN LITTLE PRESSURE APPLIED TO BRAKE PEDAL
It is possible to feel brake pedal vibrations which are linked to reactions of the system in particular
situations :
- Crossing speed bumps.
- Rear inside wheel lifts on tight bends.
If the problem is different, check the speed sensors connectors ( micro-breaks) as well as the air gaps.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 8
NOTES
38
UNEXPECTED ABS OPERATION

UNDER POOR ROAD CONDITIONS
Under poor road conditions, it is normal to feel jerky operation and vibration of the pedal and a higher
degree of tyre squeal than on a good road surface.
This results in a feeling that there is variation in efficiency, but this is normal.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 9
NOTES
38
UNEXPECTED ABS OPERATION WHEN USING SPECIAL

EQUIPMENT (MOBILE PHONE,CB...)
Check that equipment causing the problem during use is approved.

Check that this equipment has been correctly installed without modification to the original wiring, in
particular, that of the ABS (connections to earth and + after ignition/ before ignition of the ABS are not
permitted).
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 10
NOTES
38
BRAKE PEDAL TRAVEL EXTENDED FOLLOWING A

REGULATION PHASE
(WITH IRREGULAR PEDAL AT START OF REGULATION)
Passage of air from the hydraulic assembly regulation channels to brake circuits.
Bleed the circuits according to the procedure recommended in the Technical Note (use of XR25 command
modes. These command modes are described in the section "Aid").
After the operation, carry out a road test with ABS regulation.
If the fault persists, carry out the preceding operation once or twice more.
If customer complaint is particularly serious and bleeding brings about no improvement, replace the
hydraulic assembly.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 11
NOTES
38
SPONGY PEDAL
Presence of air in the brake circuits.

Bleed the circuits in the conventional way starting with the rear right, then rear left , front left then front
right.
Repeat the operation if necessary.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 12
NOTES
38
BRAKE PEDAL VIBRATION
Normal reaction of the brake pedal during an ABS regulation phase.
AFTER REPAIR
B76531.0
38-32
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ABS BOSCH
5.3
Fault chart 13
NOTES
38
NOISE FROM THE PUMP, PIPES OR HYDRAULIC ASSEMBLY
- Assembly vibration: check the presence and condition of the rubber assembly mounting pads.
- Vibration of pipes : check that all pipes are well clipped into their fixing clips and that there is no contact
between pipes or between pipes and bodywork.
To determine the origin of the noise, it is possible to use functions G03*, G04*, G05* and G06* on the XR25
kit (consult section "Aid").
AFTER REPAIR
B76531.0
38-33
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ABS BOSCH
5.3
Fault chart 14
NOTES
38
ABS WARNING LIGHT DOES NOT ILLUMINATE,

COMPUTER DISCONNECTED
Disconnect the ABS computer .

Check if the shunt is present between track 19 and track 21 of the computer connector.
AFTER REPAIR
B76531.0
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ABS BOSCH
5.3
Fault chart 15
NOTES
38
LACK OF COMMUNICATION WITH

ABS COMPUTER
Ensure that the XR25 is not at fault by trying to communicate with a computer on another vehicle. If the
XR25 is not at fault and dialogue is not being established with another computer on the same vehicle, it is
possible that a faulty computer is disturbing diagnostic lines K and L. Proceed with successive disconnections to localise this computer.
Check that the ISO interface is in position S8, that you are using the most recent version of the XR25 kit
and the correct access code.
Check the battery voltage and carry out the operations necessary to obtain the correct voltage (9.4 volts
< U battery< 17.4 volts).
Check the presence and condition of the ABS fuse on the passenger compartment connection unit (10A).
Check the connection of the computer connector and the condition of its connections.
Check the connection and condition of the connections at the R36 dashboard / ABS connector.
Check the ABS earth leads (tighten the two earth bolts above the ABS assembly).
Check that the computer is receiving the proper power supply :
- earth on track 19 of the 31 track connector,
- +after ignition on track 15 of the 31 track connector.
Check that the diagnostic socket is receiving the correct power supply:
- + before ignition on track 16,
- earth on track 5.
Check continuity and insulation of the lines of the diagnostic socket / ABS computer connections:
- between track 12 of the computer connector and track 15 of the diagnostic socket,
- between track 11 of the computer connector and track 7 of the diagnostic socket.
If dialogue is still not established after these checks, replace the ABS computer.
AFTER REPAIR
B76531.0
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IMMOBILISER
FAULT FINDING
SUMMARY
Pages
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
04
..............................................................
Customer complaints (petrol version)
..........................................................
14
...................................................................
15
Customer complaints (diesel version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Fault charts (diesel version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Conformity check
............................................................................
34
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
Fault charts (petrol version)
http://vnx.su
IMMOBILISER
82
INSTALLATION OF XR25 DIALOGUE / DECODER UNIT
Connect the XR25 to the diagnostic socket.
ISO selector on S8
Enter D56
n.56
PRECAUTION :
When carrying out the test using a multimeter, avoid using a test pin on connectors where the test pin is
of a size which could damage the clips and lead to a poor contact.
Pay attention to parts numbers on wrenches.
ERASING THE MEMORY
After repairing the immobiliser system, enter G0** on the keyboard of the XR25 kit to proceed with
erasing the memorised fault.
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IMMOBILISER
Fault finding- XR25 Fiche
PRESENTATION
OF XR25
82
FICHE N 56
FI21756
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IMMOBILISER
Fault finding- XR25 Fiche
82
DESCRIPTION OF BARGRAPHS
Illuminates when dialogue is established with the product computer, if it remains extinguished :
- there is a line , computer or tool fault.
REPRESENTATION OF FAULTS (always on coloured background)
Illuminated, indicates a fault on the part tested, the associated text defines the fault.
Extinguished, indicates non-detection of fault on the product tested.
REPRESENTATION OF STATUS (always on white background)

Engine stopped, ignition on, no operator action
Status Bargraphs on the fiche are shown as they should appear, engine stopped, ignition on, without
operator action
the kit should show
- If on the fiche, the Bargraph is shown as
the kit should show

either
the kit should show
or
Engine running
Extinguished when operation or condition specified on the fiche is no longer met.
Illuminated when operation or condition specified on the fiche is met.
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IMMOBILISER
82
Fault finding- Interpretation of XR25 Bargraphs
Bargraph 1 right hand
side extinguished
Fiche n 56
XR25 KIT / DECODER UNIT COMMUNICATION
NOTES
Check that lines K and L are not being disrupted by another computer.
Check the condition of +before ignition feed fuse.

Change the fuse if necessary.
Ensure that the XR25 kit is not the cause of the fault by trying to communicate with another computer on
the vehicle (air conditioning computer, injection computer...).
Check that the ISO interface is in position S8, that the most recent version of the XR25 cassette and the
correct access code are being used(D 56).
Check battery voltage (U > 10.5 volts). Recharge the battery if necessary.
Check that the 18 track decoder unit connector is properly connected.
Check that the decoder unit is properly fed :
- earth on track A8 of the decoder unit connector.
- + before ignition feed on tracks A9 and A1 of the decoder unit connector.
Ensure that the diagnostic socket is correctly fed.
Check and ensure the continuity and insulation of the wiring of tracks A3 and A4 of the decoder unit
connector.
If there is still no dialogue between the XR25 kit and the decoder unit, change the decoder unit.
AFTER REPAIR
When communication is established, deal with any fault bargraphs which may
be illuminated.
Carry out a conformity check.
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IMMOBILISER
side incorrect illumination
82
Fiche n 56
CODED DIESEL SOLENOID VALVE CONFIGURATION
NOTES
NONE
Using the XR25 kit, correctly reconfigure the decoder unit.

On the XR25 keyboard, enter G22*1* for a petrol vehicle
or G22*2* for a diesel vehicle
NOTE : In the diesel version, incorrect configuration of the decoder unit does not prevent proper
operation of the immobiliser. Nevertheless, if there is a fault, the immobiliser warning light will
not illuminate.
AFTER REPAIR
Erase the memorised fault by entering G0** on the XR25 keyboard.

Check that the immobiliser system is operating.
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IMMOBILISER
82
side incorrect illumination
Fiche n 56
+ AFTER IGNITION PRESENT
NOTES
Reminder: Under normal operation :

- BG 4 right hand side illuminated ignition switch in position+after ignition
- BG 4 RH side extinguished ignition switch in a position other than +after
ignition.
Check condition of the +after ignition fuse.

Change the fuse if necessary.
Ignition on , check for voltage of + 12 volts on track A7 of the 18 track decoder unit connector.
Are there 12 volts ?
YES
Change the decoder unit.
NO
Repair the electrical wiring between track A7 of the 18 track decoder unit
connector and the passenger compartment fuse board.
AFTER REPAIR

Check operation of the immobiliser system.
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IMMOBILISER
Bargraph 5 left hand
side illuminated
82
Fiche n 56
CENTRAL LOCKING SWITCH (CPE)
Check that the central locking switch is not permanently depressed as the result of
a mechanical fault .
NOTES
Check the insulation in relation to earth of

the electrical wiring between :
Decoder
unit
Central locking
B3 switch
A1
B2
B5
NO
Repair the faulty electrical wiring.
Is there insulation from earth?
YES
Change the central locking switch.
AFTER REPAIR
Erase the memorised fault by entering GO** on the XR25 keyboard.

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IMMOBILISER
82
Bargraph 6 left hand
side illuminated
Fiche n 56
DIESEL SOLENOID VALVE CLEARANCE
NOTES
Check that the computer configuration is correct :

- diesel : Bargraph 3 right hand side illuminated
- petrol : Bargraph 3 right hand side extinguished
Set the XR25 to pulse sensor mode (button "G", input on terminal "Vin").
Ignition on, check for pulses on track A6 of the 18 track decoder unit connector (test with the decoder
unit and the coded electronic unit of the solenoid valve connectors connected).
Ignition on, if there are no pulses, change the decoder unit.
Switch on the ignition for 30 consecutive seconds, then switch off the ignition and wait until the
immobiliser warning light flashes (immobiliser active).
Switch on the ignition again and check that bargraph 8 left hand side is permanently illuminated.
Is Bargraph 8 left hand side permanently illuminated ?
YES
Replace the decoder unit.
NO
Replace the solenoid valve coded electronic unit.
AFTER REPAIR

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IMMOBILISER
82
Bargraphs 6 left and 6 right hand side illuminated
Fiche n 56
ACCEPTANCE (CLEARANCE) OF THE SIGNAL BY THE DIESEL

SOLENOID VALVE AND CODED LINE
NOTES
Before beginning the fault finding, switch on the ignition for longer than 30
consecutive seconds, then switch off the ignition.
For the diesel version, if bargraphs 6 right and 6 left are illuminated, check the impact switch.
Ensure that the connector of the coded electronic unit of the solenoid valve is properly connected.
Check the condition of the electrical wiring between track A6 of the decoder unit and track 8 of the
coded solenoid valve connector and check the 12 Volts supply and earth.
Ignition on, check for pulses on track A6 of the decoder unit connector (test with decoder unit and
solenoid valve coded electronic unit connectors connected).
Are there any pulses?
YES
Replace the solenoid valve side electronic unit.
NO
AFTER REPAIR

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IMMOBILISER
side illuminated
82
Fiche n 56
CODED LINE
NOTES
NONE.
For petrol vehicles, if bargraph 6 right hand side is illuminated, check the impact switch.
Check the continuity and insulation from earth and from 12 volts of the wiring between track A6 of the
18 track decoder unit connector and track ** of the injection computer .
Repair the wiring if necessary.
Ignition on, check for pulses on track A6 of the decoder unit connector (test with decoder unit and
solenoid valve coded electronic unit connectors connected).
Are there any pulses ?
YES
NO
** track : 43 or 19 depending on engine
AFTER REPAIR

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IMMOBILISER
Fiche n 56
ANTENNA RING/DECODER UNIT CONNECTION

XR25 aid:
NOTES
side illuminated or flashing
82
*27 =
cc.1
co.0
short circuit+ 12 volts

open circuit
None.
Check the continuity and insulation with earth and 12 volts of the wiring between :
18 track decoder unit connector
(A2
4)
antenna ring
Repair the wiring if necessary.

Check that the antenna ring is properly fed with earth on track 2 and 12 Volts on track 3.
Ignition off, check for + 12 volts on track A2 of the decoder unit connector, wiring side (decoder
connector disconnected and antenna ring connector connected).
If 12 volts + before ignition feed are not measured, replace the +before ignition feed fuse
If the problem persists, replace the antenna ring.
Disconnect the 4 track antenna ring connector.
When switching the ignition on again, check for a pulse on track A2 of the 18 track decoder unit
connector (test with decoder unit and antenna ring connectors connected).
When the ignition is switched on, is there a pulse?
YES
Replace the antenna ring.
NO
AFTER REPAIR

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IMMOBILISER
11
Bargraph 11 left hand side remains extinguished

after pressing the PLIP
82
Fiche n 56
PLIP SIGNAL RECEIVED
NOTES
If BG 17right is illuminated, do not apply the following fault finding as the

decoder unit is new. Carry out the Plip programming procedure.
Only consult the following fault finding if BG 11 left remains extinguished after
having tried to lock or unlock the vehicle doors with the PLIP .
Check if locking or unlocking the doors is possible by testing with the other key. If locking or unlocking of
the vehicle doors is possible, replace the battery in the first key.
On the infrared transmitter connector, check for + 12 V before ignition feed between tracks B2 and A3.
Is this voltage present ?
YES
Check for pulses on track B2 of the infrared transmitter by pressing the PLIP (test
with the decoder unit and infrared transmitter connectors connected).
Are there any pulses when the PLIP is pressed?
NO
YES
NO
Replace the infrared transmitter.
Check the insulation in relation to the earth of the wiring between :
decoder unit
B1
B2
PLIP
B2
B3
central locking
A1
button
B5
Are they insulated from earth ?
AFTER REPAIR
YES
Repair the faulty wiring.
NO
Change the decoder unit.

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IMMOBILISER
11

after pressing the PLIP
side remains
extinguished
82
Fiche n 56
PLIP SIGNAL CORRECT
NOTES
Only consult the fault finding which follows if, when the PLIP is pressed BG 11 left
illuminates for 3 seconds and BG 11 right remains extinguished.
Check that the keys belong to the vehicle.
There is a desynchronisation between the PLIP code and the decoder unit code if bargraph 11 right
hand side remains extinguished when the PLIP is pressed (but bargraph 11 left hand side illuminates for
approximately 3 seconds before extinguishing) and locking or unlocking of the vehicle doors with the
PLIP is not possible.
Apply the procedure for resynchronising the PLIPs .
AFTER REPAIR

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IMMOBILISER
82
Fault finding - Customer complaints (petrol version)
NOTES
Only consult these customer complaints after a complete check using the XR25
COMMUNICATION
Fault
Chart
1
IGNITION ON, THE IMMOBILISER WARNING LIGHT FLASHES PERMANENTLY

(impossible to start)
Fault
Chart
2
THE IMMOBILISER WARNING LIGHT REMAINS PERMANENTLY ILLUMINATED

(even with the ignition off) OR IS PERMANENTLY EXTINGUISHED
Fault
Chart
3
IGNITION ON, THE INJECTION WARNING LIGHT FLASHES PERMANENTLY

Fault
Chart
4
WHILE DRIVING (deceleration) AND AT IDLE SPEED, THE INJECTION

WARNING LIGHT FLASHES PERMANENTLY
Fault
Chart
5
THE VEHICLE WILL NOT START
Fault
Chart
6
NO
XR25/DECODER UNIT
v0406.0
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IMMOBILISER
Fault finding - Fault Chart (petrol version)
Fault Chart 1
NOTES
82
NO XR25 / COMPUTER COMMUNICATION
Lines K and L are shared between several computers, which can disrupt them. If
the fault persists, it would be prudent to check that they are not disrupting lines K
and L.
Check the condition of the +before ignition fuse.

Replace the fuse if necessary.
Ensure that the XR25 is not the cause of the fault by trying to communicate with another computer on the
vehicle (air conditioning computer, injection computer ...).
Check that the ISO selector is on position S8 , that you are using the latest XR25 cassette and and the correct
access code (D56).
Check the battery voltage (U > 10.5 volts). Recharge the battery if necessary.
Check that the 18 track decoder unit connector is correctly connected.

Check that the decoder unit is correctly fed :
- earth on track A8 of the decoder unit connector
- + before ignition feed on track A9 of the decoder unit connector.

connector.
If there is still no dialogue between the XR25 and the decoder unit , replace the decoder unit .
AFTER REPAIR
When communication has been established, deal with any illuminated fault
bargraphs.
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IMMOBILISER
82
IGNITION ON, IMMOBILISER WARNING LIGHT FLASHES

PERMANENTLY (impossible to start)
Fault Chart 2
None.
NOTES

Connect the XR25. Use fiche n 56, selector
on S8. Enter D56.
Is there communication between the XR25
and the decoder unit?
no
See Fault Chart 1.
no
no
Refer to chart for bargraph 4RH in the

section "Fault finding - Interpretation of
XR25 bargraphs ".
no
Carry out the programming operation if the

unit is new , if not, replace the decoder unit .
yes
Check the condition of the antenna ring fuse.
Is the fuse in good condition?
yes
Switch on the ignition and check that
bargraph 4 RH is illuminated.
Is bargraph 4RH illuminated?
yes
Switch on the ignition (positive after ignition
feed) and check that
bargraph 19RH is extinguished.
Is bargraph 19RH extinguished ?
yes
AFTER REPAIR

Check that the immobiliser system is working correctly.
Erase fault memory G0**.
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IMMOBILISER
82
Fault Chart 2
CONT 1
Switch off the ignition and wait until the

immobiliser warning light flashes
(immobiliser active ).
Switch on the ignition and check on fiche
n 56 whether BG 7RH is illuminated .
Is BG 7RH illuminated ?
yes
Refer to the chart for BG 7RH in the section

"Fault finding - Interpretation of XR25
bargraphs ".
no
Check the key recognition function.
Try to start the vehicle with the second key.
Can the vehicle be started?
yes
Repair or replace the first key.
no
Replace the decoder unit .
no
Test the memory of the unit by entering #65
If "0" is displayed , test OK
If "1" is displayed ,fault .
Is "0" displayed on the screen ?
yes
Is the antenna ring correctly mounted on the
ignition switch ?
no
Refit the antenna ring correctly.
yes
AFTER REPAIR

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IMMOBILISER
82
Fault Chart 2
CONT 2
Check continuity and insulation from earth

and 12 volts of the wiring between :
antenna
ring
2
2
4
masse
+AVC
A2
decoder
bornier
no
Repair the wiring if faulty.
Is the wiring in good condition?

yes
Check for voltage of + 12 volts on track A2 of
the decoder unit (decoder connector
disconnected and antenna ring connector
connected).
Is this voltage present?
yes
Replace the antenna ring .
no
yes
(immobiliser active ). Set the XR25 to pulse
sensor mode (button "G",
input on terminal "Vin").
When switching on the ignition again, check
for a pulse on track A2 of the decoder unit
(test with decoder unit and antenna ring
connectors connected).
Is there a pulse?
yes
Replace the key.
AFTER REPAIR

v0406.0
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IMMOBILISER
82
IMMOBILISER WARNING LIGHT REMAINS PERMANENTLY ILLUMINATED

(even with ignition off) OR REMAINS PERMANENTLY EXTINGUISHED
Fault Chart 3
Check that decoder unit programming has been correctly carried out.
NOTES
Check the condition of the +before ignition

fuse.
no
Replace the fuse.
no
Carry out petrol configuration G22*1*.
no
Refer to the chart for bargraph 5LH in the

XR25 bargraphs ".
no
Repair the wiring.
yes
Check that bargraph 3RH is extinguished .
Is bargraph 3RH extinguished ?
yes
Check that bargraph 5LH is extinguished .
Is Bargraph 5LH extinguished ?
yes
of the wiring between track A5 of the 18
track decoder unit connector and the
instrument panel .
yes
AFTER REPAIR

v0406.0
82-19
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IMMOBILISER
82
Fault Chart 3
CONT
Carry out the following tests to determine the

faulty component :
- If the immobiliser warning light is
illuminated , disconnect the 18 track
decoder unit connector and check that
the immobiliser warning light
extinguishes,
extinguished , connect track A5 of the
decoder unit connector to vehicle earth
and check that the immobiliser warning
light illuminates.
Does the immobiliser warning light
illuminate correctly during the test?
no
Replace the instrument panel .
yes
AFTER REPAIR

v0406.0
82-20
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IMMOBILISER
82
IGNITION ON, INJECTION WARNING LIGHT FLASHES PERMANENTLY

Fault Chart 4
None.
NOTES

Connect the XR25. Use fiche n 56.
Selector on S8. Enter D56.
no
See Fault Chart 1.
yes
Is Bargraph 19RH illuminated ?
yes
Check the programming (G60*) if the

decoder unit is new, otherwise, replace the
unit.
no
and 12 volts of the wiring between
track A6 of the 18 track decoder unit
connector and track 19 (or 43 depending on
engine) of the injection computer.
Is the wiring in good condition ?
no
Repair the wiring .
yes
AFTER REPAIR

v0406.0
82-21
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IMMOBILISER
82
Fault Chart 4
CONT
Set the XR25 to pulse sensor mode (button

"G", input on terminal "Vin"). Ignition on,
check for pulses on track A6 of the 18 track
decoder unit connector (test with the
decoder unit and injection computer
Are there pulses?
yes
no
Replace the decoder unit or refer to the
Workshop Repair Manual, section "replacing
decoder and key kit".
AFTER REPAIR

v0406.0
82-22
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IMMOBILISER
82
WHEN DRIVING (deceleration) AND WHEN AT IDLE SPEED,

INJECTION WARNING LIGHT FLASHES PERMANENTLY
Fault Chart 5
None.
NOTES

Connect the XR25. Use fiche n 56.
Selector on S8. Enter D56.
no
See Fault Chart 1.
no
yes
XR25 still connected , check whether
BG 2RH is illuminated on the following
injection fiches:
on the Safrane:
-fiche n 27 side 1/2
on the Laguna :
- fiche n 13 (depending on the engine)
- fiche n 27 side 1/2 (depending on the
engine)
- fiche n 28 (depending on the engine) Is BG
2RH illuminated on these injection fiches?
yes
Refer to the chart for BG 2RH injection fiche
in the section "Fault finding - Interpretation
of XR25 bargraphs ".
AFTER REPAIR

v0406.0
82-23
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IMMOBILISER
82
Fault Chart 6
None.
NOTES
Check that bargraph 6RH is illuminated .

Is bargraph 6RH illuminated ?
no
There is a problem with the engine.
yes
There is a problem with the impact switch.
AFTER REPAIR

v0406.0
82-24
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IMMOBILISER
82
Fault finding - Customer complaints(diesel version)
NOTES
NO
Only consult these customer complaints after a complete check using the XR25
XR25/DECODER UNIT COMMUNICATION
IGNITION ON, IMMOBILISER WARNING LIGHT FLASHES PERMANENTLY

IMMOBILISER WARNING LIGHT REMAINS PERMANENTLY ILLUMINATED FOR

LONGER THAN 30 CONSECUTIVE SECONDS, IGNITION ON (the immobiliser
warning light illuminates when ignition turned on, in the 16 seconds
following turning on the ignition or the immobiliser warning light
illuminates for longer than 30 consecutive seconds)
Chart
1
Chart
2
Chart
3
WHEN THE IGNITION IS TURNED ON, THE IMMOBILISER WARNING LIGHT

ILLUMINATES FOR 3 SECONDS THEN EXTINGUISHES, BUT THE VEHICLE WILL
NOT START
Chart
4
THE IMMOBILISER WARNING LIGHT REMAINS PERMANENTLY ILLUMINATED

(even when ignition turned off) OR REMAINS PERMANENTLY
EXTINGUISHED
Chart
5
Chart
6
v0406.0
82-25
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IMMOBILISER
Fault finding - Fault Chart (diesel version)
Fault Chart 1
NOTES
NO XR25/COMPUTER
82
COMMUNICATION
Lines K and L are shared between several computers, which can disrupt them. If
the fault persists, it would be prudent to check that they are not disrupting lines K
and L.
Check the condition of the +before ignition fuse.

Ensure that the XR25 is not the cause of the fault by trying to communicate with another computer on the
vehicle (air conditioning computer, injection computer ...).
Check that the ISO selector is on position S8 , that you are using the latest XR25 cassette and the correct
access code (D56).
Check that the 18 track decoder unit connector is correctly connected.

Check that the decoder unit is correctly fed :
- earth on track A8 of the decoder unit connector
- + before ignition feed on track A9 of the decoder unit connector.

connector.
If there is still no dialogue between the XR25 and the decoder unit , replace the decoder unit .
AFTER REPAIR
When communication has been established, deal with any illuminated fault
bargraphs.
v0406.0
82-26
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IMMOBILISER
82
IGNITION ON, IMMOBILISER WARNING LIGHT FLASHES

PERMANENTLY (impossible to start)
Fault Chart 2
None.
NOTES

Connect the XR25. Use fiche n 56, selector
on S8. Enter D56.
no
See Fault Chart 1.
no
no
Refer to the chart for bargraph 4RH in the

section "Fault finding -Interpretation of
XR25 bargraphs ".
yes
Check the condition of the antenna ring.
yes
bargraph 4RH is illuminated .
Is Bargraph 4RH illuminated?
yes
bargraph 19RH is extinguished .
Is Bargraph 19RH extinguished ?
no
Carry out the programming operation if the

unit is new , otherwise, replace the decoder
unit .
yes
AFTER REPAIR

v0406.0
82-27
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IMMOBILISER
82
Fault Chart 2
CONT 1

(immobiliser active ).
Switch on the ignition and check on fiche
n 56 if BG 7RH is illuminated .
Is BG 7RH illuminated ?
yes
Refer to the chart for BG 7RH in the section

"Fault finding -Interpretation of XR25
bargraphs ".
no
Check the key recognition function.
Try to start the vehicle with the second key.
Can the vehicle be started?
yes
Repair or replace the first key.
no
no
Test the memory of the unit by entering #65

If "0" is displayed , test OK
If "1" is displayed, fault .
Is "0" displayed on the screen ?
yes
Is the antenna ring correctly mounted on the
ignition switch ?
no
Refit the antenna ring correctly.
yes
AFTER REPAIR

v0406.0
82-28
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IMMOBILISER
82
Fault Chart 2
CONT 2

and 12 volts of the wiring between :
antenna
ring
2
3
4
earth
+AVC
A2
decoder
bornier
no
Repair the faulty wiring .

yes
Check for voltage of + 12 volts on track A2 of
the decoder unit (decoder connector
disconnected and antenna ring connector
connected ).
Is this voltage present?
yes
Replace the antenna ring .
no
yes
(immobiliser active ). Set the XR25 to pulse
sensor mode (button "G",
input on terminal "Vin").
When turning on the ignition again, check for
a pulse on track A2 of the decoder unit (test
with decoder unit and antenna ring
Is there a pulse?
yes
Replace the key.
AFTER REPAIR

v0406.0
82-29
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IMMOBILISER
82
IMMOBILISER WARNING LIGHT REMAINS ILLUMINATED FOR

LONGER THAN 30 CONSECUTIVE SECONDS , IGNITION ON
Fault Chart 3
None.
NOTES
Check the condition of the wiring between :

solenoid valve
coded electronic
unit connector
A6
decoder
bornier
no
Repair the wiring.
no
and the solenoid feed

(12 V and earth)
yes
Set the XR25 to pulse sensor mode (button
"G", input on terminal "Vin"). Ignition on,
check for pulses on track A6 of the decoder
unit connector (test with decoder unit and
solenoid valve coded electronic unit
Are there any pulses?
yes
XR25 connected , use fiche n 56.
Carry out a mechanical check of the solenoid
valve .
-- Ignition off, enter G23*.
- Switch on the ignition. The valve should
open and close several times in 30 seconds
(listen).
Does the valve open and close for
approximately 30 seconds ?
no
Replace the solenoid valve coded electronic

unit or refer to Workshop Repair Manual
section "changing the decoder and key kit".
yes
AFTER REPAIR

v0406.0
82-30
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IMMOBILISER
82
WHEN THE IGNITION IS TURNED ON, THE IMMOBILISER ILLUMINATES FOR 3

SECONDS, THEN EXTINGUISHES, BUT THE VEHICLE WILL NOT START
Fault Chart 4
None.
NOTES
Connect the XR25. Use fiche n 56. Carry out

a mechanical check of the solenoid valve .
- Ignition off, enter G23*.
- Switch on the ignition. The valve should
open and close several times in 30 seconds
(listen).
Does the valve open and close for
approximately 30 seconds?
no
Remove the solenoid valve coded electronic

unit . Check the condition of the solenoid
valve. Ignition off , connect +12 volts to the
solenoid valve . Now try to start the vehicle.
Will the vehicle start ?
yes
yes
Replace the solenoid valve .
Solenoid valve coded electronic unit

is not faulty.
Refer to fault finding for the diesel engine.
AFTER REPAIR
no
Replace the solenoid valve coded electronic

unit .

v0406.0
82-31
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IMMOBILISER
82
IMMOBILISER WARNING LIGHT REMAINS PERMANENTLY ILLUMINATED (even

when ignition turned off ) OR REMAINS PERMANENTLY EXTINGUISHED
Fault Chart 5
Check that decoder unit programming has been properly carried out.
NOTES
Check the condition of the +before ignition

fuse.
no
Replace the fuse.
no
Refer to the chart for bargraph 5LH in the

XR25 bargraphs "
no
Repair the wiring.
no
Replace the instrument panel .
yes
Check that bargraph 5LH is extinguished .

Is bargraph 5LH extinguished ?
yes

of the wiring between track A5 of the 18
track decoder unit connector and the
instrument panel .
yes
Carry out the following tests to determine the

faulty component :
illuminated , disconnect the 18 track
decoder unit connector and check that
the immobiliser warning light
extinguishes,
extinguished , connect track A5 of the
decoder unit connector to a vehicle earth
and check that the immobiliser warning
light illuminates.
Does the immobiliser warning light
illuminate correctly during the test?
yes
AFTER REPAIR

v0406.0
82-32
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IMMOBILISER
82
Fault Chart 6
None.
NOTES
Check that bargraphs 6RH and 6LH

are illuminated.
Are the bargraphs illuminated?
no
There is either a problem with the engine or

an internal problem with the coded solenoid
valve.
yes
There is a problem with the impact switch.
AFTER REPAIR

v0406.0
82-33
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IMMOBILISER
NOTES
82
If a fault bargraph illuminates, refer to the corresponding fault chart.
Order of
operations
Function to be
checked
Action
Dialogue with XR25
D56
(selector on
S8)
Bargraph
Display and notes
n.56
1
2
Code present
X X X
Conformity of decoder
unit
G70*
Part Number displayed in 2

sequences
Interpretation of
bargraphs normally
illuminated
Type of remote control :

- Illuminated for infrared
remote control.
- Extinguished for radio
frequency remote control.
Illuminated if equipped with

courtesy light timer.
Extinguished if not fitted with
courtesy light timer.
Illuminated for programming

with 2 keys.
Extinguished for programming
with 1 key.
v0406.0
82-34
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IMMOBILISER
NOTES
Order of
operations
Function to be
checked
Action
Bargraph
Configuration of the
computer petrol/diesel
9
6
82
Forced protection
mode
Immobiliser status
10
Presence of the key
Display and notes
Illuminated if configured for a

diesel vehicle.
Extinguished if configured for
a petrol vehicle.
Command :
- G22*1* configuration for
petrol.
- G22*2* configuration
for diesel.
Illuminated only after entering

command G04* on the XR25.
Vehicle cannot be started as
long as BG 9LH is illuminated.
active : switch off the ignition
and wait approximately 10
seconds for the BG 10LH to
illuminate.
Extinguished if immobiliser
inactive.
Illuminated when the ignition

is switched on if the key is
coded
(on condition that the vehicle
was protected before the
ignition was switched on,
immobiliser warning light
flashing).
NOTE : in normal operation,
bargraphs
8RH, 9 RH and 10 RH should be
illuminated together.
v0406.0
82-35
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IMMOBILISER
NOTES
Order of
operations
Function to be
checked
Action
Bargraph
9
9
Reception of the key

code
10
10
82
Valid key code
Display and notes

is switched on
if the key is coded and has the
correct format (on condition
that the vehicle was protected
before the ignition was
switched on, immobiliser
warning light flashing).
NOTE : In normal operation ,
bargraphs
8RH , 9RH and 10RH should be
illuminated together.
is turned on if the key is coded
and has the correct format and
code (on condition that the
vehicle was protected before
the ignition was turned on,
immobiliser warning light
flashing).
NOTE: In normal operation
bargraphs 8RH, 9RH and 10RH
should be illuminated
together.
11
11
Illuminated for approximately

3 seconds if the infrared signal
is received by the decoder unit
via the infrared transmitter.
Reception of the
infrared signal from
the PLIP
11
Illuminated for approximately

3 seconds if the infrared signal
received by the decoder unit
via the infrared transmitter is
the correct signal.
v0406.0
82-36
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IMMOBILISER
NOTES
Order of
operations
12
13
14
15
82
Function to be
checked
Action
Bargraph
Reception of door
lock/unlock
information from the
central door locking
button
14
Sending of
lock/unlock
information by the
decoder unit to the
locking micromotors.
14
Sending electric
window raise
information
Display and notes
Illuminated when door

lock/unlock information is sent
by the central door locking
button and received .
Enter * 14 on the XR25 to
determine the information
received by the decoder unit :
- if * 14 = 0 door lock
information
- if * 14 = 1 door unlock
information
Illuminated when door

lock/unlock information is sent
by the decoder unit to the
locking micromotors.
Enter * 34 on the XR25 to
determine the information
sent by the decoder unit :
- if * 34 = 0 door unlock
information
- if * 34 = 1 door lock
information
(NOTE: Ignore what is written
on fiche n 56, XR25 cassette
n16).
Not used
15
16
Reception of "doors
open" information
Illuminated if door open.
v0406.0
82-37
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IMMOBILISER
NOTES
Order of
operations
16
Function to be
checked
Action
Bargraph
Display and notes
17
Information on
programming or
resynchronisation of
PLIP in progress
Illuminated if programming or
resynchronisation in progress
(PLIP).
17
17
Programming not
carried out for PLIP
information
18
Programming of 1st
key information
19
Programming not
carried out for key
information
19
19
20
Programming not
confirmed for key
information
21
82
Illuminated if programming
not carried out (PLIP).
18
Not used.
not carried out (key).
not confirmed (key).
G60* : changes to 1 when
setting is completed.
Sending of
information is blocked
Enter security code
20
v0406.0
82-38
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IMMOBILISER
Fault finding - Aid
82
ADDITIONAL CHECKS
COMMAND MODES G--*
To use this function, enter G on the XR25 , then the number of the command followed by a star.
03
Courtesy light control (Illuminates the courtesy light for 3 seconds).
04
Forced protection mode : activates the immobiliser function even if the key is correct, which allows
starting prevention to be checked. Bargraph 9 left should illuminate.
This command must be entered when the ignition is off and the immobiliser function is active.
IMPORTANT : switching the ignition off cancels this command.
05
Immobiliser warning light command (illuminates immobiliser warning light for 3 seconds ).
08
Door unlock command (activates micromotors on unlock side for 3 seconds ).
09
Door lock command (activates micromotors on lock side for 3 seconds ) .
13
End of fault finding.
22
Configuration :
- G 22 * 1 * = configuration for petrol vehicles (Bargraph 3RH should be extinguished).
- G 22 * 2 * = configuration for diesel vehicles (Bargraph 3RH should be illuminated).
23
Forced solenoid valve test mode (used only on diesel vehicles).

Activates coded solenoid valve (opening/closing) for approximately 30 seconds (listen).
Note:
- the decoder unit must be configured for a diesel vehicle
- Bargraph 8 left should be illuminated during the test.
32
Programming of second PLIP key.
39
Transponder line.
v0406.0
82-39
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IMMOBILISER
Fault finding - Aid
82
ADDITIONAL CHECKS
COMMAND MODES G--*
40
Entering the security code (Bargraph 10 left should be illuminated and the ignition turned on).
This command mode can be used to enter the security code but does not permit decoding of the
injection computer or of the coded solenoid valve.
Enter the number of the vehicles security code on the XR25 and validate with "*".
If the code number is correct, "bon" is displayed on the XR25 and bargraph 10 left extinguishes.
If the code number is incorrect, "Fin" is displayed on the XR25 and bargraph 10 left remains
illuminated.
IMPORTANT : 3 attempts may be made to enter the code. If, after the 3rd attempt, the code
remains invalid,you must wait for approximately 15 minutes before trying again (the ignition must
be switched on and off again between each attempt.)
47
Configuration of courtesy light timer :

- G 47 * 0 * = cancels courtesy light timer.
- G 47 * 1 * = activates courtesy light timer.
70
Reading the Part Number (Part number of the decoder unit).
LIST OF THE VARIOUS #
43
Type of button for electric door locks.
26
Source of the last command for the opening elements:

1 Infrared remote control
2 Central door locking button
27
Operation of the last command for the opening elements :

1 Unlock
2 Lock
65
Test E2 Prom.
95
Manufacturer (1 = Valo, 2 = Sagem).
v0406.0
82-40
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IMMOBILISER
Fault finding - Aid
82
REMOVAL- REFITTING OF THE CLIPS
To remove the clips and the wiring tabs of the two decoder unit connectors, the kit El. 1263 MUST be
used.The connector and the wiring could be irreparably damaged if this tool is not used.
Use the black tool to unclip the modules.
Use the brown tool to remove the clips.
96031R
v0406.0
82-41
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AIRBAG ANDPRETENSIONERS
FAULT FINDING
SUMMARY
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
02
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
05
.............................................................
07
.........................................................................
22
Checking conformity
Checking the pretensioners
...................................................................
23
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
http://vnx.su
88
Fault finding -Introduction

CONDITIONS FOR THE APPLICATION OF THE CHECKS DEFINED IN THIS FAULT FINDING
The checks defined in this fault finding should only be applied to a vehicle when the fault bargraph is
illuminated, indicating that the fault is present on the vehicle at the time of checking. Only a computer
fault will require replacement of the computer, whether the bargraph is permanently illuminated or
flashing .
If the fault is not present but simply memorised, the bargraph flashes and application of the checks
recommended in the fault finding section will not allow the origin of the fault to be found. In this case,
only a check of the wiring and the connection of the component in question must be carried out (it is
possible to test the wiring concerned in fault finding mode to try to obtain permanent illumination of the
bargraph ).
TOOLING REQUIRED FOR OPERATIONS ON THE AIRBAG
AND
SEAT BELT PRETENSIONER
SYSTEMS
- XR25 (with minimum XR25 cassette N 16).

- XRBAG the updated N 3 version (with the new measuring lead and its adaptors as well as the 30 track
adaptor for operations on the computer connector).
REMINDER:
When carrying out an operation on the airbag/seat belt pretensioner systems , it is essential to lock the
computer with the XR25 command G80* to avoid all risk of triggering at the wrong time (all firing lines
will be inhibited). This operating mode will be indicated by illumination of the warning light on the
instrument panel.
Never carry out any measuring operations on the airbag and pretensioners trigger lines with equipment
other than the XRBAG.
Before using a dummy ignition module, ensure that its resistance is between 1.8 and 2.5 ohms.
Only 30 track connector computers with airbag(s) function are able to be tested with the XR25.
Computers with the pretensioner function only must be checked with the XRBAG by following the checks
described in the fault finding section.
The ignition must be switched off, then on again to make the warning light extinguish following erasure
of the memory using the command G0**.
1EC761.0
88-1
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Fault finding -Wiring
88
Fault finding - XRBAG fiche

Pretensioner only
DI8811.1
A
B
C
D
H
Independent unit
Driver seat
Passenger seat
Pretensioners
+ 12 V
Earth
PRETENSIONERS
Measuring point
Correct Value
C0, C1 and C3
1.6 to 4.6
Correct insulation value: display 100 h or 9999 flashing
1EC761.0
88-2
http://vnx.su
88

Fault finding - XRBAG Fiche
Pretensioner and driver airbag
DI8812.3
A
B
C
D
E
Central unit
Driver seat
Passenger seat
Pretensioners
Drivers airbag ignition module
CT
A1
A3
A2
B1
B2
Rotary switch
+12 Volts
Earth
Warning light
Diagnostic socket
AIRBAG
PRETENSIONERS
Measuring point
Correct value
Measuring point
Correct value
C0, C2 and C4
2 to 9.4
C0, C1 and C3
1.6 to 4.6
Correct insulation value : display 100 h or 9999 flashing
1EC761.0
88-3
http://vnx.su
88
Fault finding - XRBAG Fiche

Pretensioner , drivers airbag and passengers airbag
DI8813.2
A
B
C
D
E
G
Central unit
Drivers seat
Passengers seat
Pretensioners
Drivers airbag ignition module
Passengers airbag ignition module
CT
A1
A3
A2
B1
B2
Rotary switch
+12 Volts
Earth
Warning light
Diagnostic socket
AIRBAG
Measuring point
Correct value
Driver
C0, C2 and C4
2 to 9.4
Passenger
C0 and C4
1.6 to 4.6
PRETENSIONERS
Measuring point
Correct value
C0, C1 and C3
1.6 to 4.6
Correct insulation value : display 100 h or 9999 flashing

1EC761.0
88-4
http://vnx.su
Fault finding - XR25 Fiche

PRESENTATION
OF
XR25
88
FICHE N 49
FI21749
1EC761.0
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88
MEANING OF BARGRAPHS
FAULT BARGRAPHS (always on coloured background)
If illuminated, indicates a fault on the product tested. The associated text defines
the fault.
This bargraph could be :
- Illuminated
: fault present.
- Flashing
: fault memorised.
- Extinguished
: fault absent or not found.
STATUS BARGRAPHS (always on a white background)
Bargraph always located on the top right hand side

If illuminated , indicates establishment of dialogue with the product computer.
If it remains extinguished :
- There is a tool, computer or XR25 / computer connection fault.
The following bargraph representations indicate their initial status :
Initial status: (ignition on, engine stopped, no operator action)
or
Indefinite
illuminated when the operation or the condition specified on the
fiche is met.
Extinguished
Illuminated extinguished when the operation or the condition specified on the

fiche is no longer met.
ADDITIONAL SPECIFICATIONS
Certain bargraphs have a *. The command *.., when the bargraph is illuminated,
allows additional information on the type of fault or status to be displayed.
1EC761.0
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88

NOTES
Bargraph 1 right hand side extinguished
Fiche n 49
Code present
The computers which only control the operation of the seat belt pretensioners do
not have XR25 fault finding (check to be carried out with XRBAG).
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on
another vehicle .
Check that the ISO selector is in position S8, that the latest XR25 cassette and the correct access code are
being used.
Check the battery voltage and carry out the operations necessary to obtain the correct voltage (10.5 volts
< U battery< 16 volts).
Check the presence and condition of the airbag fuse .

Check the condition of the computer connector and the condition of the connections.
Check that the computer is correctly fed :
- Disconnect the airbag computer and fit the 30 track adaptor of the XRBAG.
- Check and ensure the presence + after ignition feed between the terminals marked
Earth and +after ignition feed.
Check that the diagnostic socket is correctly fed :

- + Before ignition feed on track 16.
- Earth on track 5.
Check the continuity and insulation of the lines of the diagnostic socket / airbag computer connection:
- Between the terminal marked L and track 15 of the diagnostic socket .
- Between the terminal marked K and track 7 of the diagnostic socket .
If dialogue is still not established after these various checks, replace the airbag computer (consult the
section on "Aid" for this operation).
AFTER REPAIR
When communication is established, deal with any illuminated fault bargraphs.
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NOTES
or flashing
88
Fiche n 49
Computer
None
Replace the airbag computer (consult the section "Aid" for this operation).
AFTER REPAIR
None
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88-8
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88

2
Voltage supply
XR25 aid:
NOTES
I.dEF - 2.dEF
Fiche n 49
*02 :
1.dEF
2.dEF
3.dEF
dEF
:
:
:
:
Voltage too low

Voltage too high
Too many micro-breaks
Cumulative between faults 1.dEF/2.dEF/3.dEF
Use the 30 track adaptor of the XRBAG to operate on the computer connector .
NOTES
None
Carry out the operations necessary to obtain the correct computer power supply :
10.5 volts 0.1 < correct voltage< 16 volts 0.1.
- Check the charge circuit.
- Check the computer earth .
3.dEF
NOTES
None
For a micro-break fault, check the computer power supply lines :

- Condition of the computer connections.
- Condition of computer earth (track 9 of the 30 track connector towards front right pillar earth).
- Condition / position of the fuse.
- Condition and tightening of battery terminals.
dEF
NOTES
None
The dEF display on the kit indicates the minimum memorisation of 2 of the 3 faults declared by the
display 1.dEF , 2 . d E F and 3.dEF (bargraph flashing ).
Operation:
- Check the charge circuit.
- Condition of the computer connections.
- Check the computer earth .
- Condition / position of the fuse.
AFTER REPAIR
Erase the computer memory using the command G0**.

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88-9
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88

Resistance on the drivers airbag line

XR25 aid :
NOTES
Fiche n 49
*05 :
CC : Short-circuit
CO : Open circuit
Never carry out measurements on the trigger lines with equipment other than the
XRBAG.
Lock the computer with the command G80* on the XR25.

Switch off the ignition and remove the two mounting bolts of the steering wheel cushion.
Check that it is correctly connected.
Disconnect the steering wheel cushion and connect a dummy ignition module to the ignition module
connector . Switch on the ignition and carry out an XR25 check.
Replace the airbag cushion if the fault has been memorised (fault no longer declared).
With the ignition switched off, disconnect, then reconnect the connector for the rotary switch below the
steering wheel.
Operate on the connection if bargraph 5 left hand side begins to flash .
The XRBAG tool MUST be used for checking resistance at point C2 of the drivers airbag circuit.
If the value obtained is not correct, replace the rotary switch below the steering wheel.
Reconnect the rotary switch below the steering wheel, disconnect the computer connector and fit the 30
track adaptor.
The XRBAG tool MUST be used for checking resistance on the wire marked B on the adaptor.
If the value obtained is not correct, check the 30 track connector connection (tracks 10 and 11) and
replace the wiring if necessary.
If the checks carried out have not proven the existence of a fault, replace the airbag computer (consult
the section "Aid" for this operation).
Reconnect the drivers airbag ignition module and remount the steering wheel cushion.
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition.
carry out another check with the XR25 and, if there is no fault, unlock the
computer using command G81*.
Destroy the airbag cushion if it has been replaced (tool El. 1287).
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88

Bargraph 5 right hand side illuminated
Insulation of drivers airbag line

XR25 aid :
NOTES
Fiche n 49
*25 :
CC.1 : Short circuit at 12 volts

CC.0 : Short circuit to earth
XRBAG.
Lock the computer using command G80* on the XR25.

Switch off the ignition and remove the two mounting bolts of the steering wheel cushion .
Check the condition of the trigger wire.
The XRBAG tool MUST be use for measuring insulation appropriate to the type of fault at point C2 of the
drivers airbag circuit .
If the value obtained is not correct , replace the rotary switch under the steering wheel .
Reconnect the rotary switch under the steering wheel , disconnect the computer connector and fit the 30
track adaptor.
The XRBAG tool MUST be used for measuring insulation appropriate to the type of fault on the wire
marked B on the adaptor.
If the value obtained is not correct , check the 30 track connector connection (tracks 10 and 11) and
replace the wiring if necessary.
Reconnect the drivers airbag ignition module and remount the steering wheel cushion.
AFTER REPAIR
Carry out another XR25 check and if there is no fault, unlock the computer using
command G81*.
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88

Bargraph 6
Fiche n 49
Resistance on line 1 of the passengers airbag

XR25 aid :
NOTES
left hand side illuminated
*06 :
CC : Short circuit
CO : Open circuit
XRBAG. On this vehicle "line 1" corresponds to the single trigger line of the
passengers airbag module .

Switch off the ignition, disconnect the computer connector and fit the 30 track adaptor.
The XRBAG tool MUST be used for checking resistance on the wire marked C on the adaptor.
Is the value obtained correct?
YES
If the value obtained is correct at wire C on the adaptor, check the condition of the
computer connection .
NO
If the value obtained is not correct at wire C on the adaptor, check the 30 track
connector connection (tracks 6 and 7).
If the value remains incorrect, switch off the ignition and remove the dashboard to
gain access to the wiring of the passengers airbag module . Disconnect the ignition
module of the passengers airbag module, connect a dummy ignition module to the
ignition module , then use the XRBAG to measure the resistance on the wire marked C
on the adaptor.
If the value obtained is correct , replace the passengers airbag module .
If the value obtained is not correct, replace the airbag wiring.
Reconnect the computer and the ignition module of the passengers airbag module , then switch on the
ignition again.
Carry out an XR25 check.
If the kit still indicates the presence of a line 1 passengers airbag fault and and the checks carried out
show no evidence of a fault, replace the airbag computer (consult the section "Aid" for this operation).
AFTER REPAIR
command G81*.
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88

Insulation of line 1 or 2 of the passengers airbag

XR25 aid :
NOTES
Fiche n 49
*27 :

XRBAG. On this vehicle "line 1" corresponds to the single trigger line of the
passengers airbag module .

Switch off the ignition, disconnect the computer connector and fit the 30 track adaptor.
The XRBAG tool MUST be use for measuring insulation appropriate to the type of fault on the wire
marked C on the adaptor.
Is the value obtained correct? ?
YES
It the value obtained is correct at wire C on the adaptor, check the condition of the
computer connection .
NO
If the value obtained is not correct at the adaptor wire, check the 30 track connector
connection (tracks 6/7).
If the value remains incorrect , replace the airbag wiring.
Reconnect the computer and the ignition module of the passengers airbag module , then switch on the
ignition again.
Carry out an XR25 check.
If the kit still indicates the presence of a passengers airbag line fault and the checks carried out show no
evidence of a fault, replace the airbag computer (consult the section "Aid" for this operation).
AFTER REPAIR
command G81*.
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88

Bargraph 8
Fiche n 49
Resistance on drivers pretensioner line

XR25 aid :
NOTES
*08 :
CC : Short circuit
CO : Open circuit
XRBAG.

Switch off the ignition and check ignition module of the drivers pretensioner is correctly connected.
Disconnect the ignition module of the drivers pretensioner and connect a dummy ignition module to
the ignition module connector.
Switch on the ignition and carry out an XR25 check.
Replace the drivers pretensioner if the fault has been memorised (fault no longer declared).
The XRBAG tool MUST be used for checking resistance at point C1 (seat connector) on the line of the
drivers pretensioner .
If the value obtained is not correct , replace the wiring between points C1 and C3 (seat wiring).
Disconnect the computer connector and fit the 30 track adaptor.
The XRBAG tool MUST be used for checking resistance on the wire marked E of the adaptor .
If the value obtained is not correct , check the 30 track connector connection (tracks 1 and 2) and replace
the wiring if necessary.
Reconnect the ignition module of the drivers pretensioner .
AFTER REPAIR
command G81*.
Destroy the pretensioner if it has been replaced (tool El. 1287).
1EC761.0
88-14
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88

Resistance on the passengers pretensioner line

XR25 aid :
NOTES
Fiche n 49
*28 :
CC : Short circuit
CO : Open circuit
XRBAG.

Switch off the ignition and check that the ignition module of the passengers pretensioner is correctly
connected.
Disconnect the ignition module of the passengers pretensioner and connect a dummy ignition module
to the ignition module connector.
Replace the passengers pretensioner if the fault has been memorised (fault no longer declared).
The XRBAG tool MUST be used for checking resistance at point C1 (seat connector) of the passengers
pretensioner line.
The XRBAG tool MUST be used for checking resistance on the wire marked D on the adaptor.
If the value obtained is not correct , check the 30 track connector connection (tracks 3 and 4) and replace
the wiring if necessary.
Reconnect the ignition module of the passengers pretensioner .
AFTER REPAIR
command G81*.
Destroy the pretensioner if it has been replaced (tool El. 1287).
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88

Insulation of pretensioner lines

XR25 aid :
NOTES
Fiche n 49
*29 :

XRBAG.

Disconnect the ignition module of the drivers pretensioner and connect a dummy ignition module to
the ignition module connectors.
If the fault has been memorised (fault no longer declared), check the condition of the seat wiring.
Replace the drivers pretensioner if the wiring is not faulty.
Then carry out the same operation on the Passengers pretensioner (if not a drivers side fault ).
The XRBAG tool MUST be used for measuring insulation appropriate to the type of fault at point C1 (seat
connector) of the drivers pretensioner line.
Then carry out the same measurement on the passengers pretensioner line (if not a drivers side fault ).

The XRBAG tool MUST be used for measuring insulation appropriate to the type of fault on the adaptor
wires marked D (Passenger ) and E (Driver ) .
If one of the values obtained is not correct, check the 30 track connector connection (tracks 3 / 4 for wire
D and 1/2 for wire E) and replace the wiring if necessary .
Reconnect the ignition modules of the seat belt pretensioners.
AFTER REPAIR
command G81*.
Destroy the pretensioner(s) if it has been replaced (tool El. 1287).
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88

10
NOTES
Bargraph 10
Fiche n 49
Short circuit or insulation from 12 volts on the warning light line
Use the 30 track XRBAG adaptor to operate on the computer connector .

Check the condition of the warning light bulb .
Ensure insulation from 12 volts of the connection between the warning light and track 8 of the 30 track
connector.
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition
command G81*.
1EC761.0
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88

10
NOTES
Fiche n 49
Open circuit or insulation from earth on the warning light line
Use the 30 track XRBAG adaptor to carry out operations on the computer
connector .
Warning light extinguished

after ignition
NOTES
None

Check the condition of the warning light bulb.
Ensure the continuity of the connection between the warning light and track 8 of the 30 track
connector.
Ensure that 12 volts are reaching the warning light .
If the checks carried out have not proven the existence of a fault, disconnect the computer connector and
fit the 30 track XRBAG adaptor . Use the XRBAG in testing mode to check the operation of the warning
light on the instrument panel from the grey adaptor wire.
If it is possible to illuminate the warning light using the XRBAG, replace the airbag computer (consult
If it is impossible to operate the warning light , repeat the preceding checks.
Warning light illuminated

after ignition
NOTES
None

Ensure the insulation from earth of the connection between the warning light and track 8 of the 30 track
connector .
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the
ignition. Carry out another XR25 check and if there is no fault, unlock the
1EC761.0
88-18
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14
NOTES
Bargraph 14 left hand side
88
Fiche n 49
Computer locked
None
This bargraph 14 left hand side allows computer locked status to be seen .
When it is illuminated, all trigger lines are inhibited, preventing the release of the airbags and the seat
belt pretensioners.
This bargraph is normally illuminated in two situations :
- The computer is new (it is sold in locked mode).
- The XR25 computer locking command has been used during an operation on the vehicle
(G80*).
AFTER REPAIR
ignition. Carry out another XR25 check and if there is no fault, unlock the
1EC761.0
88-19
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14
NOTES
Bargraph 14 right hand side
88
Fiche n 49
Fault present before impact
None
This bargraph is normally illuminated in the following situations :

- An impact has been detected.
- A fault was present in the computer memory before the impact.
- This fault was declared by the illumination of the fault warning light before the impact .
Bargraph 14 left hand side can in this way justify non-release of an airbag or a seat belt pretensioner .
Consult the Techline if this bargraph is illuminated in other situations (no fault, no impact, ...).
AFTER REPAIR
Erase the computer memory using the command G0** then switch off the ignition
command G81*.
1EC761.0
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17-18-19
NOTES
Bargraphs 17, 18 and 19 left hand side
88
Fiche n 49
Computer configuration
None
Bargraphs 17, 18 and 19 left hand side allow the computer configuration to be visualised and to ensure
that it is correct for the vehicle.
AFTER REPAIR
ignition.
Carry out another XR25 check .
1EC761.0
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88

NOTES
Only carry out this conformity check after a complete XR25 check.
Order of
operations
Operation to be
checked
Action
XR25 dialogue
D49
(selector on
S8)
I.Ab
#02
22
Computer Conformity
Computer
Configuration
Warning light
operation - check
computer
initialisation
Bargraph
17 / 18 / 19
Display and remarks
Ensure that the computer

configuration shown by these 3
bargraphs corresponds to the
vehicle equipment.
3 second illumination of the

warning light when turning on
the ignition (consult fault
finding if it remains
illuminated or if it does not
illuminate).
Switch on the
ignition
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Fault finding - Pretensioner Check
88
Seat belt pretensioner circuit check

on computer without airbag function
NOTES
None
With the ignition switched off, disconnect the computer connector and fit the 30 track XRBAG adaptor.
Switch on the ignition and check the computer power supply between the terminals marked earth and
+after ignition feed.
Carry out the operations necessary to ensure a voltage between 10.5 volts and 16 volts.
The XRBAG tool MUST be used for checking resistance and tests for leaks to positive and to earth on the
adaptor wires marked D and E .
If the values obtained on the 2 circuits are correct,there is no fault on the seat belt pretensioner circuit.
Reconnect the computer .
If one of the values obtained is not correct, check the 30 track connector connection (tracks 3 / 4 for wire
D and 1/2 for wire E) and replace the wiring if necessary .
The XRBAG tool MUST be used for checking resistance and tests for leaks to positive and to earth at
point C1 of the pretensioner at fault (wire D : Passenger and E : Driver ).
If all values obtained are correct, replace the wiring between points C0 and C1, then carry out the test
again using the adaptor to check that the repair has been successful.
The XRBAG tool MUST be used for checking resistance and tests for leaks to positive and to earth at
point C3 ( Pretensioner ignition module ).
If all values obtained are correct, replace the wiring between points C1 and C3 (seat wiring), then carry
out the test again at the adaptor to check that the repair has been successful.
If one of the values is not correct at C3, replace the seat belt pretensioner, then carry out the test again
using the adaptor to check that the repair has been successful.
AFTER REPAIR
Destroy the pretensioner(s) if it has been replaced (tool El. 1287).
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Fault finding - Aid
88
REPLACING THE AIRBAG COMPUTER
The airbag computers are sold in locked mode to avoid all risk of release at the wrong time (all
trigger lines are inhibited). This operational mode is indicated by the illumination of the warning
light on the instrument panel.
When replacing the airbag computer, follow this procedure :
- Ensure that the ignition is switched off.
- Replace the computer.
- Carry out an XR25 check.
- Unlock the computer using command G81*, only when no fault is declared.
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Engine and peripherals

ENGINE AND PERIPHERALS
TOP AND FRONT OF ENGINE
FUEL MIXTURE
FUEL SUPPLY DIESEL EQUIPMENT
ANTIPOLLUTION
STARTING - CHARGING
IGNITION - INJECTION
COOLING - EXHAUST - FUEL TANK ENGINE SUSPENSION

77 11 194 226
JULY 1997
Edition anglaise

Copying or translating, in part or in full , of this document or use of the service part
Renault.

from which his vehicles are constructed"
Renault 1997
http://vnx.su
EXPLODED VIEW
PRF1000
http://vnx.su
Engine and
peripherals
Contents
Page
13 FUEL SUPPLY -
10 ENGINE AND PERIPHERALS

Consumables
Identification
Oil consumption
Oil pressure
Engine - Gearbox
Engine and transmission assembly
Sump
Crankshaft seal, timing end
Oil pump
DIESEL EQUIPMENT
10-1
10-1
10-2
10-3
10-4
10-9
10-25
10-29
10-30
11 TOP AND FRONT OF ENGINE

Timing belt
Cylinder head gasket
Replacement of valve adjusters
11-1
11-11
11-29
12 FUEL MIXTURE
Specifications
Throttle body
Inlet manifold
Exhaust manifold
Inlet-exhaust manifolds
Page
12-1
12-7
12-15
12-18
12-20
Fuel supply
Fuel cut off in case of an impact
Injector gallery
Fuel filter
Pump flow
Fuel pressure
Antipercolation device
Diesel equipment
General
Specifications
Location of components
Advance solenoid valve
Altimetric corrector
Fast idle LDA
Coded solenoid valve
Load potentiometer
Injector with sensor (needle
lift)
Injection warning light
Pre-postheating control
Fast idle control
Injection/air conditioning
programming
Computer
Defect modes
Pump
Pump -Timing
Idle speed settings
http://vnx.su
13-1
13-2
13-6
13-7
13-8
13-12
13-13
13-14
13-16
13-19
13-22
13-25
13-26
13-28
13-29
13-31
13-32
13-33
13-35
13-36
13-36
13-37
13-38
13-39
13-41
13-46
Contents
Page
17 IGNITION - INJECTION
14 ANTIPOLLUTION
Test for the presence of lead
Fuel vapour rebreathing
Oil vapour rebreathing
Exhaust gas recirculation
(EGR)
Page
(continued)
14-1
14-2
14-7
14-11
Injection/air conditioning
programming
Idle speed correction
Adaptive idle speed
correction
Richness regulation
Adaptive richness correction
17-17
17-18
17-19
17-20
17-22
16 STARTING - CHARGING
Alternator
Starter
16-1
16-7
19 COOLING - EXHAUST - FUEL TANK ENGINE SUSPENSION

Cooling
Specifications
Filling and bleeding
Testing
Diagram
Water pump
17 IGNITION - INJECTION
Ignition
Static ignition
Plugs
Injection
General
Centralised coolant temperature
management
Injection fault warning light
Immobiliser function
Computer configuration depending
on gearbox type
17-1
17-3
17-4
17-8
17-13
17-14
17-15
17-16
19-1
19-2
19-3
19-4
19-7
Exhaust
General
Exhaust pipe assembly
19-12
19-15
Fuel tank
Tank
Sender unit
Pump and sender unit assembly
19-17
19-29
19-30
Engine suspension
Suspended engine mountings
19-32
http://vnx.su
ENGINE AND ENGINE PERIPHERALS

Consumables
Type
Quantity
Components
Coat
Driveshaft roll pin holes
Loctite FRENBLOC
Locking and sealing resin
Coat
Brake caliper mounting bolts
Loctite FRENETANCH
Locking and sealing resin
Coat
Crankshaft pulley mounting bolts
Exhaust pipe paste
Coat
For sealing the exhaust
RHODORSEAL
5661
10
Identification
Vehicle type
Engine
Manual
gearbox
Capacity
(cm 3)
Bore
(mm)
Stroke
(mm)
F/K C0A
D7F 710
JB1
1 149
69
76.8
F/K C0C
E7J 780
JB3
1 390
75.8
77
F/K C0D
F/K C0E
F8Q 662
F8Q 630
JB1
1 870
80
93
Ratio
9 .65/1
9 .5/1
2 1.5 /1
Engine Workshop Repair Manuals to be consulted depending on the type of engine:

Engine
Document
Mot. D
D7F
E7J
F8Q
Mot. E
Mot. F (D)
10-1
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Oil consumption
10
OIL CONSUMPTION MEASUREMENT PROCEDURE
a) Filling to the maximum level

The operation must be carried out with the engine hot (one rotation of the cooling fan assembly) and after settling for 15 minutes to allow all the oil to drain into the sump.
Check visually using the dipstick.
Top up to the maximum level.
Seal the drain plug (with a paint mark on both the filler plug and the sumps drain plug) in order to be
able to check later that it has not been removed.
b) Customer driving
Ask the customer to drive the vehicle for a period corresponding to about 1250 miles (2,000 km) or before
the minimum level is reached.
c)
Refilling to the maximum level

The operation must be carried out with the engine hot (one rotation of the cooling fan assembly) and after a settling time of 15 minutes.
Check visually using the dipstick.
Top up to the maximum level.
Note the quantity of oil and the mileage covered since the last filling to the maximum level.
d) Measurement of the oil consumption
OIL CONSUMPTION =
Quantity of topping up oil (in litres)

---------------------------------------km (in thousands)
10-2
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Oil pressure
Mot. 836 -05
Oil pressure measuring kit

EQUIPMENT REQUIRED
22 mm long socket
CHECKING
ENGINE CHECKING
The oil pressure should be checked when the engine is warm (approximately 80C).
D engine
Idling
4 000 rpm
Contents of kit Mot. 836-05.
0.8 bar
3.5 bars
E engine
Idling
3 000 rpm
1 bar
3 bars
F engine
1 000 rpm
3 000 rpm
87363R1
USE
D engine
E engine
F engine
C+F
C+E+F
B+F
10-3
http://vnx.su
1.2 bars
3.5 bars
10
D7F engine

Engine - Gearbox
10
B. Vi.
31-01
Set of three punches for roll

pins
Mot.
1202
Hose clip pliers
Mot.
1273
Mot.
1311-06
Tool for removal of fuel pipe
Mot.
1379
Tool for retaining engine on

sub-frame
T. Av. 476
Ball joint extractor
EQUIPMENT REQUIRED
Load positioner
TIGHTENING TORQUES (in daN.m)
Brake caliper guide bolt
Shock absorber base bolts
18
Driveshaft gaiter mounting bolt
2.5
Wheel bolt
Left-hand suspended mounting bolt
on gearbox
9
6.2
Left-hand suspended mounting bolt

and nut on body
2.1
Right hand suspended

engine mounting bolt on engine
6.2
Right hand suspended

engine mounting bolt on body
6.2
13034S
REMOVAL
Drain:
- the cooling circuit (bottom hose of the
radiator),
- the gearbox oil,
- the engine oil if necessary.
Put the vehicle on a 2 post lift.

Disconnect:
- the battery,
- the electrical connectors from the engine
connection unit and its environment.
Remove:
- the battery,
- the bonnet,
- the wheels,
- the air intake pipe,
- the expansion bottle and fix it to the engine.
10-4
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D7F engine

Engine - Gearbox
Left-hand side of the vehicle
Remove:
- the brake caliper mounting bolt, then fix it to
the shock absorber spring,
- the three driveshaft gaiter mounting bolts,
- the track rod end with the aid of tool
T.Av.476,
- the shock absorber base bolts.
Tilt the hub to disconnect the driveshaft from the
gearbox.
Right-hand side of the vehicle
Remove:
- the driveshaft roll pins with the punches
B.Vi.31-01,
- the brake caliper mounting bolt, then fix it to
the shock absorber spring,
- the track rod end with the aid of tool
T.Av.476,
- the shock absorber base bolts.
Tilt the hub to disconnect the driveshaft from the
gearbox.
Remove the earth strap mounting bolt (gearbox
side)
10-5
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10
D7F engine

Engine - Gearbox
Disconnect the gear control at the position of the

gearbox output lever after releasing the gaiter.
10
the heater hoses on the bulkhead side (with

plastic unions),
13085R
93912R1
(with metal unions),
Slacken bolt (A) without removing it and remove

bolt (B) from the engine tie-bar.
92661R1
Disconnect:
- the accelerator cable,
- the canister pipe,
- the brake servo vacuum pipe,
- the hoses between the radiator and the
engine block, on the engine block side,
13084R
the connectors of the oxygen sensor and fan,

the fuel pipes.
10-6
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D7F engine

Engine - Gearbox
Remove:
- the computer support plate.
- the power assisted steering pipe mountings
on the engine,
- the power assisted steering pump belt (see
section 07),
- the power assisted steering pulley,
- the power assisted steering bolts.
10
the mounting bolts (2) of the rubber engine

mounting pad (1).
Note the position of the engine mounting pad(1)

in relation to the body.
Release the power assisted steering unit.

Attach the load positioner to the engine lifting
rings.
12924R2
Remove the engine and transmission assembly

after taking the power assisted steering unit out
of the engine compartment and protecting the
radiator.
99893S
Remove:
- the gearbox side support,
12924R1
10-7
http://vnx.su
D7F engine

Engine - Gearbox
10
REFITTING (special notes)
Refitting is the reverse of removal.

Tighten the suspended engine mounting bolts to the recommended torque.
NOTE : tighten the suspended engine mounting bolts on the body in the order recommended below:
- 1 bolt A to a torque of 2.1 daNm.
- 2 bolt B to a torque of 2.1 daNm.
- 3 bolt C to a torque of 2.1 daNm.
12924R3
Apply Rhodorseal 5661 to the driveshaft roll pin hole.

Press the brake pedal several times to bring the pistons into contact with the brake pads.
Refit the power assisted steering pump belt (see section 07).
Fill:
- the gearbox with oil,
- the engine with oil (if necessary),
- the cooling circuit and bleed it (see section 19).
10-8
http://vnx.su
D7F engine

10
B. Vi.
31-01
Set of punches for roll pins
Mot.
1040-01
Dummy sub-frame for

removing and refitting engine
and transmission assembly
Mot.
1202
Hose clip pliers
Mot.
1311-06
Tool for removal of fuel pipe
Mot.
1379

sub-frame
T. Av. 476
T. Av. 1233-01
Tool for sub-frame and axle

assembly
Shock absorber base bolts
18
Track rod end
3.7
Front sub-frame mounting bolt
6.2
Rear sub-frame mounting bolt
10.5
Driveshaft gaiter mounting bolt

Wheel bolt
2.5
9
Mounting nut for rubber engine mounting

pad on left suspended engine mounting
6.2
Mounting bolt for front right suspended

engine mounting on the engine
6.2

engine mounting on the body
6.2
Steering shaft yoke bolt
2.5
13034S
Drain:
- the cooling circuit (disconnect the bottom
hose of the radiator),
- the gearbox oil if necessary,
- the engine oil if necessary.
REMOVAL
Remove:
- the battery,
- the wheels,
- the air intake pipe,
- the upper radiator mountings,
- the expansion bottle and fix it to the engine,
- the power assisted steering fluid reservoir,
and secure it onto the engine.

Disconnect:
- the battery,
- the electrical connectors from the engine
connection unit and its environment.
10-9
http://vnx.su
D7F engine

Disconnect:
- the canister pipe,
- the brake servo pipe,
- the heater hoses,
- the oxygen sensor connector,
- the fuel pipes.
10
SPECIAL NOTES FOR VEHICLES FITTED WITH

DRIVERS AIR BAG
WARNING
In order to avoid any risk of damage to the rotary

switch beneath the steering wheel, the following
instructions should be followed:
Before disconnecting the steering column from
the rack, the steering wheel MUST be immobilised with the wheels straight with the aid of a
"steering wheel lock" throughout the operation.
If there is any doubt about the rotary switch
being properly centred, the steering wheel
must be removed in order to apply the centring
method described in the Technical Note covering the 2nd generation air bag.
Remove:
- the shock absorber base bolts,
- the steering shaft yoke bolt.
REMINDER: this kind of work must only be carried

out by properly trained and qualified staff.
Remove:
- both the sub-frame reinforcements,
- the earth strap mounting bolt on the body
side,
- the exhaust downpipe nuts.
97390-1R
10-10
http://vnx.su
D7F engine

Disconnect the gear control:

- at the position of the gearbox output lever after releasing the gaiter,
- at the level of the gear lever after removing
the central heat shield.
10
Insert a wooden block between the gearbox and

the sub-frame.
Diagram showing the holes drilled in tool Mot.
1040-01 (dimensions in mm).
Pull the control lever (2) towards the rear of the

vehicle.
10621R
93912R2
Fit tool Mot. 1379 onto the sub-frame and take

the weight off the right-hand engine mounting,
using the threaded rod (1).
92442-1R2
10267R1
Fix tool Mot. 1040-01 underneath the sub-frame,

having first fitted the shims Mot. 1379 onto this
tool.
10-11
http://vnx.su
D7F engine

Remove:
- the gearbox suspended mounting nut, then
tap it with a copper hammer to release the
suspended mounting stud,
- the suspended engine mounting bolts on the
engine.
Lower the lift until the tool touches the ground.
98755R
Remove the four mounting bolts of the subframe.

Take out the engine and transmission assembly by
lifting the body.
10-12
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10
D7F engine

10
Use tool T. Av. 1233-01 to position the engine and transmission assembly in relation to the body.
Tighten the suspended engine mounting bolts and nuts to the recommended torque.
12924R4
Apply Rhodorseal 5661 to the driveshaft roll pin hole.

Press the brake pedal several times to bring the pistons into contact with the brake pads.
Fill:
- the gearbox with oil (if necessary),
- the engine with oil (if necessary),
- the cooling circuit and bleed it (see section 19).
10-13
http://vnx.su
E7J engine

10
Mot. 1040-01
Dummy sub-frame for removing

and refitting engine and
transmission assembly
Mot. 1159
Tool for maintaining engine on

sub-frame
Mot. 1202
Hose clip pliers
Mot. 1448
Mot. 1311-06
Tool for removing fuel pipe

-
6.2
10.5
the mounting bolts (1); pull away the brake

calipers as shown in the diagram below and
attach them to the suspension springs,

engine mounting cover on engine
6.2
Mounting nut for front right suspended

engine mounting cover
4.4
Mounting nut for rubber engine mounting pad

on front left-hand side member support
6.2
Shock absorber base bolt
18
Brake caliper mounting bolt
Wheel bolt
REMOVAL

Disconnect the battery.
12994R1
Drain:
- the cooling circuit through the bottom hose
of the radiator,
- the gearbox and the engine if necessary.
the shock absorber base bolts,
Remove:
- the bonnet,
- the front wheels,
- the tie-rods between sub-frame and body,
10-14
http://vnx.su
E7J engine

the exhaust heat shield and the gear control

on the lever and gearbox sides,
10
Disconnect:
- the wiring connections and the hoses on the
thermostat support,
- the hoses on the expansion bottle,
- the heater hoses (there are two types of assembly to be disconnected, as shown in the
diagrams below),
12988R
the exhaust pipe clamp between the catalytic

converter and the expansion chamber,
the earth strap on the gearbox,
the front bumper,
the air intake pipe from the air filter,
the injection computer support after disconnecting the 55 track connector and that of
the impact switch.
13085R
13084R
13088R2
10-15
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E7J engine

the relay plate (4), the connector (5) and the

fuse support (6) by removing the fuse holder
(7),
10

DRIVERS AIR BAG
WARNING
In order to prevent any risk of damage to the rotary switch beneath the steering wheel, the following instructions should be observed:
Before disconnecting the steering column and
the rack, the steering wheel MUST be immobilised with the wheels straight, using a "steering wheel lock", throughout the operation.
If there is any doubt that the rotary switch is
properly centred, the steering wheel must be
removed in order to apply the centring method
described in section 88 "Air bag".
Fit tool Mot. 1159 between the sub-frame and the

cylinder block.
13034R
the canister pipe,

the fuel supply and return pipes with the aid
of tool Mot. 1311-06, after removing the cover,
the accelerator and clutch cables.
Unclip the power assisted steering reservoir and

place it on the engine.
Remove:
- the upper mountings of the radiator and attach it to the engine,
- the nut and the eccentric bolt of the steering
shaft yoke, after pushing back the guard.
99024R2
97390S1
10-16
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E7J engine

10
Fit retaining lug Mot. 1159 in place of the coolant

pipe mounting on the cylinder block.
13086R
the mounting bolts (3).
99310R
Remove the suspended engine mounting cover.
12993-1R3
13359R
Insert a wooden block between the gearbox and

the sub-frame.
Remove:
- the nut (1), then tap it with a copper hammer
to release the suspended engine mounting
stud.
10-17
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E7J engine

Fix tool Mot. 1040-01 underneath the sub-frame.
10
REFITTING
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 mountings of
the sub-frame on the body.
Tighten the sub-frame mounting bolts to a torque
of:
6.2 daN.m at the front,
- 10.5 daN.m at the rear.
Fit the heat shields correctly.
Apply Loctite FRENBLOC to the caliper mounting
bolts and tighten them to the recommended torque.
Press the brake pedal several times to bring the
pistons into contact with the brake pads.
98755R1
Fill:
- the engine and gearbox with oil, if necessary,
the cooling circuit and bleed it (see section 19
"Filling - bleeding").

Remove the sub-frame mounting bolts and take
out the engine and transmission assembly by lifting the body.
NOTE : for any operation requiring separation of
the engine, gearbox and sub-frame assembly,
take care to mark the position of Mot. 1159 on the
sub-frame.
10-18
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F8Q engine

10
Mot. 1040-01
Dummy sub-frame for removing refitting the engine and

transmission assembly
Mot. 1159
Tool for maintaining engine on

sub-frame
Mot. 1202
Hose clip pliers
Mot. 1448
Mot. 1311-06

-
6.2
10.5
the mounting bolts (1); pull away the brake

calipers as shown in the diagram below and
attach them to the suspension springs,
Mounting bolt for front right suspended engine

mounting cover on engine
6.2
Mounting nut for front right suspended engine
mounting cover
4.4
Mounting nut for rubber engine mounting
pad on front left side member support
6.2
18
Wheel bolt
REMOVAL

12994R1
Drain:
- the cooling circuit through the bottom hose
of the radiator,
- the gearbox and the engine if necessary.
the shock absorber base bolts,
Remove:
- the bonnet,
- the front wheels,
- the tie-rods between sub-frame and body,
10-19
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F8Q engine

-
10
the exhaust heat shield and the gear control

on the lever and gearbox sides,
the exhaust downpipe,
the earth strap on the gearbox,
the front bumper,
the air intake pipe of the air filter,
the fuel supply and return unions (A) and (B),
the connectors (2), (3), (4) and (5).
Unclip the fuel pipes from the air filter unit and
the timing cover and unclip the diesel filter from
its support and move the assembly to one side.
12988R
13083-1R
10-20
http://vnx.su
F8Q engine

For the locking of the quick release unions, refer

to the diagrams below:
10
Remove the computer support.
13088R1
11734R
Disconnect:
- the hoses on the expansion bottle,
- the heater hoses (there are two types of assembly to be disconnected, as shown in the
diagrams below),
11733R
13085R
10-21
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F8Q engine

10
Remove:
- the upper mountings of the radiator and attach it to the engine,
shaft yoke, after pushing back the guard.
13084R
the relay plate (4), the connector (5) and the

fuse support (6) by removing the fuse holders
(7),
97390S1

DRIVERS AIR BAG
WARNING
In order to prevent any risk of damage to the rotary switch beneath the steering wheel, the following instructions should be observed:
Before disconnecting the steering column and
the rack, the steering wheel MUST be immobilised with the wheels straight, using a "steering wheel lock", throughout the operation.
If there is any doubt that the rotary switch is
properly centred, the steering wheel must be
removed in order to apply the centring method
described in section 88 "Air bag".
13034R

the accelerator and clutch cables.
Unclip the power assisted steering reservoir and

place it on the engine.
10-22
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F8Q engine

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

cylinder block.
10
Remove the suspended engine mounting cover.
13086R1
99024R2
Insert a wedge between the gearbox and the subframe.

Remove:
- the nut (1), then tap it with a copper hammer
to release the suspended engine mounting
stud.
Fit tool Mot. 1159 in place of the coolant pipe

mounting on the cylinder block.
99310R
13086R
10-23
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F8Q engine

Remove the mounting bolts (3).
10
REFITTING
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 mountings of
the sub-frame on the body.
Tighten the sub-frame mounting bolts to a torque
of:
6.2 daN.m at the front,
- 10.5 daN.m at the rear.
Fit the heat shields correctly.
Apply Loctite FRENBLOC to the caliper mounting
bolts and tighten them to the recommended torque.
pistons into contact with the brake pads.
12993-1R3
Fill:
- the engine and gearbox with oil, if necessary,
the cooling circuit and bleed it (see section 19
"Filling - bleeding").
Fix tool Mot. 1040-01 underneath the sub-frame.
98755R1

Remove the sub-frame mounting bolts and take
out the engine and transmission assembly by lifting the body.
NOTE : for any operation requiring separation of
the engine, gearbox and sub-frame assembly,
take care to mark the position of Mot. 1159 on the
sub-frame.
10-24
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D7F engine

Sump
Sump mounting bolt

Drain the engine.
Remove:
- the oil level sensor using a 19 mm half-moon
wrench,
- the engine-gearbox undertray.
99900S
Remove the sump mounting bolts.

Rotate the sump towards the rear of the vehicle in
order to release the oil pump strainer from the
sump partitioning.
Clean the sealing surfaces without scratching the
aluminium.
REFITTING
Proceed in the reverse order of removal and fit a

new gasket.
10-25
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10
E7J / F8Q
engines

Sump
10
Mot. 1233-01
Threaded rods for lowering the

sub-frame
6.2
10.5
E7J sump bolt

F8Q sump bolt
1
1.5
Steering shaft yoke mounting bolt

Engine tie-bar bolt
the lower ball joint mountings and the track

rod ends for the E7J engine,
the sub-frame and body tie rods,
the gear control on the gearbox side,
bolt (1), and slacken engine tie-bar bolt (2),
without removing it,
3
6.2
Wheel bolt
REMOVAL

Drain the engine oil.
13359R1
Remove:
- the front wheels,
shaft yoke, after pushing back the guard,
the bottom mountings of the bumper,

the exhaust downpipe for the F8Q engine.
Special notes for the E7J engine

Remove:
- the exhaust manifold heat shield,
- the catalytic converter,
- the engine flywheel guard,
- the power assisted steering pipe mountings
on the cylinder block and the multifunction
mounting.
97390S1
10-26
http://vnx.su
E7J / F8Q
engines

Sump
10
Engines of all types

Remove:
- the mounting bolts (3),
- the sub-frame mounting bolts, inserting the
threaded rods Mot. 1233-01 as you go.
12993-1R3
Gradually lower the sub-frame with the aid of the threaded rods Mot. 1233-01 until
dimensions X1 and X2 are reached approximately.
13507R
E7J engine
X 1 = 9 cm
F8Q engine
X 2 = 12 cm
X 1 = 7 cm
Remove the sump.
10-27
http://vnx.su
X 2 = 9 cm
E7J / F8Q
engines

Sump
REFITTING
Clean the sump.

E7J engine
Apply an approximately 3 mm wide bead of
RHODORSEAL 5661 as shown in the diagram below.
99179S
Do not forget to replace the two half-moon gaskets on each side of the sump.
F8Q engine
Fit a new after-sales gasket.
10-28
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10
D7F engine

Crankshaft seal, timing end
10
Mot. 1054
TDC pin
Mot. 1273
Mot. 1289-03
Centring fork for suspended engine

mounting limiter
Mot. 1355
Tool for fitting pump seal
Mot. 1374
Pump seal extractor
Mot. 1379
Tool for maintaining engine on subframe
REFITTING
Crankshaft output mounting bolt
Refit the new seal onto the crankshaft output without damaging it when passing the timing
sprocket drive groove.
2 + 90

mounting on the engine
6.2
Position it using tool Mot. 1355.

mounting on the body
6.2
Timing belt tension wheel nut
REPLACEMENT
REMOVAL
Remove the timing belt (see section 11 "Timing

belt").
Use tool Mot. 1374 to remove the crankshaft seal.
99788R
Refit the new timing belt (see the method described in section 11 "Timing belt").
99787R
Screw the body of the tool into the seal using nut
(1), then use bolt (2) to extract the seal.
10-29
http://vnx.su
D7F engine

Oil pump
10
Mot. 1054
TDC pin
Mot. 1273
Mot. 1355
Tool for fitting oil pump
Mot. 1379
Tool for maintaining engine on subframe
REFITTING
Systematically replace the oil pressure seal (3).
2 + 90
Bolt mounting front right suspended

engine mounting on engine
6.2
Bolt mounting front right suspended

engine mounting on body
6.2
REMOVAL
Remove:
- the timing belt (see method described in
section 11 "Timing belt"),
- the oil level sensor with the aid of a 19 mm
half-moon wrench,
- the oil dipstick,
- the crankshaft pulley and sprocket,
- the engine flywheel guard.
99790R
Apply a bead of RHODORSEAL 5661 to the sealing

surface.
Lift the engine and gearbox assembly with the aid

of tool Mot. 1379.
Remove the sump bolts.
Rotate the sump towards the rear of the vehicle in
order to release the oil pump strainer from the
sump partitioning.
Remove:
- the oil pump strainer
- the oil pump
Clean the sealing surfaces without scratching the
aluminium.
98964S
IMPORTANT : the oil pump is driven by two studs

located on the crankshaft.
10-30
http://vnx.su
D7F engine

Oil pump
Refit:
- the oil pump onto the engine and tighten it to
a torque of 0.9 daN.m,
- the new seal onto the crankshaft output without damaging it when passing the timing
sprocket drive groove.
Position it with the aid of tool Mot. 1355..
99788R
Refit the strainer with a new O-ring.

Clean the sealing surfaces (cylinder block, sump).
Refit the sump.
Tighten the bolts to a torque of 1 daN.m.
Refit:
- the new alternator and power assisted steering pump belts (see tension values in section
07 "Accessories belt tension").
10-31
http://vnx.su
10
D7F engine

Timing belt
Mot. 1054
TDC pin
Mot. 1135-01
Tool for tensioning timing

belt
Mot. 1273
Mot. 1379
Tool for securing engine to

subframe
Mot. 1386
Tool for pre-tensioning timing

belt
TIGHTENING TORQUES
(in daN.m)
Fit tool Mot. 1379.

Crankshaft accessories pulley
mounting bolt
2 + 90
Mounting bolt for front right

suspended engine mounting
on engine
6.2
Mounting bolt for front right

suspended engine mounting
on vehicle body
6.2
REMOVAL
Place the vehicle on a two post lift.

10267R
Remove :
- the front right hand wheel,
- the belt from the alternator and the power
assisted steering pump if fitted (see section
07),
- the crankshaft accessories pulley.
11-1
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11
D7F engine

Timing belt
Remove the suspended engine mounting.
11
Remove the timing belt by slackening nut ( 5 ).
12924S1
Remove the timing cover, water pump cover and

suspended engine mounting cover on the cylinder
head .
Turn the engine in the operating direction until
the timing reaches its setting point (the camshaft
and crankshaft markings are aligned), whilst inserting pin Mot. 1054 into the flywheel.
DI1041R
99795R
11-2
http://vnx.su
D7F Engine

Timing belt
11
REFITTING
PROCEDURE FOR TENSIONING TIMING BELT
Line up the markings of the timing belt with

those of the camshaft and crankshaft sprockets.
Remove pin Mot. 1054.

Fit the spacer (1) of tool Mot. 1386 and tighten
the crankshaft sprocket bolt.
IMPORTANT : The camshaft sprocket bears five

markings, of which only the rectangular one on
the surface of one of the teeth represents TDC;
the other markings are intended as an aid for adjusting the valve rockers.
10881R
a) Fit tool Mot. 1273 and, using tool

Mot. 1135-01, turn the tension wheel anticlockwise until the value of 20 US is obtained
(turn the sensor wheel until it is tight, as indicated by three clicks).
10072S
10479R1
11-3
http://vnx.su
D7F Engine

Timing belt
Tighten the tension wheel nut.
11
Fit tool Mot. 1273 and note the tension measurement, which should be 203 US (fitting tension),
or simply adjust by varying the position of the
tension wheel using Mot. 1135-01 and repeat the
tensioning process in (b).
Turn the engine at least twice (never in the opposite direction to normal operation).
Insert the pin in the engine at TDC, then remove
the pin .
Tighten the tension wheel nut to a torque of

5 daN.m.
Check that the timing is correct on the crankshaft

and camshaft side.
IMPORTANT
Slacken the tension wheel nut and turn it slightly

clockwise using tool Mot. 1135-01 until the two
holes of the tension wheel are lined up
horizontally.
Following each variation of the tension wheel

position, turn the engine at least twice before
proceeding to measure the tension .
Apply the pretensioning of 1 daN.m which allows
all belt play to be eliminated.
Retighten the tension wheel nut.

b) Turn the engine at least twice (never in the
opposite direction to normal operation).

Fit the suspended engine mounting .
Insert the pin in the engine at TDC then remove the pin.
Using tool Mot. 1386, apply a pretensioning
torque of 1 daN.m between the crankshaft
sprocket and the water pump.
12924S1
10881R
11-4
http://vnx.su
E7J Engine

Timing belt
11
Mot. 591-02
Index pin
Mot. 591-04
Angle tightening wrench
Mot. 1135-01
Tool for tensioning timing

belt
Mot. 1273
EQUIPMENT REQUIRED
Engine support tool
TIGHTENING TORQUES (In daN.m or /and )
Wheel bolts
Crankshaft pulley bolts
Tension wheel nut
9
2 + 68 6
Remove :
- the front right wheel along with the mudguard,
- the suspended engine mounting cover,
Bolt for suspended engine mounting cover 6.2

Nut for suspended engine mounting cover 4.4
REMOVAL
Place the vehicle on a 2 post lift.

Fit the engine support tool.
13359R
the belts for the alternator and the power

assisted steering pump.
13370S
11-5
http://vnx.su
E7J Engine

Timing belt
the crankshaft pulleys and hub,

the timing cover.
11

13362S
Bring the engine to the setting point.

10072S
Align the markings (L) of the crankshaft sprocket

with the fixed marking (M); the marking (N) of
the camshaft sprocket must be in the position illustrated below.
Slacken the nut (O) and and release the tension
wheel , then remove the belt.
13506R
(1) Tensioner direction of rotation.
11-6
http://vnx.su
E7J Engine

Timing belt
REFITTING
An arrow indicating the direction of rotation and

two dashes for setting are marked on the surface
of the belt .
Check that the engine is at the setting point.
Bring the belt markings in line with the sprocket
markings .
Observe the mounting direction for the belt and
begin to position it on the crankshaft sprocket.
Carry out the tensioning of the belt using tool
Mot. 1135-01, until the fitting value is obtained
(see section 07 "Timing belt tension ").
Tighten the nut (O) of the tension wheel to a torque of 5 daN.m.
It is essential to tighten the nut of the tension
wheel to a torque of 5 daN. to avoid any slackening which may cause a deterioration in the engine .
Refit the crankshaft pulley, being sure to tighten
the bolt to a torque of 2 daN.m with an angle of
68 6.
Refit and tension the accessories belts (see section
Never refit a belt once removed , but replace it.
11-7
http://vnx.su
11
F8Q Engine

Timing belt
11
Mot. 1054
TDC pin
Mot. 1273
EQUIPMENT REQUIRED
Engine support tool

14mm torx socket
Remove :
- the accessories belt,
- the suspended engine mounting cover.
TIGHTENING TORQUES (in daN.m or/and )
Wheel bolts
Crankshaft pulley bolt
9
2 + 115 15
Tension wheel nut

Bolt for suspended engine mounting
cover
Nut for suspended engine mounting cover
5
6.2
4.4
REMOVAL
Place the vehicle on a 2 post lift.

Remove :
- the front right hand wheel and the mudguard,
- the protective plastic covering over the suspended engine mounting cover .
13086R1
13370S
11-8
http://vnx.su
F8Q Engine

Timing belt
11
Remove :
- the timing covers,
Adjusting the timing

Turn the crankshaft so that the camshaft timing
reference mark is visible through the timing window .
12518R
13095S
the crankshaft pulley.
Slacken the tension wheel and remove the belt.
Remove the TDC pin plug .
NOTE : Slackening the tension wheel bolt by

more than one turn may cause it to come loose .
Fit the TDC pin, tool Mot. 1054.
12419R
11-9
http://vnx.su
F8Q Engine

Timing belt
11
REFITTING
Check that the pin Mot. 1054 is in place.

Fit the timing belt by aligning the belt markings
with those of the camshaft, injection pump and
crankshaft sprockets.
13094R
Tighten the tension wheel nut to 5 daN.m.

NOTE : it is essential to tighten the tension wheel
nut to a torque of 5 daN.m to avoid any slackening which may bring about a deterioration in the
engine.
Replace the crankshaft pulley bolt.
13096R
Tension the timing belt by tightening a bolt ( A )

on the inner timing housing.
Refit the crankshaft pulley , being sure to tighten

the bolt to a torque of 2 daN.m with an angle of
115 15.
Fit tool Mot. 1273 and tension the belt until the
fitting value is reached (see section 07 "Timing
belt tension").

Refit the accessories belt (see section 07
"Accessories belt tension").
NOTE : Never refit a belt once it has been removed, but replace it.
11-10
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D7F Engine

11
Mot. 591-04
Angle wrench for tightening

cylinder head and index
Mot. 1202
Hose clip pliers
Mot. 1273
Mot. 1379
Tool for securing engine to

subframe
EQUIPMENT REQUIRED
12mm torx socket

Angular tightening wrench
Remove:
- the dipstick,
- the air filter,
- the fuel supply and return pipes level with the
timing belt cover on the cylinder head
2 + 90

6.2

engine mounting on vehicle body
6.2
Wheel bolts
REMOVAL

Remove the bonnet, and the right hand wheel .
Drain the cooling circuit.
Fit the engine support tool, Mot. 1379.
11-11
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D7F Engine

Disconnect :
- the spark plug leads using tool (3) which is integrated to the plastic cover (4),
99894R1
99940R
the canister pipe along with the fuel vapour

rebreathing hoses on the solenoid valve,
the connectors :
of the ignition module,
of the injectors,
of the idle speed regulation stepping
motor,
of the throttle position potentiometer,
of the air temperature sensor.
Extract the hose connecting the water pump to

the heater matrix, and the electrical wiring loom
from the heat shield on the rocker cover.
11-12
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11

D7F Engine
Remove :
- the mounting bolts (5) for the throttle body retaining bracket on the
cylinder head,
- the mounting nuts (3) for the manifold on the cylinder head
- the mounting bolts (4) of the manifold on the valve rocker cover
- the inlet manifold, throttle body and injector gallery assembly.
99937R1
the thermostat hoses,

the valve rocker covers,
the cylinder head mounting bolts,
the cylinder head.
11-13
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11
D7F Engine

CLEANING
It is very important not to scratch the gasket faces
of the aluminium components.
11
CHECKING THE GASKET FACE
Check for gasket face bow using a straight edge

and a set of shims .
Use the Dcapjoint product to dissolve any part of

the gasket which remains attached.
Maximum deformation : 0.05 mm.
Apply the product to the parts to be cleaned; wait

about ten minutes, then remove it using a
wooden spatula.
No regrinding of the cylinder head is permitted.

REFITTING
The cylinder head is centred by two dowels at the

rear of the engine.
REMINDER: in order to obtain the correct tightening of the bolts, use a syringe to remove any oil
which may have entered the cylinder head mounting bolt holes .
Grease the threads and under the bolt heads with

engine oil.
Adjustment of the valve rockers and tightening
of the cylinder head should be carried out when
the engine is cold.
92076S
Wear gloves whilst carrying out this operation.

Care must be taken whilst carrying out this operation in order to avoid any foreign bodies entering the oilways supplying oil under pressure to
the camshaft (oilways are located both in the cylinder block and the cylinder head).
Failure to follow to this advice could lead to the
blocking of the jets and thus cause rapid deterioration of the cams and tappets.
11-14
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D7F Engine

Tighten the cylinder head using an angular tightening wrench (see section 07 "Tightening the cylinder head").
Tighten using tool Mot. 591-04.
99902S
Line up the reference marks on the timing belt

with the markings on the sprockets.

10072S
Remove the TDC pin .

Refit the timing belt (see method described in
chapter 11 "Timing belt ").
11-15
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11
D7F Engine

ADJUSTMENT OF VALVE ROCKERS (IF

NECESSARY)
VALVE CLEARANCE ADJUSTMENT VALUE

(in mm)
Partly refit the suspended engine mounting timing cover on the engine using two bolts.
Inlet
Exhaust
11
0.05
0.15
Bring the engine to TDC , cylinder n. 1 in ignition

phase .
Turn the crankshaft clockwise (viewed from the
timing side ) to reach the first reference mark.
ADJUST : exhaust 1
exhaust 3
move forward to the second mark :

ADJUST: inlet 1
inlet 3
third mark :
ADJUST: exhaust 2
exhaust 4
99905S

fourth mark :
ADJUST: inlet 2
inlet 4
Remove the tool retaining the engine on the subframe, Mot. 1379.
NOTE : tightening the inlet manifold :
- progressively hand tighten the six nuts until
the inlet manifold comes into contact with the
cylinder head, then tighten them to a torque
of 1.5 daN.m,
- fit the upper bolts and tighten them to a torque of 0.9 daN.m.
Fill and bleed the cooling circuit.

Adjust the accelerator cable.
10072S
11-16
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E7J Engine

11
Mot. 588
Retaining bracket
Mot. 591-02
Index
Mot. 591-04
Angle tightening angular

wrench
Mot. 1159

subframe
Mot. 1202
Hose clip pliers
Mot. 1273
Mot. 1311-06
EQUIPMENT REQUIRED
Engine support tool

55mm torx socket
TIGHTENING TORQUES (in daN.m or /and )
Tension wheel nut

Bolt for suspended engine mounting
5
2 + 68 6
6.2
cover
Nut for suspended engine mounting cover 4.4
Wheel bolts
DEPOSE
Place the vehicle on a 2 post lift .

Remove :
- the bonnet ,
- the timing belt (see method described in section 11, "Timing belt ").
99024R2
Drain the cooling circuit through the lower radiator hose.

Fit tool Mot. 1159 between the engine subframe
and the cylinder block.
11-17
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E7J Engine

Fit the bracket Mot. 1159 in place of the coolant

pipe mounting on the cylinder block, then remove
the engine support tool.
the throttle position potentiometer connector,

the accelerator cable
the air intake pipe, having disconnected the
air temperature connector,
99310R
Remove :
- the connector along with the pipe on the absolute pressure sensor,
- the stepping motor connector,
13338S
13339S
11
the cover on the air filter assembly,

the air filter assembly,
11-18
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E7J Engine

11
the connectors of the ignition coils, along

with the connector at (1),
the coil (2),
the pipes at (3) along with the connector (4),
the pipe at (5),
the lifting bracket (6),
the fuel supply and return pipes (7) using tool
Mot. 1311-06,
the injector connectors,
the cylinder head cover ,
13365S
the heat shield along with the exhaust downpipe,

the alternator,
the mounting at (8) along with connector (9)
of the pressostat,
the mounting bolt for the power assisted
steering pump and move this to one side ,
the mounting bolts for the multi-function support and move this to one side,
13360R
the connectors and hoses on the thermostat

support ,
13364R1
11-19
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E7J Engine

the mounting at (10),

the bolt (11) of the strut and slacken the nut
at (12),
the mounting bolt (13) of the dipstick guide
tube,
11
the cylinder head .
Fit the cylinder liner retaining brackets, tool

Mot. 588.
92062R
13336-1R1
Unhook the wiring loom at (14).
CLEANING
Remove :
- the cylinder head bolts except for (F) which
must simply be loosened, then pivot the cylinder head around the bolt.

wooden spatula.
Care must be taken whilst carrying out this operation in order to avoid any foreign bodies entering the oilways supplying oil under pressure to
the camshaft (oilways are located both in the cylinder block and the cylinder head).
Failure to follow to this advice could lead to the
blocking of the jets and thus cause rapid deterioration of the cams and tappets.
92106R
11-20
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E7J Engine
ADJUSTMENT OF
NECESSARY)
Check for gasket face bow, using a straight edge

and a set of shims.
11
VALVE ROCKERS
(IF
Maximum deformation: 0.05 mm.
Adjustment values (cold engine) (in mm) :

- inlet
- exhaust
"Tilt" method
REFITTING
(special notes)
Remove the cylinder liner brackets Mot. 588.

Check for the presence of the centring dowel (A).
0.10
0.25
Place the valves of the

cylinder concerned in
the "end of exhaustbeginning of
inlet"position
Adjust the valve rocker

clearance for the
cylinder concerned
98713R1
Position the cylinder head gasket.

Grease the threads and under the bolt heads .
Refit the cylinder head (shortest bolts on the inlet
side ).
Tighten the cylinder head (see section 07
"Tightening the cylinder head").
Refit the timing belt , (see section 11 "Timing
belt").
Correctly refit the heat shields.
Fill and bleed the cooling circuit, (see section 19
"Filling and Bleeding").
11-21
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E7J Engine

11
Open exhaust valve method

Bring the exhaust valve of cylinder n 1 to the fully open position, then adjust the inlet valve clearance for
cylinder n 3 and the exhaust valve clearance for cylinder n 4.
Follow the same method for the other cylinders, in the order shown by the table below.
Exhaust valve to be opened.
Inlet valve to be adjusted.
Exhaust valve to be adjusted.
78373R
11-22
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F8Q Engine

11
Mot. 251-01
Dial gauge support tool
Mot. 252-01
Plate for measuring piston

protrusion
Mot. 591-02
Index
Mot. 591-04
Angular tightening wrench
Mot. 1054
TDC pin
Mot. 1159
Tool for mounting engine on

subframe
Mot. 1202
Hose clip pliers
Mot. 1273
Mot. 1311-06
EQUIPMENT REQUIRED
Engine support tool

55mm torx socket
Fit tool Mot. 1159 between the subframe and

the cylinder block.
TIGHTENING TORQUES (in daN.m or/and )
Tension wheel nut

2 + 115 15
Bolt for suspended engine mounting cover 6.2
4.4
Wheel bolts
REMOVAL
Place the vehicle on a two post lift .

Remove :
- the bonnet,
section 11 "Timing belt").
Drain the cooling circuit via the lower radiator
hose.
99024R2
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F8Q Engine

11
Place bracket Mot. 1159 at the mounting of the

coolant pipe on the cylinder block, then remove
the engine support tool.
99461R
99310R
Remove :
- the exhaust downpipe,
- the hoses and connectors of the cylinder head
coolant pipe housing outlet,
- the connection at (1) using tool Mot. 1311-06,
the air filter assembly by disconnecting the

EGR solenoid valve and the air temperature
sensor (unclip the fuel supply pipes from the
air filter housing),
the air inlet pipe
the accelerator cable
the feeds for the heater plugs ,
the connector of the injector with sensor,
along with the fast idle solenoid valve connector (5),
the fuel supply and return unions at (A) and
(B).
Disconnect connector (6) from the diesel fuel filter, remove it from its support and move the diesel fuel filter pipe assembly to one side.
13097R
11-24
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F8Q Engine

11
13083-1R1
To release the quick release unions, refer to the

following diagrams.
11734R
11-25
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F8Q Engine

11
Remove :
- the accessories belt tensioning system,
- the cylinder head bolts.
Release the cylinder head by setting aside the
lower part of the lower camshaft housing,
without causing the cylinder head to pivot, since
this is centred by the two dowels at ( C ).
11733R
Remove the fuel pipe support (7).

Slacken the mounting bolts for the lower timing
cover, without removing them.
99173-1R
Using a syringe, extract any oil which may have

entered the cylinder head mounting holes .
This is necessary in order to obtain the correct
tightening of the bolts.
Protect the oil outlet duct in order to prevent any
foreign bodies from entering the oilways in the
cylinder head.
Failure to take this advice could lead to the
blocking of the oilways, resulting in a rapid deterioration of the camshaft.
13093R
11-26
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F8Q Engine

11
Check for gasket face bow, using a straight edge

and a set of shims.
CLEANING
Maximum deformation: 0.05 mm.


wooden spatula.
Check the cylinder head for cracks.
99180S
11-27
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F8Q Engine

MEASURING THE THICKNESS OF THE CYLINDER

HEAD GASKET
11
Refit the cylinder head gasket selected previously. This is centred by two dowels at (C).
Checking piston protrusion

Clean the piston heads in order to eliminate any
traces of deposits.
Turn the crankshaft in its operating direction
once, to bring piston n 1 close to TDC .
Fit tool Mot. 252-01 on the piston.
Fit tool Mot. 251-01, complete with dial gauge
Mot. 252-01. on the plate Ensure that the dial
gauge measuring pin is in contact with the cylinder block; then locate the piston TDC.
NOTE : All measurements are to be carried out in
the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston.
99173-1R
Bring the pistons to mid-stroke position to

prevent them from coming into contact with the
valves during the tightening of the cylinder head .
Centre the cylinder head on the dowels.
Lubricate the threads and under the heads of the
mounting bolts.
Tighten the cylinder head (see section 07
"Tightening the cylinder head").
Refit the timing belt, (see method described in
99173R
Fill and bleed the cooling circuit , (see section 9

"Filling -bleeding").
Measure the piston protrusion.

ONLY TAKE INTO CONSIDERATION THE
DIMENSIONS OF THE PISTON WITH THE
GREATEST PROTRUSION.
For a maximum piston protrusion:

- lower than 0.868 mm, use a gasket marked by
a tab with two holes ,
- included between 0.868 mm and 1mm, use a
gasket marked by a tab with one hole,
- greater than 1mm, use a gasket marked by a
tab with three holes.
11-28
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F8Q Engine

SPECIAL TOOLING
Mot. 1366-01
11
REQUIRED
Tool for removing valve adjusters

(additional item to Mot. 1366)
Studs for mounting manifolds on

cylinder head
Nut for mounting manifolds on

cylinder head
Mounting bolt for strut on inlet manifold
Mounting bolt for strut on cylinder block
2.7
2.5
2.5
86911-1S
Place the vehicle on a two-post lift

CHECKING THE VALVE CLEARANCE
Remove the air filter housing along with the cylinder head cover.
Compare the two dimensions noted to the recommended dimensions, and replace the adjusters if necessary .
Place the valves of the cylinder concerned at the

"end of exhaust - beginning of inlet" position and
check the clearance .
Clearance ( in mm ), when the engine is cold :

-
Inlet:
0.10
Exhaust :
0.25
11-29
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F8Q Engine

11
REPLACEMENT OF VALVE ADJUSTERS
For inlet valves
In order to carry out this operation it is necessary

to remove the inlet and exhaust manifolds (see
section 12 Inlet/Exhaust Manifolds) .
Turn the engine in the operating direction,in

order to bring the valve into contact with tool
Mot. 1366-01 (rotate the camshaft by 90 in
relation to the fully open position).
Fully open the valve concerned (by turning the

engine in its operating direction).
For the exhaust valves
Insert tool Mot. 1366-01 into the duct concerned .
It is vital to turn the engine in the opposite direction to normal operation (in order to avoid the
locking of the engine), until the valve comes into
contact with tool Mot. 1366-01 (rotate camshaft
by 90 in the relation to the fully open position).
Extract the valve adjuster using a screwdriver and
a magnetic tool.
NOTE : during the refitting of the valve adjuster,

extract any oil which may be in the bottom of the
pushrod bore ( C ) .
11231R
98895R1
REFITTING
11232-1R
11-30
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FUEL MIXTURE
Specifications
D7F engine
12
Engine
Vehicle
Gearbox
Type Suffix
XC0A
JB1
D7F
710
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
Ratio
69
76.8
1149
9.65/1
Suffix
D7F
710
C61
EU 96
Tests at idle speed*
Engine
Type
Catalytic
converter
Depollution
standard
Engine
speed
[rpm]
74050
Fuel***
[minimum octane
rating]
Pollutant emission **
CO (%) (1)
CO 2 (%)
HC (ppm)
0.5 max
14.5 min
100 max
Lambda ()
0.97<<1.03
Unleaded (OR 95)
(1) at 2500 rpm, CO must be a maximum of 0.3
*
**
***
For a coolant temperature above 80C and after stable speed of 2500 rpm, for about 30 seconds. Test to
be carried out after return to idle speed.
For legal values refer to your country specification.
OR 91 unleaded compatible.
Temperature in C ( 1)
20
40
80
90

Type CTN
Resistance in Ohms
5000 to 7000
1700 to 3300
800 to 1550

Type CTN
Resistance in Ohms
6700 to 8000
2600 to 3000
1100 to 1300
270 to 300
200 to 215
12-1
http://vnx.su
D7F engine
DESCRIPTION
Computer
FUEL MIXTURE
Specifications
MAKE/TYPE
SAGEM or
MAGNTI MARLLI
Injection
Fuel filter
Fuel pump
Tracks
Resistance
1-2
1.5
1 - 4 |1 - 3
2 -3 | 2 - 4
3-4
0.6
HT - HT
8 K
Resistance 220
EYQUEM : RFC50LZ2E
NGK : BKR5EK
Gap: 0.9 mm
Tightening torque: 2.5 to 3 daN.m
Mounted under vehicle in front of fuel tank

Replaced during major service
WALBRO
Pressure regulator
Submerged in fuel tank

Flow: at least 80 litres/hour at a regulated pressure
of 3 bars and a voltage of 12 V
Regulated pressure
Zero vacuum :
Vacuum of 500 mbars :
Solenoid injectors
35 tracks on manual gearbox vehicles without option

55 tracks on air conditioning vehicles
Static with 2 dual output

monobloc coils
Power module integral
in computer
One pinking sensor
tightening torque : 2.5 daN.m
Plugs
SPECIAL NOTES
Multipoint with semi-sequential regulation
Ignition
TDC sensor
12
SIEMENS
Voltage:
Resistance :
12-2
http://vnx.su
12 Volts
14.5 1
3 0.2 bars
2.5 0.2 bars
D7F engine
DESCRIPTION
Throttle body
FUEL MIXTURE
Specifications
12
MAKE/TYPE
SPECIAL NOTES
MAGNETI MARELLI
diameter 36 mm
873 633
Idle speed regulation stepping

motor
AIR PAX
Throttle position
potentiometer
Voltage: 12 V (at high frequency)

Resistance : tracks A-D 100 10
tracks B-C 100 10
Voltage: 5 V
Resistance :
-

canister
Solenoid valve
Heated oxygen sensor
Diagnostic function
Voltage:
Resistance :
BOSCH
FICHE n 27
CODE D13
SELECTOR S8
Track
No load
Full load
AB
AC
BC
1300
1360
2300
1300
2350
1260
12 Volts
35 5
Voltage at 850 C
Rich mixture > 625 mvolts
Lean mixture : 0 to 80 mvolts
Heating resistance, tracks A-B : 3 to 15
Tightening torque : 5 daN.m
Throttle potentiometer:
Regulated idle speed :
Full load :
Idle speed R.C.O. :
10 # 17 50
185 # 17 240
4 % # 12 14 %
Adaptive idle speed R.C.O. :- 4.3 % # 21 +3.9 %

Adaptive richness operation :
106 # 30 150
Adaptive idle speed richness :
106 # 31 150
12-3
http://vnx.su
FUEL MIXTURE
Specifications
E7J engine
12
Engine
Vehicle
Gearbox
Type Suffix
XC0C
Manual
E7J
780
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
Ratio
75.8
77
1390
9.5/1
Suffix
E7J
780
C63
EU 96
Tests at idle speed*
Engine
Type
Catalytic
converter
Depollution
standard
Engine
speed
[rpm]
75050
Fuel***
(minimum octane
rating)
Pollutant emission **
CO (%) (1)
CO 2 (%)
HC (ppm)
0.5 max
14.5 min
100 max
Lambda ()
0.97<<1.03
Unleaded (OR 95)
(1) at 2500 rpm, CO must be a maximum of 0.3
*
**
***
For a coolant temperature above 80C and after stable speed of 2500 rpm, for about 30 seconds. Test to
be carried out after return to idle speed.
For legal values refer to your country specification.
OR 91 unleaded compatible.
Type CTN
Resistance in Ohms
Type CTN
Resistance in Ohms
20
40
80
90
7470 to
11970
3060 to 4045
1315 to 1600
6700 to 8000
2600 to 3000
1100 to 1300
270 to 300
200 to 215
12-4
http://vnx.su
E7J engine
DESCRIPTION
Computer
Injection
FUEL MIXTURE
Specifications
MAKE/TYPE
SPECIAL NOTES
55tracks
SIEMENS
FENIX 5
Multipoint with semi-sequential regulation

Static with 2 dual output
monobloc coils
Power module integral
in computer
One pinking sensor
tightening torque : 2.5 daN.m
Ignition
-
TDC sensor
Plugs
Fuel filter
Fuel pump
Tracks
Resistance
1-2
0.5
1-3
2 -3
HT - HT
10 K
Resistance 220
EYQUEM : RFC52LS
CHAMPION : RC10PYC
Gap: 0.9 mm
Tightening torque: 2.5 to 3 daN.m
Mounted under vehicle in front of fuel tank

Replaced during major service
WALBRO
Pressure regulator
Submerged in fuel tank

Flow: at least 80 litres/hour at a regulated pressure
of 3 bars and a voltage of 12 V
Regulated pressure
Zero vacuum :
Vacuum of 500 mbars :
Solenoid injectors
12
SIEMENS
Voltage:
Resistance :
12-5
http://vnx.su
12 Volts
14.5 1
3 0.2 bars
2.5 0.2 bars
E7J engine
DESCRIPTION
Throttle body
FUEL MIXTURE
Specifications
12
MAKE/TYPE
PIERBURG
SPECIAL NOTES
diameter 41 mm
714 227
Idle speed regulation stepping

motor
Voltage: 12 V (at high frequency)

Resistance : tracks A-D 52 5
tracks B-C 52 5
Throttle position
potentiometer
Voltage: 5 V
Resistance :
-

canister
Solenoid valve
Heated oxygen sensor
Diagnostic function
DELCO REMY
Voltage:
Resistance :
Track
no load
full load
1-2
1-3
2-3
5440
4500
2160
2200
4460
5340
12 Volts
35 5
Voltage at 850 C
Rich mixture > 625 mvolts
Lean mixture : 0 to 80 mvolts
Heating resistance, tracks A-B : 3 to 15
Tightening torque : 4.5 daN.m
NGK
FICHE n 27
CODE D13
SELECTOR S8
Throttle potentiometer:
Regulated idle speed :
Full load :
Idle speed R.C.O. :
16 # 17 50
185 # 17 243
2 % # 12 15 %
Adaptive idle speed R.C.O. :- 2.4% # 21 +6.2 %

Adaptive richness operation :
64 # 30 192
Adaptive idle speed richness :
64 # 31 192
12-6
http://vnx.su
D7F engine
FUEL MIXTURE
Throttle body
12
Throttle body mounting bolt on

inlet manifold
Throttle body stiffening bracket
mounting bolt on cylinder head
1
1
There are no special notes for removal - refitting.
12-7
http://vnx.su
E7J engine
FUEL MIXTURE
Throttle body
Remove the four throttle body mounting bolts (5)

and remove the throttle body.
Throttle body mounting bolt
12
REMOVAL

Remove the air filter.
Remove the air intake pipe (1).
13338R
REFITTING
Replace the throttle body seal.

Refitting is then the reverse of removal.
13339R1
Disconnect:
- the connectors :
of the stepping motor (2),
of the throttle potentiometer (3).
12-8
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D7F engine
FUEL MIXTURE
Inlet manifold
12

Injector gallery mounting bolt on manifold
Manifold mounting nut on cylinder head
1.7
Manifold mounting stud on cylinder head
There are no special notes for removal - refitting
12-9
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E7J engine
FUEL MIXTURE
Inlet manifold
Lower the vehicle.
Inlet manifold bolt and nut
12
Remove the air intake pipe (A) connecting the

throttle body to the air filter.
REMOVAL
Remove:
- the air filter,
- the injector gallery (see section 13).
Lift the vehicle.
Remove the strut (1) (to gain access to the bolt
fixing the strut on the right-hand side of the vehicle, remove the mudguard and the right-hand
wheel).
13339R2
Disconnect the accelerator cable and the electrical

connectors (2) connected to the throttle body.
Remove the bolts and nuts (3) securing the manifold.
13130R
13335-1R
12-10
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FUEL MIXTURE
Inlet manifold
E7J engine
12
Remove the two bolts (4) mounting the retaining

bracket on the cylinder block.
13338R1
Extract the manifold.

REFITTING
Replace the inlet manifold gaskets.

12-11
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D7F engine
FUEL MIXTURE
Exhaust manifold
12
Manifold mounting nut

Manifold mounting stud
Exhaust downpipe mounting bolt
2.5
1
2.2
There are no special notes for the removal - refitting.
12-12
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E7J engine
FUEL MIXTURE
Exhaust manifold
12
Manifold mounting bolt
REMOVAL
Remove the multifunction support (1) (see section

10).
Disconnect the exhaust manifold / exhaust link
(2).
Remove the heat shield (3).
Remove the exhaust manifold.
13239R2
REFITTING
Replace the manifold gasket.

12-13
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F8Q engine
FUEL MIXTURE
Inlet/Exhaust manifolds
12
Remove the nuts securing the manifolds:

- nuts (A) from above,
- nuts (B) from below.
Manifold mounting studs on cylinder head 1

Manifold mounting nuts on cylinder head 2.7
Inlet manifold strut mounting bolt
2.5
Cylinder block strut mounting bolt
2.5
REMOVAL
Remove the air filter (two mounting bolts at the

top, two mounting nuts at the bottom (1)).
PRO12.1
Special note
To remove nut (C) located above the starter motor, use a small ratchet (6.35 mm square) and a
universal joint.
13047-1R1
Remove, from above, the two nuts fixing the exhaust downpipe to the manifold.
Slacken, without removing it, the nut on the
clamp connecting the downpipe to the exhaust
pipe.
Tilt the exhaust downpipe towards the gearbox.
13047R
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F8Q engine
FUEL MIXTURE
Inlet/exhaust manifolds
REFITTING
Replace the manifold gaskets (metal part of the

gasket on the manifold side).
Replace the gaskets between the inlet manifold
and the air filter.
Replace the steel gasket between the exhaust manifold and the exhaust downpipe.
For the other operations, refitting is the reverse of
removal.
12-15
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12
FUEL SUPPLY
Fuel cut off in case of an impact
OBJECTIVE
The main function of this feature is to avoid any

fires that may result from the leakage of fuel during an accident. In order to achieve this, all
components pumping fuel from the fuel tank will
automatically stop functioning during and immediately after the impact. They can then only be
made to operate again by a mechanical action carried out by the driver or the repairer.
13
in diesel engines, between the + supply and

the electrical solenoid (or the coded solenoid
valve if the vehicle is fitted with an engine immobiliser).
OPERATING PRINCIPLE
During the impact, the ball of the inertia switch

moves up and interrupts the electrical connection.
In petrol engines, the + supply of the pump relay
control circuit (236) is cut. Neither the pump or
the injectors will receive any further supply of
electricity .
DESCRIPTION
The system consists simply of an inertia switch (1),
which:
- detects the impact,
- and thus cuts off the electrical circuit.
The fuel contained in the tank is actually isolated.

In diesel engines, the + supply of the electrical
solenoid or of the coded solenoid is cut off.
The pump can no longer take in fuel, and there is
no longer any high pressure. All risk of fire due to
the outlet of diesel fuel at high pressure onto the
engine is removed.
RESETTING AND OPERATING
THE
SWITCH
In order to reset the inertia switch, it is sufficient

to press it down in order to replace the ball bearing in its original position .
IMPORTANT: for petrol engines, , having reset
the switch, it is VITAL to erase the memory of the
computer, using the XR25. The injection computer will memorise a pump relay fault once the
system has gone into operation .
13051R
This is fitted:
in petrol engines, between track 1 of the
pump relay (236) and the + 12 V supply ,
13-1
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FUEL SUPPLY
Injector gallery
D7F Engine
Mot. 1311-06
Tool for removing the fuel

supply unions
Bolt mounting injector gallery on manifold 1
IMPORTANT: during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
REMOVAL
Disconnect :
- the battery,
- the pressure measurement pipe (1) of the
pressure regulator,
- the fuel return pipe (2),
- the electrical connector of the injectors (3)
99937R3
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13
D7F Engine
FUEL SUPPLY
Injector gallery
Disconnect the fuel supply pipe (4) using the tool

Mot. 1311-06 with the largest section (the fuel
supply pipe is equipped with a removal tool
which is attached to the connection incorporated
in the vehicle ).
13
Remove the two bolts (5) mounting the injector

gallery on the manifold.
Slide the injector gallery, along with the injectors,
between the manifold and the cylinder head.
Extract the injector gallery from the right hand
side of the vehicle.
NOTES :The fuel pressure regulator (6) is clipped
to the injector gallery.
There is an intermediate connector (7) between

the injector connector (8) and the computer.
99375R
To disconnect the unions, slip tool Mot. 1311-06

between the two stems (A) and (B).
Press on the tool to lift the two retaining clips,
then pull on the union.
10046R
99461R1
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DF7 Engine
FUEL SUPPLY
Injector gallery
In order to extract an injector, remove the clip

(9), then press on the fastener (10) before pulling
on the injector.
13
REFITTING
Replace the O rings at the base of the injector (if

the injector has been removed, also replace the
seal which is level with the injector head).
To ensure that the fuel supply unions are correctly fastened, it is necessary to hear a"click" whilst
fastening.
For all other operations, refitting is the reverse of
removal .
10047R
PRC13.1
13-4
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E7J Engine
FUEL SUPPLY
Injector gallery
IMPORTANT: during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
13
In order to remove an injector, remove the clips at

(8), then pull on the injector .
REMOVAL

Remove the air filter.
Remove:
the fuel supply pipe (1)
the fuel return pipe (2)
the fuel pressure regulator pipe (3) .
Remove the three bolts (4) mounting the injector
gallery (5).
99373R
Remove the injector gallery.

REFITTING
Replace the O rings at the base of the injector (if

the injector has been removed, also replace the
seal which is level with the injector head).
To ensure that the fuel supply unions are correctly fastened, it is necessary to hear a"click" sound
whilst fastening.
removal .
13244R
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FUEL SUPPLY
Fuel filter
Petrol
engines
13
Mot. 1265
Pliers for removing quick release

unions
LOCATION
The fuel filter is located under the vehicle, in

front of the fuel tank.
96420R3
Remove bolt (3) and remove the fuel filter.

REFITTING
99214R
REPLACEMENT
Observe the flow direction of the fuel (marked by

an arrow on the filter).
It is recommended to replace the fuel filter at

each vehicle major service.
Reconnect the pipes by hand (tool Mot. 1265 is

not required ).
IMPORTANT : during the opening of the fuel circuit , be sure to use a cloth to avoid possible projections of fuel due to the residual pressure.
Ensure that the quick release unions are correctly

fastened .
Refit the safety clips (1).
REMOVAL
Before removing the filter take precautions to

catch fuel that will run out of the pipes (the pipes
should not be clamped as they would be damaged).
Remove the clips (1).
Disconnect the pipes fitted with quick release
unions (2) using tool Mot. 1265.
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FUEL SUPPLY
Pump flow
Petrol
engines
13
Mot. 1265

unions
EQUIPMENT REQUIRED
2 000 ml measuring cylinder
It is advised to check the pump supply flow

through the fuel return pipe connected to the
pump-fuel sender unit assembly.
CHECKING THE PUMP FLOW
Disconnect the fuel return pipe (1) (Mot. 1265).

Connect a piece of pipe to the hose and place this
into a 0-2 000 ml graduated measuring cylinder.
Shunt terminals (3) and (5) of relay (K) on the DF7
engine, or for the E7J engine shunt at (L) on the
fuel pump relay (which is located in the engine
fuse box ). In one minute, the pump flow must be
a minimum of 1.3 litres with a voltage of 12
volts.
96093R2
IMPORTANT
During this operation, it is essential :

to refrain from smoking and handling incandescent objects close to the working area,
to take precautions against possible fuel
projections which may occur due to the residual pressure in the supply pipes when they
are removed.
12839S
If the fuel flow is low, check the pump feed voltage (approximately 10 % reduction in flow for a
voltage drop of 1 Volt)
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FUEL SUPPLY
Fuel pressure
DF7 Engine
13
CHECKING THE FUEL PRESSURE

Mot. 1311-01
Mot. 1311-05
Mot. 1311-06
Fuel pressure test kit (with a pressure

gauge 0; + 10 bar tool kit)
Junction tool (for union K)
Tool for removing fuel supply unions
Disconnect the fuel supply pipe using the tool

Mot. 1311-06 with the largest section (see method
described in section 13 "Injector gallery").
99375R
Connect tool Mot. 1311-05 to the injector gallery,

then reconnect the fuel supply pipe to the tool
itself.
99939S
99934R1
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DF7 Engine
FUEL SUPPLY
Fuel pressure
13
Connect pressure gauge 0 ; 10 bars along with

the flexible hose, Mot. 1311-01.
99938-1R
Shunt terminals (3) and (5) on the pump relay (K) ,

which is situated in the engine fuse box.
12839S
The pressure must be 3 bars 0,2.

By applying a pressure of 500 mbars to the
pressure regulator, a fuel pressure of 2.5 bars
0.2 should be obtained.
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FUEL SUPPLY
Fuel pressure
EF7 Engine
13
CHECKING THE FUEL PRESSURE

Mot. 1311-01
Mot. 1311-05
Fuel pressure test kit (with a pressure

gauge 0; + 10 bar tool kit)
Junction tool (for union J)
Disconnect the fuel supply pipe.

Fit tool Mot. 1311-04 on the injector gallery, then
reconnect the fuel supply pipe to the tool itself.
13244-1R
99376R
Connect the pressure gauge 0; + 10 bars with

the flexible pipe Mot. 1311-01.
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E7J Engine
FUEL SUPPLY
Fuel pressure
13
Shunt terminals (3) and(5) of the fuel pump relay

(L) located in the engine fuse box .
12839S
The pressure must be 3 bars 0.2.

By applying a pressure of 500 mbars to the
pressure regulator, a fuel pressure of 2.5 bars
0.2 should be obtained.
13-11
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FUEL SUPPLY
Antipercolation device
E7J Engine
13
When the ignition is switched off, the coolant temperature monitoring mode begins.
Monitoring mode
no
Water temperature 101C
yes
High speed cooling fan assembly command
no
Cooling fan assembly control time

10 minutes
Coolant temperature 96C

yes
yes
Cooling fan assembly stops
Exit from monitoring mode
The monitoring mode is left 2 minutes after switching off the ignition in cases where the coolant
temperature is not greater than or equal to 101C or once the coolant temperature falls below 92C.
13-12
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no
DIESEL EQUIPMENT
General
13
The use of electronic injection in Diesel engines has allowed the operational power of these engines to be
optimised, thus reducing the emission rate of pollutant gases.
The system consists of a computer, which receives information from:
- the coolant temperature sensor,
- the air temperature sensor,
- the engine speed sensor,
- the vehicle speed sensor,
- the load potentiometer,
- the injection start sensor, which forms part of the injector of cylinder n 3 (injector with sensor).
It controls :
- the injection pump :
the altimetric corrector (F8Q 630) via a relay
the advance solenoid valve.
- the cold engine starting system (heater plugs and pre-postheating unit),
- the exhaust gas recycling system (EGR),
- the diesel injection fault warning light,
- the preheating warning light,
- the solenoid valve controlling the fast idle speed LDA,
- the relay controlling the power assisted steering electric pump assembly (for vehicles with air conditioning), the pump assembly is supplied once the engine speed exceeds 650 rpm.
It carries out a self diagnosis procedure which may be visualised through the XR25 .
SPECIAL FEATURES
On the injection pump it is possible to replace:

- the load potentiometer,
- the advance solenoid valve,
- the altimetric corrector,
- the electrical solenoid.
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DIESEL EQUIPMENT
Specifications
13
Engine
Vehicles
Gearbox
Type Suffix
Bore
(mm)
Stroke
(mm)
Capacity
(cm 3)
Ratio
Catalytic
converter
Depollution
standard
XC0D
JB
F8Q
662
80
93
1 870
21.5/1
C67
EU96
XC0E
JB
F8Q
630
80
93
1 870
21.5/1
C67
EU96
ENGINE SPEED (rpm)
Vehicles
Idle speed
SMOKE OPACITY
no load
maximum
full load
maximum
Homologation value
Legal maximum
XC0D
825 50
4 600 100
4 100 100
1.05 m -1 (35 %)
2.5 m
-1
(64 %)
XC0E
825 50
4 600 100
4 100 100
1.11 m -1 (36 %)
2.5 m
-1
(64 %)
Siemens CTN type
Resistance in Ohms
Siemens CTN type
Resistance in Ohms
20
40
80
90
7470 to
11970
3060 to 4045
1315 to 1600
3060 to 4045
1315 to 1600
300 to 370
210 to 270
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DIESEL EQUIPMENT
Specifications
DESCRIPTION
Computer
Injection
Injection pump
MAKE/TYPE
SPECIAL NOTES
LUCAS
25 track (in case of computer replacement,

programme the new computer to memorise the
full load position of the load potentiometer)
Indirect
LUCAS DIESEL
8448B171 A/231A
(F8Q 630)
8448B152 B/241B
(F8Q 662)
Pump setting (obtain TDC
point using 8 mm pin)
Injector holders
13
Rotary pump fitted with :

- an advance solenoid valve,
- an altimetric corrector (F8Q 630).
Dimension ( X ) on pump
LUCAS DIESEL
LCR 6735 405
Tightening torque: 7 daN.m (injector on injector

holder and injector holder on cylinder head )
Holder for injector with sensor

(needle lift)
LUCAS DIESEL
LDCR020011AA1

Resistance 105
Injectors
LUCAS DIESEL
RDN OSDC 6902
Opening pressure : +5
- 5 130 bars
Maximum pressure difference: 8 bars
EGR solenoid valve
Voltage: 12 volts
Resistance : 46 5
Injector pipes
interior : 2.5 mm
Length: 330 5 mm
Preheating relay housing
With pre-postheating function (command

controlled by the computer)
Plugs
BERU
Pencil type plug
Resistance : 0.8
TDC sensor
Resistance : 220
Fast idle solenoid valve
Voltage: 12 V
Resistance : 46
Advance corrector
Voltage: 12 V
Resistance : 11.5
Load potentiometer
Voltage : 5 V
Resistance : (in K , approximately )
Track
(10 track connector)
5-4
3-4
3-5
Fault finding
no load
full load
4.5
5.6
2.8
4.5
2.8
5.6
Voltage : 12 V
Resistance : 15.5
Fiche n 43
Code D34
Selector S8
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DIESEL EQUIPMENT
13
12874
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EGR valve and solenoid valve

Air temperature sensor (white connector)
Coolant temperature sensor (white connector)
Diesel injection computer
Fuel filter
Pre-postheating plug relay housing
TDC sensor
Fast idle solenoid valve
Electrical solenoid / coded solenoid
Digital DPC injection pump
Load potentiometer
Injector with sensor (needle lift)
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DIESEL EQUIPMENT
12
14
13
11
9
8

Injector with sensor
Load potentiometer
Electrical solenoid / coded solenoid valve
Idle speed solenoid valve
3
2
13

12872R
19
EGR solenoid valve
12869-1R
6
5
16
4
Pre-postheating plug relay housing

Fuel filter
Inertia switch
Injection computer
12871R
13083R
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DIESEL EQUIPMENT
20
13
EGR valve
87970R
17
18
Diesel injection fault warning light

Preheating warning light
Warning light illuminates when ignition is
switched on during preheating phase.
13047-1R
Engine speed sensor
13048R
12839S
C Power assisted steering pump assembly relay

H Altimetric corrector relay
L Injection locking relay
M Diesel heating relay
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DIESEL EQUIPMENT
Advance solenoid valve (1)
13
10314-1R
Mot. 997-01
Tool for removing injector and

advance solenoid valve
REMOVAL
Disconnect the electrical connector from the

pump.
Remove the two terminal connectors for the advance solenoid from the 10 track pump connector.
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DIESEL EQUIPMENT
13
13342R
To remove the terminals from the pump

connector :
Remove the protective sheath grouping the pump

actuators.
1) Pull the yellow guide to release the terminal

connectors, then press on the two tabs on
each side of the connector.
Remove the protective cover from the solenoid

valve.
Remove the solenoid valve using tool Mot. 99701.
2) Extract the yellow guide.

3) Pull the wire to be removed.
4) The terminal connector is secured by two
tabs, one on each side ; using a screwdriver,
move one of these to one side (the action of
pulling on the wire prevents the tab from
going back into place).
5) Using a screwdriver, move the other tab to
one side.
The terminal connector can now be removed from
the connector.
10579R1
Passage of connector
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DIESEL EQUIPMENT
13
Bleed the diesel circuit using the priming pump

before starting the engine.
REFITTING
It is VITAL to remove the small filter (3) situated at

the bottom of the system, using a pair of thinnose pliers, and replace with a new filter.
It is IMPERATIVE to erase the computer memory

by pressing G0**.
The outer part serves as a seal and locks on

tightening the actuator.
It is vital to road test the vehicle after the

operation.
Replace, in the following order : the seal at (4) of

the "banjo" return connection (5) ; the new
activator (1) fitted with an external filter, along
with the the two seals at (6) and (7).
Tighten the actuator to a torque of 3 daN.m
using socket Mot. 997-01.
Place the new protective cover (2)on the actuator.
Reconnect the two terminals to the connector.
Reconnect the connector itself.
Replace the protective sheath on the wiring,
along with the retaining clip.
ITB191917
13127R
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F8Q 662
DIESEL EQUIPMENT
13
13129R
Mot. 997-01
Mot. 1140
Tool for removing injector

Tool for removing altimetric
corrector
REMOVAL
Remove the high pressure pipes.

Remove the injector with sensor(cylinder n 3),
using tool Mot. 997-01.
Remove the electrical connector from the pump.
Remove the two terminals for the altimetric corrector from the 10 track pump connector.
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F8Q 662
DIESEL EQUIPMENT
13
13342R
To remove the terminals for the pump

connector:
Remove the protective sheath grouping the pump

actuators.
1) Pull the yellow guide to release it from the

terminals, then press the two tabs on either
side of the connector.
Remove the protective cover from the solenoid

valve.
Remove the altimetric corrector (1) using tool
Mot. 1440.
2) Extract the yellow guide.

3) Pull the wire to be removed.
4) The terminal is held in place by two small tabs,
one on each side; using a screwdriver, move
one of the tabs to one side (the action of
pulling on the wire prevents the tab from
going back into place.
5) Using a screwdriver move the other tab to one
side.
The terminal may now be removed from the
connector.
10579R2
Connector passage
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F8Q 662
DIESEL EQUIPMENT
13
REFITTING
Reconnect the connector.
It is VITAL to remove the small filter (2) situated at

the bottom of the system using a pair of thin nosed pliers, and replace it with a new one.
Replace the protective sheath on the wiring,

along with the retaining clip.
Bleed the diesel circuit using the priming pump
before starting the engine.
Tighten the actuator (1) to a torque of 3 daN.m

using the socket Mot. 1440.
It is IMPERATIVE to erase the computer memory

by pressing G0**.
Place a new protective cover on the actuator.

Reconnect the two terminals to the connector.
It is vital to road test the vehicle after this

operation.
13128R
FUNCTION : it acts on the flow in proportion to altitude ; if the vehicle is running at

an altitude greater than or equal to 1 000 metres, the computer reduces the flow by
3 mm3/stroke. The conventional flow is reestablished if the vehicle runs at an altitude lower than 900 metres.
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DIESEL EQUIPMENT
Fast idle speed LDA
13
REFITTING AND ADJUSTING THE LDA
Fit the LDA (1) on the rear fitting of the injection

pump (2).
Clip the retaining clip (3) onto the LDA.
13043R
Fit the cable stop (4) on the cable.

Position the cable grip on the cable; the
dimension X must be 2 mm 1. Tighten the
cable grip nut.
13044R
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DIESEL EQUIPMENT
13
10314R3
10713R1
10315R2
99780-1R
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DIESEL EQUIPMENT
On this type of vehicle, the replacement of the
solenoid valve and of the coded electronic unit (A)
requires the removal of the injection pump from
the engine.
REMOVAL
With the pump on the bench, remove the protective fittings at (B).
These are secured by shear bolts which may be removed either :
- using a small cold chisel or a punch and hitting
on the conical heads of bolts (C), (D) and (E)
to loosen them,
- using tool Mot. 1372 for bolt (F), drilling it
using the 4 mm diameter drill (drilling depth
approximately 4 mm) and the large diameter
drilling guide tube on the fitting side (2).
Use extractor (3) and its handle to remove it .
REFITTING
Tighten the fuel cut off solenoid valve to a torque

of 2 daN.m.
Refit a heat shrink cover on the fuel cut off solenoid, ensuring the wiring is correctly routed.
Refit the fittings using shear bolts and observing
their location and that of the spacers,
(depending on fitting).
IMPORTANT : using a torque wrench, tighten the
bolts, then remove the bolt heads by bending
them using a tube inserted in the bolt heads.
Location of bolts :
D
: 5 x 25 mm ; torque = 0.55 daN.m
C and F : 6 x 40 mm ; torque =
E
: 5 x 33 mm ; torque =
1.2
daN.m
0.55 daN.m
Refit the cable of the fast idle speed LDA and

tighten the cable grip, leaving 2 mm play.
Refit the injection pump on the engine.
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13
DIESEL EQUIPMENT
Load potentiometer
13
In the factory, vehicles are programmed with the full load position. (memorising the voltage delivered by the
potentiometer in the full load position). This value is used to adjust the load potentiometer after it has been
replaced. It is therefore essential, if the diesel injection computer has to be replaced during the vehicles lifetime , to carry out this programming (G31*).
If it is necessary to replace the load potentiometer, in order to adjust it we compare the voltage delivered by
the potentiometer in full load position, with the value memorised. The new potentiometer is said to be correctly adjusted when the two voltages are equal. This is displayed on the XR25. G32* indicates the difference in voltage between the value memorised and the one from the potentiometer. The adjustment is correct if this value is equal to 0 in the full load position.
The potentiometer and the computer cannot be replaced at the same time (if necessary, replace the potentiometer first and then the computer).
REPLACEMENT OF THE LOAD POTENTIOMETER (operation to be carried out by two people)
Remove the three terminals for the load potentiometer from the 10 track pump connector (see method
described in section 13 "Advance solenoid valve").
Remove the two bolts mounting the faulty potentiometer, extract this, and fit the new potentiometer .
Hand tighten the two bolts mounting the potentiometer but do not lock them - it should be possible to turn
the potentiometer body .
Connect the XR25, and switch on the ignition.
Set the selector to S8.
Enter code
then
Press down on the accelerator pedal (full load position). Do not act directly on the load lever.
Holding the full load position, turn the potentiometer body until the value 0 appears on the XR25 display (if
you are too far from the 0 value, the screen will display HL , which means "Hors Limite"= "Off limits". Just
to turn the potentiometer body to obtain the display of a decimal value).
Tighten the two bolts mounting the potentiometer in the full load position, when the value read is 0.
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DIESEL EQUIPMENT
PROGRAMMING
13
THE FULL LOAD POSITION

Carry out the programming of the full load position; in order to do this :
Connect the XR25 .
Set the selector to S8.
Enter code
Enter code
When the display flashes "PF", press the accelerator pedal down as far as it will go.
The programming is complete when
the screen displays the following
wording:
then
Bargraph N.12 on the right hand side should now be extinguished.

DPCN LUCAS injection computers are configured before sale to "with air conditioning". If the vehicle is not
fitted with an air conditioning system, use command G50*4* on the XR25 to carry out the "no air conditioning " programming.
DPCN LUCAS "injection computers are configured before sale to "with power assisted steering " (power assisted steering with pump assembly). If the vehicle is not fitted with a power assisted steering pump assembly, use command G50*9* on the XR25 to carry out the "no power assisted steering pump assembly"
programming.
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DIESEL EQUIPMENT
13
COMPUTER CONFIGURATION IN RELATION TO AIR CONDITIONING.
For vehicles equipped with air conditioning , enter G50*3* on the X R 2 5

For vehicles without air conditioning ,
enter G50*4* on the XR25 .
COMPUTER CONFIGURATION IN RELATION TO THE PAS (POWER ASSISTED STEERING PUMP ASSEMBLY)
The vehicle may have two types of PAS assembly :

- a PAS assembly including a high pressure pump driven by a belt. In this case, the computer must be
configured without PAS : enter G50*9* on the XR25 ,
- a PAS assembly with a pump assembly which is driven electrically and controlled by the injection computer. ( this type of PAS is fitted in all vehicles which are also equipped with AC). In this case, the computer
must be configured with PAS : enter G50*8* on the XR25.
IMPORTANT : according to the above explanations, only two types of combination are possible for the illumination of bargraphs 18 and 19.
Vehicle with AC
and PAS pump assembly
Vehicle without AC and PAS pump assembly

(with conventional PAS)
18
18
CA
19
19
DA
NOTE : if the computer has been replaced, remember to carry out the programming of the load potentiometer full load position (see "Load potentiometer " section ).
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DIESEL EQUIPMENT
Injector with sensor (needle lift)
13
PRM1315
1
2
3
4
5
Plunger rod
Spacer
Injector
Spring
Winding
The needle lift sensor is integrated to the injector

holder (cylinder n 3). Its function is to transmit
the movements of the injector needle to the
computer. This allows the start of injection to be
deduced. The computer processes this information and uses it to compare the advance requested to the advance corrector on the pump to the
advance actually applied . In this way, the system
works as a closed loop.
Tooling required for the removal of the injector :
Mot. 997-01.
Tightening torque: 7 daN.m.
NOTE : it is possible to modify tool Mot. 997 by
milling the socket at (A), through which passes
the connector of the injector with sensor (B).
10579R1
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DIESEL EQUIPMENT
Injection warning light
13
OPERATING PRINCIPLE OF THE DIESEL INJECTION WARNING LIGHT ON THE INSTRUMENT PANEL
On switching on the ignition, the diesel injection fault warning light is illuminated.
gine begins to run.
Fault in a component of the injection assembly
Faults in the following components may cause the warning light to illuminate :
- injector with sensor
- advance solenoid valve,
- engine speed sensor ,
- load lever potentiometer,
- pre-postheating (according to version).
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It extinguishes as the en-
DIESEL EQUIPMENT
The pre-postheating function is controlled by the
computer, which controls the preheating plug relay housing.
13
b) Fixed preheating
After the preheating warning light has
extinguished (variable preheating), the
plugs remain fed for 8 seconds before the
engine is started.
1) Ignition - Preheating
The preheating process is divided in two
phases :
2) Starting the engine

During the action of the starter motor, the
four plugs are fed continuously.
a) Variable preheating
This is dependent on the coolant temperature, on the battery voltage and on altitude (internal computer sensor) when the
ignition is switched on (the preheating
warning light illuminates).
3) Engine running - Postheating

The postheating also may be divided in two
phases:
a) Fixed postheating
13041S
After starting the engine, the plugs are

supplied simultaneously for a period of 10
seconds.
b) Variable postheating
Variable postheating begins when fixed
postheating ends. The time during which
the plugs are fed (continuously) depends
upon :
- the coolant temperature
- the engine speed ,
- the load (load potentiometer on pump
lever ).
Maximum preheating limit (battery voltage lower than 9.3 volts and altitude higher than 2 000 m).
Minimum preheating limit (battery
voltage greater than 10.5 volts altitude
lower than 350 m).
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DIESEL EQUIPMENT
13
time (s)
For an idle speed and load lever
position
180
- 20
20
40
60
Coolant temperature C
Variable postheating may be interrupted :

- permanently, if the coolant temperature is >
60C,
- temporarily , if the unit receives full load
information for more than 3 seconds; the
function is established once again if the
engine returns to idle speed or low load,
- temporarily again if the battery voltage is
>16 V; the function is restored if Ubatt
< 15 V.
In all cases, the total duration of the postheating
function will never exceed 3 minutes.
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DIESEL EQUIPMENT
Fast idle speed control
The fast idle speed function is controlled by the
computer via a solenoid valve operating the diaphragm (versions with or without air conditioning).
The fast idle speed control becomes operational :
- if, on switching on the ignition, the coolant
temperature is below 10C,
F8Q 662
Coolant
Fast idle speed
temperature
cut-off
on switching
temperature
ignition on (C)
(C)
10
5
0
- 10
- 20
-
F8Q 630
Fast idle speed
cut-off
temperature
(C)
20
20
30
40
50
11
15
20
25
30
if the engine speed falls to 650 rpm and the

vehicle speed is lower than 15 mph (25 km/h)
(engine start improvement programming).
The fast idle speed is cut off once the speed
becomes > 850 rpm
NOTE :
- Fast idle speed operational :
solenoid valve not operated,
cable loose, and not tensioned.
- Nominal idle sped :
solenoid valve operated
cable tensioned
SPECIAL FEATURES : once the AC has been
selected on the instrument panel, the fast idle
speed function is activated.
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13
DIESEL EQUIPMENT
Injection/air conditioning programming
13
CONNECTION BETWEEN AIR CONDITIONING ASSEMBLY AND INJECTION COMPUTER
The electrical connection :

- from the air conditioning computer to the diesel injection computer consists of one wire. This track only
carries the information that the AC is operating. From this, the diesel injection computer deduces the AC
selection information : track 11,
- from the diesel injection computer to the air conditioning computer consists of one wire. This track
carries all information regarding authorising and preventing operation of the compressor : track 19.
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the diesel injection computer stops the compressor from functioning.
Engine start programming
After the engine has started running, the compressor is prevented from functioning for 3 seconds.
Performance return programming
If the full load position is detected, the AC compressor is prevented from functioning for 8 seconds.
Stalling prevention programming
If the engine speed is lower than 650 rpm., the compressor is automatically cut off. It will only be allowed to
function again if the engine speed exceeds 775 rpm.
13-36
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DIESEL EQUIPMENT
Computer
13
CONNECTION
PRM1316
1 -<-
Computer supply
14-->-
Plug relay control
2 -----
Computer earth
15 -->-
Altimetric corrector relay control
3 -----
Sensor earth
16 -->-
Fast idle speed control
4 -->-
Potentiometer lever supply
17 -->-
Load lever position information
5 -->-
EGR solenoid control
18 -->-
Fault finding warning light control
6 -->-
Advance corrector control
19 -->-
AC prevention control
7 -<--
Needle lift signal
20 -->-
8 -<--
Engine speed signal
Power assisted steering pump assembly

relay control
9 -->-
Preheating warning light control
21 -----
10 -<--
Fault finding information line L
22
Not used
11 -<--
AC status
23 -<--
Load lever signal
12 -<--
Vehicle speed signal
24 -<--
Air temperature signal
13 -><-
Fault finding information line K
25 -<--
Coolant temperature signal
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DIESEL EQUIPMENT
Defect modes
13
If there is a fault with one of the components listed below, the computer enters "defect mode", which means
that replacement values are used to ensure engine operation.
Set values (for replacement)
Faulty
component
Advance
corrector
Coolant sensor
Running time
function
Air sensor
Temperature
= 22C
Pre-postheating
time
EGR function
Fast idle speed
AC function
Cut
Running time
function
Cut
Cut
20 % load lever
position
Preheating : 30C
Postheating :
80C
Postheating:
30 % load lever
position
Load
potentiometer
100 % load lever

position
Altitude sensor
Altitude
= 900 m
Altitude
= 900 m
Cut
Battery
16 V < U < 6 V
Ubatt = 13.5V
Not controlled
TDC sensor
Minimum
advance
Solenoid valve
fully open
position
Cut
Speed
= 2 000 rpm
Speed
= 2 000 rpm
Needle lift
sensor
Defect mode
advance
(Carto soft
F8Q 662)
Maximum
advance
(F8Q 630)
Vehicle speed
sensor
Position :
V = 175 km/h
Position :
V = 175 km/h
Position :
V = 175 km/h
Heater plugs
relay housing
Cut
Postheating :
Not controlled
until ignition is
switched off
then on again
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DIESEL EQUIPMENT
Pump
13
Mot. 1054
TDC pin
Mot. 1200
Pump-pulley retaining tool
Mot. 1317
Nut mounting the pump shaft

to the RAM pulley
Pump mounting bolt
4.5
2.2
Pin the engine using tool Mot. 1054. For this

operation, turn the engine so that the index of
the camshaft sprocket is in line with the marking
on the timing cover (use a mirror).
REMOVAL
Disconnect the battery. Then remove :

-
the suspended engine mounting housing (1),

the injection pump pulley housing (2).
99183R
DI1302-1
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DIESEL EQUIPMENT
Pump
Remove :
- the fuel supply pipe (A),
- the fuel return pipe (B),
- the pump connector (C),
- the accelerator cable (D),
- the vacuum pipe (E) connected to the fast
idle speed LDA,
- the high pressure wiring loom using tool Mot.
1383,
13
Fit tool Mot. 1200 or Mot. 1317 , for retaining the

pump pulley.
12410R
Inserting a torx screwdriver in the gaps of the

RAM pulley, slacken:
the three bolts mounting the pump
- the central nut securing the pump shaft to the
RAM pulley.
10578R
Slacken the central nut and all three of the bolts

mounting the pump until they are completely
free.
the rear support mounting bolt.
Extract the pump.

REFITTING
Clean the pump shaft very thoroughly, using solvent to eliminate all trace of grease.
Refit the pump.
Tighten the three bolts mounting the pump .
Pretighten the central nut of the pump to 2
daN.m.
IMPORTANT : it is vital to carry out a pretightening operation before the final tightening; tighten the central pump nut to a torque of 4.5
daN.m.
Carry out the timing operations (see "Pump Timing").
12869R

removal.
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DIESEL EQUIPMENT
Pump - Timing
13
Mot.
Mot.
Mot.
Mot.
Mot.
Mot.
1054
1079
1200
1317
135
1359
TDC pin
LUCAS pump timing kit

Pump-pulley retaining tool
Set of tools for operations on a
RAM pulley (micrometric adjustment)
RAM pulley nut (adjustment locking)
IMPORTANT : the engine must only be rotated by

turning a wheel, in 5th gear, and in its operating
direction; if it is accidentally turned in the
opposite direction, repeat the operations for
checking and adjusting the timing.
CHECKING THE SETTING OF INJECTION PUMPS
FITTED WITH RAM PULLEYS
Turn the engine twice in the operating direction

(moving one wheel and having engaged 5th
gear).
Remove the timing shaft plug situated on the
pump cover.
Fit tool Mot. 1079 and zero the dial gauge on
pump cam "rest" zone (this operation will be
made easier by turning the engine in its operating
direction).
91258R2
NOTE : in order to obtain a precise adjustment,

and to avoid bringing the dial gauge to its limit, it
is advisable to adjust it to 1 mm.
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DIESEL EQUIPMENT
Pump - Timing
-
Components of tool Mot. 1079

A
B
C
13
Fit the pin, tool Mot. 1054.
Timing pin
Dial gauge support
30 mm dial gauge
12419R
Keep a constant pressure on the pin.
Turn the engine slowly until the pin

penetrates into the slot in the crankshaft .
Turn the engine in its operating direction (clockwise from timing end).
Check the pump piston lift, which may be read

on the dial gauge.
Locate the spot on the camshaft pulley where

the reference mark will appear .
The value is marked on the load

potentiometer lever.
If the value is incorrect, adjust the timing (see

following method).
91285R
Lock the engine using tool Mot. 1054, according

to the following procedure :
-
- Stop the engine from turning half a tooth

fore the two reference marks align.
be-
DI1303-1
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DIESEL EQUIPMENT
Pump - Timing
MODIFICATION OF TOOL
13
IMPORTANT : slightly loosen the bolt (1) using

tool Mot. 1359 (take care - left hand thread) so
that the flange (B) can rotate freely.
Mot. 1358
For the adjustment of H T D 2 pullies, carry out the

following modification:
File down the three brackets on the tool by 1.5
mm.
98694R2
12275S
TIMING ADJUSTMENT OF INJECTION PUMPS

FITTED WITH RAM PULLEYS
Remove the the RAM pulley protective cover.

Fit tool Mot. 1317 or Mot. 1200 to immobilise the
pulley.
12411R
12338R
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DIESEL EQUIPMENT
Pump - Timing
13
Fit tool Mot. 1358 into the three openings of

flange (B).
Turn the tool - flange assembly so that the three
pins of the tool fit into the three slots in the adjusting ring bolt.
91258R2
Components of tool Mot. 1079
12312R2
A
B
C
Turn the tool-flange assembly clockwise until tool

Mot. 1358 locks, thus allowing the pulley to be
placed at the start of timing position .
Timing pin
Dial gauge support
30 mm dial gauge
Remove the immobilising tool Mot. 1317 or

Mot. 1200.
Turn the engine twice in its operating direction
(moving one wheel and having engaged 5th
gear).
Fit tool Mot. 1079 and zero the dial gauge on
the pump cam "rest" zone (this operation will be
made easier by turning the engine in its operating
direction).
NOTE : in order to obtain a precise adjustment,
and to avoid bringing the dial gauge to its limit, it
is advisable to adjust it to 1 mm.
91285R
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DIESEL EQUIPMENT
Pump - Timing
13
Lock the engine using tool Mot. 1054, according

to the following procedure :
Keep a constant pressure on the pin.
Turn the engine in its operating direction (clockwise from timing end).
Turn the engine slowly until the pin

penetrates in the slot in the crankshaft.
Locate the spot on the camshaft pulley where

the reference mark will appear .
- Using tool Mot. 1358, set the timing,

turning the tool anticlockwise until the timing
value is obtained.
- Stop the engine from turning half a tooth

before the two reference marks align.
- The value is marked on the load lever.

NOTE : if the timing value is exceeded during
adjustment, bring the engine back by one
revolution , to recuperate the play using tool
Mot. 1358 , then repeat the previous timing
phase.
Leave pin Mot. 1054 in place.

Slightly pretighten bolt (1) using tool Mot. 1359,
to a torque not exceeding 2 daN.m (left hand
thread).
IMPORTANT : the torque wrench used for this
operation must operate to the left .
Remove the pin Mot. 1054.
Fit tool Mot. 1377 or 1200 to immobilise the
pulley.
DI1303-1
Turn the engine by hand anticlockwise to bring

the locking tool into contact with the pulley.
Fit pin Mot. 1054.
Tighten bolt (1) to a torque of 9 daN.m, using

tool Mot. 1359.
Turn the engine over twice and check the pump
timing once again.
12419R
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DIESEL EQUIPMENT
Adjusting idle speed
It is vital to make these adjustments when the engine is warm, and after the engine cooling fan
has operated at least twice.
IDLE SPEED AND RESIDUAL FLOW

(anti-stalling)
13
ADJUSTMENT
a) Ensure that the fast idle speed function is not

operational .
b) Adjust the idle speed to 825 25 rpm. using
screw (1).
c)
Place a 4 mm shim between the load lever (2)

and the residual flow screw (3).
d) Adjust the engine speed to 1 250 50 rpm.

using the residual flow screw (3).
e) Remove the 4 mm shim then accelerate
sharply twice.
f)
The idle speed adjustment and anti-stalling

function adjustment must be carried out
correctly, since these operations directly
influence the behaviour of the engine at idle
speed and in the deceleration phase (hesitation
idle speed lasts too long, etc.).
12870R
1
2
3
4
5
Check the conformity of the idle speed; if

necessary, repeat the idle speed adjustment
and check the residual flow once more.
Idle speed adjustment screw

Load lever
Residual flow adjustment screw (anti-stalling
function)
Fast idle lever
Idle speed cable grip
FAST IDLE SPEED
Without applying a vacuum to the LDA, position

the cable grip (5) at 2 1 mm from the fast idle
speed lever (4).
NOTE : the fast idle speed value is not directly adjustable; it is adjusted on the injection unit.
CHECKING THE MAXIMUM SPEED
Whilst the engine is warm, accelerate to full load ;

the engine speed must be between 4 500 and
4 700 rpm (this adjustment can only be carried
out in a Renault Injection Centre workshop).
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Petrol
engine
ANTIPOLLUTION
Test for the presence of lead
14
This test can only be carried out using a lead testing kit supplied by NAUDER.
To obtain a testing kit, contact your local After Sales Head Office.
Part numbers :
- Complete kit : T900

- 40 test papers : T900/1
93703S
METHOD
a - Test conditions :
- Engine stationary.
- Exhaust pipes warm.
- Do not test when the temperature is below 0C.
b - If necessary use a soft cloth to clean the inside of the exhaust pipe so any soot deposits are removed.
c - Wearing the gloves, take a test paper and moisten it slightly with distilled water (the paper is not
effective if it is too wet).
d - Press the damp paper onto the cleaned exhaust pipe immediately and hold it there firmly for about a
minute.
e - Remove the test paper and allow to dry. The test paper will turn red or pink if lead is present.
IMPORTANT : The test for lead should only be carried out on the exhaust pipe, never on the oxygen
sensor.
14-1
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ANTIPOLLUTION
D7F Engine
14
OPERATING DIAGRAM OF THE CIRCUIT
99933R
1
2
3
4
R
Inlet manifold
Fuel vapour absorber (canister)
RCO control solenoid valve
Cylinder head
Pipe from fuel tank
PRC14.1
14-2
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E7J Engine
ANTIPOLLUTION
14
OPERATING DIAGRAM OF THE CIRCUIT
13123R
1
2
3
4
R
Inlet manifold
RCO control solenoid
Throttle body
Pipe from fuel tank
14-3
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ANTIPOLLUTION
CONDITION FOR BLEEDING THE CANISTER
engine)
(E7J
CONDITION FOR BLEEDING THE CANISTER ( D7F

engine)
During richness regulation
Coolant temperature greater than 50C.
Air temperature greater than 15C.
No load position not recognised (if there is a fault

in the throttle potentiometer sensor, the
condition of no load position not recognised is
replaced by an engine speed condition
R > 1500 rpm.).
Coolant temperature greater than 50C.
Air temperature greater than 15C.
Full load position recognised (function of

engine speed and manifold pressure).
Coolant temperature greater than+ 15 C

Air temperature greater than +10 C.
No load position not recognised (if there is a
fault in the throttle potentiometer sensor, the
condition of no load position not recognised is
replaced by an engine speed condition
R > 1500 rpm.).
It is possible to visualise the cyclical opening ratio

for the canister bleed solenoid using the X R 2 5
and #23. The solenoid is closed if #23 = 0.7 %
Outside richness regulation
14
If there is a fault in the oxygen sensor, bleeding is

permitted outside of no load conditions.
It is possible to visualise the cyclical opening ratio
for the canister bleed solenoid using the X R 2 5
and #23. The solenoid is closed if #23 = 0.7 %
(minimum value).
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ANTIPOLLUTION
14
At idle speed connect a pressure gauge

(- 3 ; +3 bars) (Mot. 1311-01) to the "CAN" outlet
on the solenoid valve, to check there is no vacuum
(the command value read by the XR25 for #23 remains minimal X = 0.7 % ). Is there a vacuum ?
CHECKING CANISTER BLEED OPERATION
Incorrect operation of the system may cause the

idle speed to be unstable or the engine to stall.
Check the conformity of the circuit (see
operational diagrams)
YES
Ignition off, use a vacuum pump to apply a

vacuum of 500 mbars to the solenoid valve
at (C). This should not vary by more than 10
mbars in 30 seconds.
Does the pressure vary?
YES
The solenoid valve is faulty. Renew it. Air

must be blown into the pipe (A) connecting
the solenoid valve to the canister to remove
any particles of active carbon.
NO
There is an electrical fault. Check the circuit.
NO
Under bleeding conditions (not at idle

speed, engine warm), the vacuum should
increase (the value for #23 on the XR25
should also be seen to increase).
Be sure to check that the pipe marked "CAN" on

the solenoid valve is correctly connected to the
canister.
Check the condition of the pipes to the fuel tank.
97393R6
1 Inlet manifold
2 Canister bleed solenoid valve
3 Canister
4 Fuel tank
14-5
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ANTIPOLLUTION
14
LOCATION-REMOVAL OF COMPONENTS
REMOVAL OF THE FUEL VAPOUR ABSORBER (1)
CANISTER BLEED SOLENOID VALVE (1)
This is located in the front right hand wheel arch.
E7J Engine
REMOVAL
It is mounted above the inlet manifold,

underneath the cover
Disconnect the pipe connecting the canister to the

inlet manifold, from the top of the vehicle.
From the bottom, remove the wheel arch .
Disconnect the pipe at (2) connecting the
canister to the fuel tank.
Remove the three bolts at (3) mounting the
canister (1) then extract it.
13242R2
D7F Engine
It is mounted at the front, on the lifting bracket.
13049R
99939-1R3
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D7F Engine
ANTIPOLLUTION
14
CIRCUIT DIAGRAM
99932R
1
2
3
4
5
6
Cylinder head cover

Inlet manifold
Oil vapour rebreathing pipe connected upstream from the throttle body (the circuit is used
for medium and high loads)
Oil vapour rebreathing pipe connected downstream from the throttle body
Air pipe
Throttle body
14-7
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D7F Engine
ANTIPOLLUTION
14
CHECKING THE CIRCUIT
To ensure the correct operation of the

antipollution system, it is important to keep the
oil vapour rebreathing system clean and in good
working condition.
PRC14.2
14-8
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ANTIPOLLUTION
E7J Engine
14
CIRCUIT DIAGRAM
13335R
1
2
3
Cylinder head
Inlet manifold
Oil vapour rebreathing pipe connected
upstream from the throttle body (the circuit is
used for medium and high loads)
Oil vapour rebreathing pipe connected
downstream from the throttle body
CHECKING
To ensure the correct operation of the

antipollution system, it is important to keep the
oil vapour rebreathing system clean and in good
working condition.
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ANTIPOLLUTION
F8Q Engine
14
13042R
1
2
3
4
Engine
Oil decanter
Air filter
Inlet manifold
14-10
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F8Q Engine
ANTIPOLLUTION
Exhaust gas recirculation (EGR)
14
13046R
1
2
3
4
5
6
7
8
9
13045R
14-11
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EGR valve
EGR solenoid (ON/OFF)
Vacuum pump
Engine
Exhaust manifold
Inlet manifold
Air filter
Injection computer
F8Q Engine
ANTIPOLLUTION
To remove the EGR solenoid (2), remove the air
filter .
12871R1
To remove the EGR valve (1), remove the air filter

first, and replace the seal between the solenoid
valve and the inlet manifold after each removal
operation.
13047-1R2
SPECIAL NOTES
In order to remove the steel pipe connecting the

EGR valve to the air filter, it is necessary to
remove the EGR valve .
14-12
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14
F8Q Engine
ANTIPOLLUTION
The EGR is controlled by the computer via an
ON/OFF solenoid valve.
The operation of the EGR solenoid valve is dependent upon the following parameters :
- the air temperature,
- the coolant temperature ,
- the altitude,
- the position of the load lever ,
- the vehicle speed ,
- the engine speed .
The EGR function is cut if :
- the air temperature < 16C or
- the coolant temperature < 45C or
- the engine speed/ load potentiometer value is
greater than a certain threshold .
The EGR is cut after operating at idle speed for 40
seconds (at zero vehicle speed).
Once the vehicle speed > 25 mph (40 km/h), the
EGR is operational again. It will be cut again after
40 seconds of operating at idle speed at zero vehicle speed.
XR 25 bargraph 14 RH is illuminated if the EGR
function is permitted. In order to determine if the
EGR is actually controlled, use #24. if the value is
different from 0, the EGR is activated .
14-13
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14
STARTING - CHARGING
Alternator
16
IDENTIFICATION
ENGINE
ALTERNATOR
CURRENT
D7F
DELPHI 104 802 215
80 A
E7J
VALEO
A 11 VI 87
75 A
F8Q
VALEO A 11 VI 88
75 A
CHECKING
After 15 minutes warming up at a voltage of 13.5 volts.
Engine rpm
75 amps
80 amps
1000
46
54
2000
68
75
3000
71
80
4000
72
82
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STARTING - CHARGING
Alternator
16
The customer complains of a lack of charge and

the warning light is operating correctly.
OPERATION - FAULT FINDING
These vehicles are equipped with alternators with

internal ventilation and integral regulator, also
with a warning light on the instrument panel
which has the following functions :
- when the ignition is switched on, the light illuminates
- when the engine is started the light extinguishes,
- if the light illuminates whilst the engine is
running there is a "charging "fault.
LOOKING FOR FAULTS
The warning light does not illuminate when the

ignition is switched on.
If the regulated voltage is less than 13.5 V, check

the alternator. The fault could be caused by :
- a diode which has been damaged,
- a phase which is cut,
- contaminated or worn tracks.
Checking the voltage
Connect a voltmeter across the battery terminals
and read the battery voltage.
Start the engine and increase the engine speed
until the needle registers a stable regulated
voltage.
This voltage should be between 13.5 V and 14.8 V.
Check:
- all electrical connections are good.
- the bulb has not blown. (Earth the circuit and
the bulb should illuminate).
Connect as many consumers as possible, the

regulated voltage should be between 13.5 V and
14.8 V.
The warning light illuminates when the engine is

running.
IMPORTANT : if arc welding work is to be carried

out on the vehicle, the battery and regulator
must be disconnected.
This indicates a charging fault which could be

caused by :
- the alternator drive belt being broken or the
charging wiring being cut,
- internal alternator damage (rotor, stator,
diodes or brush),
- a regulator fault,
- excess voltage.
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STARTING - CHARGING
Alternator
16
FAULT FINDING
OPTIMA 5800 Diagnostic station
CHECKING THE CHARGING CIRCUIT USING THE DIAGNOSTIC STATION
The OPTIMA 5800 diagnostic station allows the alternator to be checked by measuring the voltage and current delivered , with or without electrical consumers .
NOTE : the Amps clamp used for this station is of the inductive type (measurement range: 0 to 1 000 A). It
is fitted without disconnecting the battery, which allows the the computer memory and adaptive information to be saved.
Fit the Amps clamp directly at the alternator output, with the arrow pointing towards the alternator (any incorrect positioning is detected by the station).
The measurement is carried out in three stages :
- measurement of the battery voltage, ignition off,
- measurement of the regulated voltage and of the current supplied, without consumers,
- measurement of the regulated voltage and current supplied, with a maximum number of consumers.
On completion of the test, the values noted will lead to the following fault finding messages :
- Battery voltage, no load < 12.3 V = battery uncharged.
Without consumers :
- Regulated voltage > 14,8 V = > regulator faulty ,
- (regulated voltage, no load < 13.2 V) or (charging current< 2 A) = >charging fault.
With consumers :
- Regulated voltage > 14.8 V = > regulator faulty,
- Regulated voltage < 12.7 V = > it is necessary to check the alternator supply in relation to its specifications :
Engine
D7F
E7J
F8Q
Nominal current
70
75
75
Minimum current which the alternator must

supply, all consumers connected
53
51
55
Current (amps)
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STARTING - CHARGING
Alternator
16
FAULT FINDING (continued)
If the electrical supply measured is too low, check:

- the wear of the alternator (brush...),
- the battery connections,
- the engine earth strap,
- the conformity of the alternator,
- the belt tension.
If the electrical supply measured is correct and the regulated voltage is too low, the alternator is not faulty.
The cause of the problem is to be attributed to one of the following sources :
- the vehicle has too many electrical consumers,
- the battery is discharged.
16-4
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STARTING-CHARGING
Alternator
D7F / E7J
Engines
16
Mot. 1273
REMOVAL
E7J Engine
Place the vehicle on a two post lift .
Tension the belt using the bolt at (1) and tighten

the nut at (2) , having measured the tension.
Disconnect the battery as well as all electrical

connections leading to the alternator.
Remove :
- the alternator belt and that of the power assisted steering pump for the D7F engine (if
fitted),
- the alternator.
REFITTING

D7F Engine
Tensioning of the alternator belt is carried out
using the locally manufactured tool shown below (threaded rod 100 mm in length (X) and three
M6 nuts).
13363R
See section 07 "Accessories belt tension" for the

tension values.
10617R
16-5
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STARTING-CHARGING
Alternator
F8Q Engine
16
Mot. 1273
REMOVAL
the cross member mounting bolts and remove

it in order to remove the alternator.

Disconnect the battery as well as all electrical
connections leading the alternator.
Remove :
- the front right wheel arch,
- the alternator mountings as well as the belt,
- the support (A),
13188S
REFITTING

See section 07 "Accessories belt tension" for the
tension values.
13092R
16-6
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STARTING - CHARGING
Starter motor
IDENTIFICATION
ENGINE
STARTER MOTOR
D7F
VALEO D7 E1
Bosch 0001116001
E7J
D6 RA 73
F8Q
Bosch 0001108180
16-7
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16
STARTING - CHARGING
Starter motor
16
FAULT FINDING
OPTIMA 5800 Diagnostic station
CHECKING THE STARTER MOTOR
USING THE DIAGNOSTIC STATION
Checking of the starter motor is carried out using the OPTIMA 5800, by measuring the battery voltage and
the current absorbed in the engine starting phase. The following operation faults may be highlighted :
- a fault in the battery ( the voltage falls during the starting phase),
- locking of the starter motor (the current absorbed is too high),
- a fault in the engine starter gear (the current absorbed is too low).
In order to carry out the measurement, it is necessary to stop the vehicle from starting :
- for D7F and E7J engines : disconnect the engine speed sensor (located on the clutch housing ,
- for F8Q engines : disconnect the pump electrical solenoid and isolate the terminal.
NOTE :
- an open circuit on the engine speed sensor or the ignition creates a fault memorised by the injection
computer, this fault must then be erased from the memory using the XR25 (see " Injection" section),
- if the engine is fitted with an immobiliser, it is sufficient to lock the doors using the remote control.
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D7F Engine
STARTING - CHARGING
Starter motor
REMOVAL
Place the vehicle on a lift, and disconnect the battery.

Disconnect the starter electrical connections.
10076R
Remove the two starter mounting bolts.

REMOVAL
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16
E7J Engine
STARTING - CHARGING
Starter motor
-
REMOVAL

Remove :
- the battery,
- the injection computer mounting, after having disconnected the 55 track connector as
well as the impact switch connector,
16
the front right hand wheel ,

the driveshaft pin using punches B. Vi. 31-01,
the upper shock absorber bolt and slacken the
lower bolt.
Tilt the hub and release the driveshaft assembly

from the gearbox.
Remove the starter connections , as well as the
mounting bolts and extract these from the bottom of the vehicle.
REFITTING

Check for the presence of the centring dowel
which should be located at (B).
13088S
the mounting (1) for the power assisted steering pipe, along with the strut at (A),
13087R
13336-1R
16-10
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F8Q Engine
STARTING - CHARGING
Starter motor
16
REMOVAL

Remove:
- the air filter inlet pipe,
- the battery,
- the computer support mounting bolts as well
as the connectors at (1), then move the
computer support/ diesel filter assembly to
one side.
13087R1
the starter connections,

the starter motor itself.
REFITTING

Check for the presence of the centring dowel,
which should be located at (B).
13088R3
the starter mounting bolts and the heat shield

(A),
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IGNITION
Semi-static ignition
17
D7F Engine
PRESENTATION
The system comprises:

-
the injection computer (the ignition power

stage is integrated into the computer),
two dual output coils, (for the D7F engine,
these are moulded into one),
four spark plugs,
an anti-interference condenser (4).
DESCRIPTION - OPERATING PRINCIPLE

COMPUTER
The injection computer (120), depending on the

information received from various sensors, but
principally depending on the engine speed and
load, determines:
- the number of degrees of advance to be used
and consequently the ignition point,
- which cylinders are at TDC and consequently
the ignition coil to be operated.
99931-1R2
E7J Engine
The spark is created at the two cylinders at TDC by

cutting the earth to the coil concerned.
COILS (1)
There are two coils. They are of the dual output

type (they cannot be separated in the D7F engine ).
They are controlled separately by the computer.
They create two sparks simultaneously.
Both coils are connected to an anti-interference
condenser.
13242R
Special features of the E7J engine

The coil at (2) has a black electrical connector. It
creates a spark simultaneously at cylinders 1 and
4. It is controlled by track 28 of the injection
computer.
The coil at (3) has a grey electrical connector . It
creates a spark simultaneously at cylinders 2 and
3. It is controlled by track 29 of the injection
computer.
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IGNITION
Semi-static ignition
D7F Engine
17
D7F Engine
Electrical connector
Electrical connector
Track
Allocation
coil control for cylinders

1-4
coil control for cylinders

3-2
+anti-interference
condenser
+after ignition
coil control by
computer
Track
+after ignition
+anti-interference
condenser
Allocation
Test to be made
between tracks
Resistance
Test to be made
between tracks
Resistance
1 - 2
1.5
1 - 2
0.5
1 - 3
1 - 3
1 - 4
2 - 3
2 - 3
HT - HT
10 k
2 - 4
3 - 4
0.6
HT - HT
8 k
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IGNITION
Spark plugs
D7F/E7J
Engines
Engine
D7F
E7J
17
Make
Type
EYQUEM
NGK
RFC 50 LZ 2E
BKR 5EK
EYQUEM
CHAMPION
RFC 52 LS
RC 10 PYC
Flat skirt with seal

Gap: 0.9 mm
Tightening torque : 2.5 to 3 daN.m
D7F Engine
To disconnect the spark plug leads, use the tool (3), which is integrated to the plastic cover (4) on the cylinder head.
99894R1
99940R
NOTE : to remove the spark plugs, use the tool kit, Ele. 1382.
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D7F Engine
INJECTION
General
17
SPECIAL NOTES FOR MULTIPOINT INJECTION
35 track SAGEM or MAGNETI MARELLI computer for vehicles without options.
55 track SAGEM computer , SAFIR or MAGNETI MARELLI type
Semi-sequential multipoint injection. Injectors controlled two by two (injectors for cylinders 1 and 4 followed by injectors for cylinders 2 and 3).
Semi-static ignition with dual single unit coils.
Canister bleed solenoid valve controlled by RCO signal.
Computer configuration depending on gearbox type (manual gearbox or automatic transmission).
The maximum engine speed permitted is 6 200 rpm.
Idle speed correction depending on :

- battery voltage,
- air conditioning
- power assisted steering pressostat.
Injection warning light on instrument panel not operational.
Use fault finding fiche n 27.
for versions with air conditioning.
FITTING A 2ND GENERATION ENGINE IMMOBILISER REQUIRES A SPECIAL PROCEDURE FOR REPLACING THE
COMPUTER.
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E7J Engine
INJECTION
General
17
SPECIAL NOTES FOR MULTIPOINT INJECTION
55 track SIEMENS FENIX 5 computer.
Semi-sequential multipoint injection. Injectors are controlled two by two (injectors for cylinders 1 and 4
followed by cylinders 2 and 3).
Semi-static ignition with dual coils.
Canister bleed solenoid controlled by RCO signal.
Computer configuration depending on gearbox type (manual gearbox or automatic transmission)
Idle speed correction depending on :

- air conditioning,
- power assisted steering pressostat,
- battery voltage.
Injection warning light on instrument panel operational.
Use fault finding fiche n 27.
Maximum speed :
- 6 200 rpm if 1st , 2nd or 3rd gears
- 6 000 rpm if 4th,or 5th gears.
FITTING A 2ND GENERATION ENGINE IMMOBILISER REQUIRES A SPECIAL PROCEDURE FOR REPLACING THE
COMPUTER.
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D7F Engine
INJECTION
General
17
LOCATION OF COMPONENTS
13081
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Coil
Air filter
Oxygen sensor
Absolute pressure sensor
Throttle position potentiometer
Idle regulation stepping motor
Injection computer
Inertia switch
Locking relay
Fuel pump relay
TDC sensor
Fuel vapour recycling solenoid valve
Tool for removing spark plug leads
Pinking sensor
Power assisted steering pressostat
Pressure regulator
Anti-interference condenser
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E7J Engine
INJECTION
General
17
LOCATION OF COMPONENTS
13082
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Air filter
Pinking sensor
Idle speed regulation stepping motor
Injection computer
Inertia switch
Fuel pump relay
TDC sensor
Oxygen sensor
Coil for cylinders 2 - 3
Power assisted steering pressostat
Coil for cylinders 1 - 4
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D7F Engine
8
9
INJECTION
16 Pinking sensor
(tightening torque: 2.5 daN.m)
Injection computer
Inertia switch
13051R1
4
5
6
7
11311R1

13 Fuel vapour recycling solenoid

11313R4
99939-1R2
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17
D7F Engine
INJECTION
1 Coil
19 Anti-interference condenser
17
Oxygen sensor
(tightening torque : 5 daN.m)
99931-1R1
H Locking relay
K Fuel pump relay
12993R
17 Power assisted steering pressostat
13050R
12839S
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E7J Engine
8
9
INJECTION
Injection computer
Inertia switch
13240R
17
13239R
Pinking sensor
(tightening torque: 2.5 daN.m)
13336R
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E7J Engine
1
14
16
18
INJECTION
6 Throttle position potentiometer
11 TDC sensor

Coil for cylinders 2-3
Coil for cylinders 1-4
13242R1
4
5
7
17
13337R

13 Oxygen sensor
(tightening torque : 4.5 daN.m)
13339R
13243R
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INJECTION
E7J engine
17
15 Power assisted steering pressostat
13241R
Fan assembly relay (for versions with air

conditioning)
L Fuel pump relay
M Fan assembly relay (for versions without air
conditioning) slow speed fan assembly (with
air conditioning)
12839S
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INJECTION
Coolant temperature management
D7F Engine
17
244
Injection coolant temperature sensor and

coolant temperature indication on
instrument panel.
3 track sensor, of which two tracks are
allocated to the injection coolant
temperature information, and one to the
indication of the coolant temperature on
the instrument panel.
259
Warning coolant temperature switch for

instrument panel.
Operating principle
Sensor 244 allows :
- the coolant temperature to be shown on the
instrument panel,
- the injection computer to receive constant information on the engine coolant temperature
.
11634R2
The injection computer, depending on the coolant temperature, controls :

- the injection system,
- the cooling fan assembly.
The engine cooling fan assembly is controlled
at fast speed (both slow and fast speeds are
controlled by the air conditioning system) if
the temperature is greater than 99C. If the
temperature falls below 96C, it cuts off
automatically ( if a check has to be carried out,
ensure that the air conditioning is not operational).
E7J Engine
13239R1
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INJECTION
Injection fault warning light
17
PRINCIPLE FOR ILLUMINATION OF INJECTION FAULT WARNING LIGHT ON INSTRUMENT PANEL
Vehicles not equipped with the immobiliser function:

When the ignition is switched on, the warning light illuminates constantly for 3 seconds , then extinguishes.
Vehicles with immobiliser function deactivated:

When the ignition is switched on, the injection warning light illuminates constantly for 3 seconds and
then extinguishes.
When the doors are unlocked, the red immobiliser light, which was previously flashing, extinguishes.When ignition is switched on, it illuminates for 3 seconds , then extinguishes.
Vehicles with immobiliser function activated:

When the ignition is switched on, the computer does not recognise the code, and stops the engine from
starting. The injection warning light remains illuminated for 3 seconds and then extinguishes.
Before the ignition is switched on, the red immobiliser light flashes. On switching the ignition on, it
flashes more rapidly.
If a fault is detected in the immobiliser system whilst the engine is running, the injection warning light
flashes in the engine speed range between idle speed and 1 500 rpm approximately .
Fault in a component of the injection system

The warning light is illuminated if a fault has been detected in:
- the pressure sensor,
- the vehicle speed,
- the throttle potentiometer,
- the idle speed regulation stepping motor.
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INJECTION
Immobiliser function
17
This vehicle is fitted with a 2nd generation immobiliser system.

REPLACING THE INJECTION COMPUTER
All computers are supplied uncoded, but are capable of being programmed with a code.
When replacing the computer, the vehicle code must be programmed in and then a check must be made to
ensure that the immobiliser system is operational.
To do this, it is sufficient to carry out the following operations:
- turn the ignition on for a few seconds and turn it off again,
- remove the key to guarantee the immobiliser function.
CHECKING THE IMMOBILISER FUNCTION
Remove the key from the ignition switch. After 10 seconds the red immobiliser warning light will flash.
For special notes on testing an injection computer (test part), refer to section 82: "Immobiliser".
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INJECTION
Computer configuration depending on gearbox type
17
COMPUTER CONFIGURATION DEPENDING ON GEARBOX TYPE (MANUAL GEARBOX OR AUTOMATIC

TRANSMISSION)
Each time the injection computer is replaced, it must be programmed with the type of gearbox (manual or
automatic) which is fitted in the vehicle. The computers are designed to function with either type of gearbox.
Method for configuring the computer
Connect the XR25
Select S8
Switch on the ignition
Enter D13 then
For vehicles fitted with manual gearbox :
Enter G50* 2*
For vehicles fitted with automatic transmission :
Enter G50* 1*
The screen will display :
if the configuration has not been made
then
if the configuration is complete
To ensure that the computer has memorised the data correctly, switch the ignition back on , using fault finding fiche n 27; the fault bargraph 20 LH should be extinguished, whilst the 19 LH or RH status bargraph
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INJECTION
Injection/air conditioning programming
17
THIS VEHICLE IS FITTED WITH A VARIABLE OUTPUT COMPRESSOR

AIR CONDITIONING/INJECTION COMPUTER CONNECTION
The electrical connection :

-
between the air conditioning computer and the injection computer consists of a single wire (track 5).
This track carries two types of information :
- the fast idle speed request information . For this information to be transmitted to the injection
computer , two conditions must be fulfilled :
the air conditioning function must have been selected on the control panel ,
the pressure in the air conditioning circuit must be greater than a certain threshold.
If this information is transmitted, the fast idle speed is obtained (it is therefore normal that
sometimes, when the air conditioning is switched on, engine idling, there is no fast idle speed ).
- the Absorbed Power information. This information has no influence on the idle speed. It simply
informs the injection computer of the torque value taken up by the compressor; the computer, in
turn, acts on the idle speed regulation solenoid. The absorbed power may be visualised using the
XR25. When the air conditioning is switched on , #44 should be between 300 and 5 000 watts.
IMPORTANT: the value at #44 or idle speed is never equal to 0, whatever the status of the
compressor, off or on . The minimum value which may be read using #44 is approximately 300
watts.
between the the injection computer and the air conditioning computer consists of a single wire (track
51). This track carries the information regarding the authorisation or prevention of compressor
operation.
COMPRESSOR OPERATION
PROGRAMMING
During certain operating phases, the injection computer prevents the compressor from operating.
Programming when starting engine
The compressor is prevented from functioning for 10 seconds after starting the engine .
Recovery of performance ( D7F engine)
Depending on the torque required by the driver and on the power absorbed by the air conditioning
compressor, the injection computer stops or allows the operation of the compressor .
Anti-stalling function (D7F engine)
If the no load position is recognised , and the engine speed is lower than 600 rpm, and if the power absorbed
by the compressor is greater than 300 watts, the compressor disengages .
It engages again if:
- the no load position is recognised when the engine speed reaches 850 rpm.,
- if the no load position is not recognised when the engine speed reaches 1 800 rpm.
Thermal protection programming ( E7J engine )
The compressor does not engage in cases where the coolant temperature is greater than or equal to +
115C.
Over-revving protection (E7J engine )
The compressor is prevented from operating if the engine speed is greater than 5 900 rpm.
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INJECTION
Idle speed correction
CONNECTION BETWEEN THE
17
AND THE
INJECTION COMPUTER
The injection computer receives information from the power assisted steering pressostat . This varies
depending on the pressure present in the hydraulic circuit. The higher the pressure, , the more energy is
absorbed by the power assisted steering pump.
To compensate for this energy absorption, the injection computer increases the opening ratio of the idle
speed regulation stepping motor.
The information is received on track 13 of the injection computer. If the pressostat is closed , the computer
receives an earth . The idle speed is adjusted to 800 rpm for the D7F engine and 850 rpm for the E7J
engine .
IDLE SPEED CORRECTION DEPENDING ON THE BATTERY VOLTAGE
The objective of this correction is to compensate for the drop in voltage, due to consumer operation when
the battery is poorly charged To correct this, the idle speed is increased, allowing the alternator to rotate
faster and consequently increase the charging voltage.
The lower the voltage, the greater the degree of correction. Correction of the engine speed is therefore
variable. It begins when the voltage drops to below 12.7 Volts. Correction begins at the nominal engine
speed and may reach a maximum of 880 rpm for the D7F engine and 930 rpm for the E7J engine .
IDLE SPEED CORRECTION DEPENDING ON AIR CONDITIONING OPERATION
The injection computer increases the idle speed to 850 rpm. for the D7F engine and 880 rpm . for the E7J
engine , provided it receives the fast idle speed information from the air conditioning computer.
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INJECTION
Adaptive idle speed correction
17
PRINCIPLE
Under normal warm engine operating conditions , the R.C.O. idle speed value at #12 varies between a
high value and a low value, until the nominal idle speed is obtained .
It is possible that during variations in the operation of the vehicle (running in, engine wear..), that the
R.C.O. idle speed value could become close to the highest or lowest values.
The adaptive correction (#21) of the R.C.O. idle speed (#12) allows the slow variations in the engine air requirement to be corrected, so that the R.C.O. ( #12) is recentred to an average nominal value.
This correction only becomes effective if the coolant temperature is higher than 75C, 20 seconds after
starting the engine and if the nominal idle speed regulation phase has been reached.
VALUES FOR THE R.C.O. IDLE SPEED AND ITS ADAPTIVE CORRECTION
D7F 710
engine
E7J 780
engine
Nominal idle speed (#06)
X = 740 rpm
X = 750 rpm
R.C.O. idle speed (#12)
4 %X14 %
2 %X15 %
Limit value:
- minimum : - 4.3 %
- maximum :+3.9 %
Limit value:
- minimum : - 2.4 %
- maximum :+6.2 %
Adaptive idle speed (#21)
INTERPRETATION OF THE GATE VALUES
In the case of excess air (air leak or throttle stop incorrectly adjusted ..) the idle speed increases, and the
R.C.O.idle speed value at #12 decreases , in order to return to the nominal idle speed; the value of the
R.C.O.idle speed adaptive correction at #21 decreases to re-centre the R.C.O. idle speed at #12.
In the case of a lack of air (contamination, etc.), the process is inverted : the R.C.O. idle speed at #12 increases and the adaptive correction at #21 also increases, in order to re-centre the #12 to an average nominal value.
IMPORTANT : It is vital, after erasing the memory from the computer (disconnecting the battery), to let the
engine run at idle speed before returning the vehicle to the customer, so that the adaptive correction can be
correctly reset.
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INJECTION
Richness regulation
17
OXYGEN SENSOR VOLTAGE (#05)
Reading #05 on the XR25 : the value read is the voltage sent to the computer by the oxygen sensor; it is expressed in volts (the value actually varies between 0 and 1 000 millivolts).
When the engine is in the loop phase, the voltage value should oscillate rapidly and should be between
5050 mV (lean mixture) and 850 50 mV (rich mixture) and vice versa.
The smaller the gap between the upper and lower values, the poorer the information from the sensor (the
gap is usually at least 500 mV).
RICHNESS CORRECTION (#35)
The value given under # 35 on the XR25 represents the average value of richness corrections made by the
computer depending on the richness of the burnt mixture as seen by the oxygen sensor (the oxygen sensor actually analyses the oxygen content of the exhaust gases directly from the richness of the burnt mixture).
The richness correction has a centre point of 128 with thresholds of 0 and 255 (experience has shown that under normal operating conditions # 35 is located close to 128 with only a small amount of variation).
- Value less than 128 : request for mixture to be made leaner.
- Value greater than 128 : request for mixture to be made richer.
ENTRY INTO RICHNESS REGULATION MODE
Loop phase
Richness regulation begins after the timed starting period :
-
for no load, if the coolant temperature has reached :
46C for the E7J engine ,
30C for the D7F engine.
outside no load conditions if the coolant temperature is greater than :
+ 20C for the E7J, engine
+ 20C for the D7F engine.
The timed starting period is dependent on the coolant temperature :

-
at 20C it is a maximum of :
3 minutes for the E7J engine,
1 minute 20 seconds for the D7F engine,

at 80C it is a maximum of :
1 minute 30 seconds for the E7J engine,
35 seconds for the D7F engine,
If richness regulation has not yet started, #35 = 128
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INJECTION
Richness regulation
17
Non-loop mode
When richness regulation is occurring, the operating phases when the computer ignores the voltage information from the oxygen sensor are:
- Full load: #35 = variable and greater than 128
- Sharp acceleration: #35 = variable and greater than 128
- Deceleration with no load information (injection cut) : #35 = 128
- Oxygen sensor fault: #35 = 128
DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT
If the voltage from the oxygen sensor is incorrect (# 05 varies only slightly or not at all) during richness regulation, the computer will only enter defect mode (# 35 = 128 ) if the fault has been present for 3 to 5 minutes.
The fault will be memorised in this case only.
If an oxygen sensor fault is present and recognised and if the fault has already been stored, the system enters
the open loop mode directly (# 35 = 128 )
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INJECTION
17
PRINCIPLE
In the loop mode (see section 17 "Richness regulation"), richness regulation (# 35 ), corrects the injection timing to give fuel metering which is as close as possible to richness 1. The correction value is close to 128, with
limit values of 0 and 255.
Variations may affect the components of the injection system and the correction may drift towards 0 or 255,
to ensure richness 1 is obtained.
Adaptive correction allows the injection mapping to be adjusted to recentre the richness regulation to 128
and to ensure a constant authority of correction to make the mixture leaner or richer.
Adaptive correction to richness regulation has two parts:
- Adaptive correction for average and high engine loads (#30)
- Adaptive correction for idle speed and low engine loads (#31).
Adaptive corrections take 128 as the average value after initialisation (erasing the memory) and have the
following threshold values:
D7F
Engine
E7J
Engine
106 #30 150
40 #30 192
106 #31 150
40 #31 192
Adaptive correction only takes place when the engine is warm, in the loop phase (#35 variable) and for a
specified manifold pressure range.
The engine must have operated in the loop mode for several pressure zones in order that adaptive correction begins to change to compensate for the variations in engine operating richness.
Following reinitialisation of the computer (return to 128 for # 30 and # 31 ) a special road test must therefore
be carried out.
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INJECTION
17
ROAD TEST
Conditions :
-
Engine warm (coolant temperature > 75 C).
Do not exceed engine speed

and
4 400 rpm. for the D7F engine.

4 800 rpm. for the E7J engine.
For this test , it is advisable to start from a fairly low engine speed , in 3rd or 4th gear using progressive acceleration to stabilise the required pressure for 10 seconds in each zone (see table).
NOTE : for the D7F engine, for example, for zone n 1, attempt to maintain the average of 320 mbars for
at least 10 seconds.
Pressure zones to cover during the test (reading #01)

Zone n 1
(mbars)
220
Zone n 2
(mbars)
340
Zone n 3
(mbars)
470
Zone n 4
(mbars)
600
Zone n 5
(mbars)
730
870
E7J
Average 280
260
Average 405
385
Average 535
510
Average 665
635
Average 800
760
D7F
Average 320
Average 450
Average 570
Average 700
Average 865
Following this test the corrections will be operational.

# 31 varies more significantly for idle speed and low loads and # 30 for average and high loads, but both
are operational over all of the manifold pressure ranges.
The test should be followed by a normal, smooth and varied drive, covering a distance of 3 to 6 miles (5 to
10 km).
After the test, read the values for #30 and #31. Initially 128, they may have changed. If not, repeat the test
ensuring that the test conditions are observed.
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970
INJECTION
17
INTERPRETATION OF INFORMATION GATHERED DURING A ROAD TEST
If there is a lack of fuel (injectors dirty, fuel pressure and flow too low...), richness regulation # 35 increases to
obtain the richness as close as possible to richness 1 and adaptive correction # 30 and # 31 increases until the
richness correction returns to oscillate around 128.
If there is an excess of fuel, the situation is reversed : Richness regulation # 35 reduces and adaptive
correction # 30 and # 31 also reduces to recentre the richness correction (# 35) around 128.
NOTE : the analysis which may be made using # 31 remains difficult since this correction mainly operates for
idle speed and low loads and is also very sensitive.
Hasty conclusions should not therefore be drawn from this gate value, rather the position of # 30 should be
examined.
The information from these two gates gives an idea about the engine operation richness, and may be used as
a guide for fault finding. In order for these to be put to good use during fault finding, no conclusion may be
drawn from their value unless they are at the minimum or maximum correction limit, and if both gate values
were offset in the same direction.
IMPORTANT : # 30 and # 31 should only be examined and analysed after a customer complaint, an operating fault and if they are at the threshold with the value for # 35 also offset (# 35 varies above 175 or below 80).
17-24
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COOLING
Specifications
19
VOLUME AND GRADE OF ANTI-FREEZE
Engine
Volume (in litres)
D7F
E7J
F8Q
7.5
Grade
Special notes
GLACEOL RX (type D)
recommended coolant
only
Protection down to - 20 2C ,
warm, temperate and cold countries
Protection down to - 37 2C for
extreme cold countries
THERMOSTAT
Engine type
Starts opening (in C)
Fully open (in C)
Travel (in mm)
D7F - E7J - F8Q
89
101
7.5
19-1
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COOLING
Filling and bleeding
There is no heater matrix water control valve.
Water flow is continuous in the heater matrix,
which contributes to the cooling of the engine.
FILLING
Check the tightening of the drain plug(s).

Open the two bleed screws.
Fill the circuit through the opening in the expansion bottle.
Tighten the bleed screws as soon as the liquid
flows in a continuous jet.
Start the engine (2 500 rpm).
Adjust the level by overflow for a period of about
4 minutes .
Close the bottle.
BLEEDING
Allow the engine to run for about 10 minutes at

2 500 rpm, until the fan(s) operate (time necessary
for automatic degassing).
Check the liquid level is at the "Maximum" marker.
DO NOT OPEN THE BLEED SCREWS WHILST THE
ENGINE IS TURNING.
RE-TIGHTEN THE EXPANSION BOTTLE CAP WHILST
THE ENGINE IS WARM.
19-2
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19
COOLING
Testing
19

M . S . 554-01
M . S . 554-06
M . S . 554-07
Adapter for M.S. 554-05

Adapter for M.S. 554-05
Kit for testing cooling circuit
sealing
1 - Testing the sealing of the circuit
2 - Checking the rating of the valve.
Replace the expansion bottle valve with adapter

M.S. 554-01.
If liquid passes through the expansion bottle

valve,the valve must be replaced.
Connect this to tool M.S. 554-07.
On pump M.S. 554-07 fit tool M.S. 554-06 and fit

the assembly on the valve to be checked.
Let the engine warm up then turn it off.

Pump to put the circuit under pressure.
Stop pumping at 0.1 bar less than the valve is
rated.
Increase the pressure which should stabilise at the

valve rating pressure with a test tolerance of
0.1 bar.
Valve rating :
The pressure should not drop, otherwise look for

the leak.
Slowly unscrew the union of tool M.S. 554-07 to
decompress the cooling circuit, then remove tool
M.S. 554-01 and refit the expansion bottle valve
with a new seal.
Engine
Colour of valve
Valve rating (in

bars)
D7F-E7J-F8Q
Brown
1.2
97871R
19-3
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D7F Engine
COOLING
Diagram
19
10070-2R
1
2
3
4
5
Engine
Radiator
Hot bottle with permanent degassing
Heater matrix
3 mm diameter restriction
Water pump
Thermostat
Bleed screw
The fan assembly is controlled at high speed by

the injection computer if the coolant temperature is greater than 99C.
The expansion bottle valve is brown, and its rating

is 1.2 bar.
If the coolant temperature is lower than 96C, the

fan assembly stops operating.
19-4
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E7J Engine
COOLING
Diagram
19
13508R
1
2
3
4
5
6
Heater
Radiator
Heater matrix
Thermostat mounting
Water pump
Thermostat
Bleed screw
Temperature switch
The fan assembly is controlled at high speed by

the injection computer if the coolant temperature is greater than 99C.
The expansion bottle valve rating is 1.2 bar

(colour:brown).
If the coolant temperature is lower than 96C, the

fan assembly stops operating.
19-5
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F8Q Engine
COOLING
Diagram
19
13504R
1
2
3
4
5
6
Water pump
Heater
Radiator
Heater matrix
Thermostat mounting
Thermostat
Bleed screw
Temperature switch
The expansion bottle valve rating is 1.2 bar

(colour:brown).
19-6
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COOLING
Water pump
D7F Engine
19
Mot.
Mot.
Mot.
Mot.
1054
1202
1273
1289-03
TDC pin
Hose clip pliers

Tool for centring the suspended engine movement limiter
Tool for retaining engine on subframe
Mot. 1379
Crankshaft output mounting bolts
2 + 90
Bolt for mounting front right suspended

6.2
Bolt for mounting front right suspended

engine mounting on vehicle body
6.2
Water pump mounting bolt
0.9
REMOVAL

10478S

CLEANING
Remove:
section 11 "Timing belt),
- the power assisted steering pump pulley (if fitted),
- the upper alternator mounting bolt and
slacken the lower bolt,
- the bolts for mounting the power assisted
steering pipe on the cylinder block,
- the bolts for mounting the power assisted
steering pump on its support (move the power assisted steering pump-pipe assembly to
one side),
- the power assisted steering pump support,
- the water pump hose,
- the tension wheel along with the water pump
itself.

of all aluminium components.
Use the product Dcapjoint to dissolve the part
of the gasket which remains attached.
Apply the product to the part to be cleaned, wait
approximately 10 minutes, then remove it using a
wooden spatula.
The wearing of gloves is recommended during
this operation.
19-7
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COOLING
Water pump
D7F Engine
19
REFITTING
Special notes
Sealing of the water pump is carried out using
RHODORSEAL 5661, the bead (J) must be applied
following the illustration below.
Apply a bead of LOCTITE 518 on the sealing surface (L) between the inlet pipe elbow and the water pump.
10272R

Remember to remove the TDC pin.
19-8
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COOLING
Water pump
E7J Engine
19
Mot.
Mot.
Mot.
Mot.
Mot.
591-02
591-04
1135-01
1202
1273
Index
Angle tightening wrench
Tool for tensioning the timing belt
Hose clip pliers
EQUIPMENT REQUIRED
Engine support tool
REFITTING
The sealing of the water pump is carried out using

the product LOCTITE 518; the bead (H) must be
applied following the diagram below.
Tension wheel nut

5
2 + 68 + 6
Bolt for suspended engine mounting cover
6,2
4,4
Water pump bolt
2,2
Water pump nut
1
Wheel bolts
9
REMOVAL

Drain the cooling circuit from the lower radiator
hose.
Remove:
section 11 "Timing belt),
- the timing tension wheel,
- the water pump, and extract this from above.
92068R

chapter 11 "Timing belt").
CLEANING

Fill and bleed the cooling circuit (see section 19

"Filling - Bleeding").

wooden spatula.
this operation.
19-9
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COOLING
Water pump
F8Q Engine
19
Mot. 1202
Hose clip pliers

EQUIPMENT REQUIRED
Engine support tool
Water pump bolt

Bolt for water pump pulley
Bolt for crankshaft pulley
1.6
2
2 + 115 15
REMOVAL
the front right wheel arch,

the accessories belt,
the crankshaft pulley (A),
the water pump pulley (B) , lowering the engine as far as possible,
the injection pump housing (C),
the bolt at (1) and move the alternator to the
right.

Drain the cooling circuit through the lower radiator hose.
Remove :
- the plastic protector for the suspended engine
mounting cover,
- the suspended engine mounting cover,
13090R
13086R1
19-10
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COOLING
Water pump
F8Q Engine
19
- the bolts mounting the water pump and extract

this from above.
13089S
CLEANING

wooden spatula.
this operation.
REFITTING

Refit and tension the accessories belt. (see section
Fill and bleed the cooling circuit (see section 19
"Filling and bleeding").
19-11
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EXHAUST
General
During operation, the catalytic converter reaches
high temperatures, and consequently, it is vital
not to park the vehicle in a place where combustible materials could come into contact with it, and,
as a result, ignite.
19
ATTACHMENT OF THE PIPE UNDER THE BODY
The attachment of the pipe under the body is by

the rubber mounting at (1).
This can generally be unhooked by hand by taking the weight off the exhaust pipe.
Under certain conditions, these materials could

ignite.
However, in certain cases, it may be necessary to

slacken the bolts retaining the support ( 2) under
the body in order to more easily unhook the rubber mountings.
IMPORTANT:
- the seal, between the exhaust manifold gasket face and the catalytic converter (inclusive), must be in perfect condition,
_
it is imperative that every gasket removed be
REPLACED (especially at the catalytic converter
flange)
- during removal and refitting, the catalytic
converter must not undergo repeated mechanical shocks, as it will be damaged.
12847-1R
CUTTING
THE EXHAUST PIPE
The exhaust pipes are of the monoblock type.

There is no join from the beginning of the catalytic converter or the expansion box, to the end of
the silencer.
It will therefore be necessary, when replacing one
of the components in After Sales, to cut the
exhaust pipe.
For this, it is absolutely essential to accurately :
- mark the area to be cut,
- use the cutting tool Mot. 1199-01,
- fit the after sales sleeve .
19-12
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EXHAUST
General
19
MARKING THE AREA TO BE CUT
The area to be cut is defined by two punch marks

on the exhaust pipe.
99226-1R
Depending on engine, there are a maximum of

two cutting areas on the exhaust pipe, situated
between the catalytic converter and the
expansion box and between the expansion box
and the silencer.
The distance between the two markings is 90 mm.
To cut the tube, mark the central point (D) between the two markings (P1 and P2).
P1
P2
90 mm
DI1901
IMPORTANT: to cut the exhaust pipe, it is essential to use tool Mot. 1199-01; this tool allows
2mm thick pipes to be cut.
19-13
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EXHAUST
General
19
Once a collar has been used once, renew it.
FITTING THE AFTER SALES SLEEVE
95478R1
99227S
The nut on the collar has a groove (A) to ensure it

is tightened to the correct torque. When the nut is
tightened and the groove disappears, it causes a
distinct clicking sound and the nut is then tightened to the correct torque (2.5 daN.m).
To avoid any leaks in the exhaust pipe, the sleeve

must be correctly positioned over the two exhaust
pipe sections. The pipe must be against the stops
inside the sleeve.
Begin by positioning the sleeve over the used section of the pipe, adjust the collar by tightening
gently.
NOTE : there are two different diameters of

sleeve available:
- 50 mm,
- 45 mm .
Check the position of the pipe in relation to the

stops.
IMPORTANT:
- check that there is no point of contact between the exhaust pipe and the vehicle body,
- check for the presence and correct positioning
of all heat shields for the exhaust pipe,
- check that the two cutting marks are correctly
aligned.
Fit the new section of the pipe.

Before fitting the sleeve on the pipe, apply a little
mastic to the inner ring on the sleeve to prevent
leaks.
(Exhaust mastic, Part Number. 77 01 421 161
SODICAM).
IMPORTANT : the bolt and nut used for tightening the sleeve must be aligned vertically to
avoid any risks of touching the underside of the
body.
19-14
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EXHAUST
Pipe assembly
19
DIAGRAM OF EXHAUST PIPES AND LOCATION OF CUTTING AREAS
E7J Engine
D7F Engine
13126R
1
2
3
ZC
13124R
Expansion box
Silencer
Catalytic converter
Pipe cutting area
19-15
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EXHAUST
Pipe assembly
19
DIAGRAM OF EXHAUST PIPES AND LOCATION OF CUTTING AREAS
F8Q Engine
13125R
1
Catalytic converter
2
Silencer
ZC Pipe cutting area
19-16
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FUEL TANK
Fuel tank
19
Mot. 1199-01
Exhaust pipe cutting tool
Mot. 1265

fuel unions
Mot. 1265-01
EQUIPMENT REQUIRED
INTAIRCO pneumatic siphoning pump, for

petrol or diesel tank draining system (see EQUIPMENT
catalogue).
Sender unit- pump nut
Attach to the outlet at (A), a pipe long enough to

be placed into a container outside the vehicle .
NOTE : Alternatively, an INTAIRCO pneumatic siphoning pump may be used (see EQUIPMENT catalogue).
IMPORTANT : during all the fuel tank removal

and refitting operations, refrain from smoking
and be sure not to handle incandescent objects in
the vicinity of the working area.
DRAINING THE FUEL TANK
(Petrol version)
Remove the pump-sender unit assembly steel access cover.

Remove the clip which shows if the assembly has
been pushed in (if fitted).
Disconnect the quick release union at (1), tool
Mot. 1265.
97163R2
19-17
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FUEL TANK
Fuel tank
In the engine compartment, disconnect the fuel
pump relay at (K) , which is located in the engine
connection unit.
DRAINING THE FUEL TANK
19
( Diesel
version)
Since Diesel versions are not fitted with an electrical fuel pump, a manual pump must be used to
drain the tank.
For example, the INTAIRCO pneumatic siphoning
pump is suitable for this operation (see
EQUIPMENT catalogue),
99641S
Remove the pump-sender unit steel access cover.

Remove the clip which shows if the assembly has
been pushed in (if fitted).
Disconnect the quick release union at (1), tool
Mot. 1265.
12839S
Shunt tracks 3 and 5 and let the fuel flow until it

runs out in intermittent jets.
Disconnect the shunt.
Reconnect the relay.
97163R2
Connect the pneumatic pump rubber tube to the

outlet union at (A).
Drain the tank.
19-18
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TANK
Fuel Tank
REMOVAL OF THE TANK (petrol or
sions)
19
Disconnect the petrol filter.
diesel ver-
Remove the heat shields at (3) and (4) , which are

situated below the tank and beneath the handbrake cables.

Remove the exhaust mounting bracket (5).

Disconnect the electrical connector (2) and the
quick release unions, tool Mot. 1265 or Mot.
1265-01.
12866R
Tilt the exhaust towards the right hand side of the

vehicle.
97163R4
Lift the vehicle.

Separate the exhaust pipe from the exhaust
down pipe.
Remove the exhaust mounting bracket from the
middle of the vehicle.
19-19
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FUEL TANK
Fuel tank
19
Before the handbrake adjuster is disengaged, dimension X must be noted.
99091R1
Disengage the adjuster in such a way that both

the left and right hand cables can be easily released (carefully release the plastic cable stop (6)).
12873R
Unclip the hydraulic brake pipes on the fuel tank

side.
Disconnect the two unions at (7) and (8) using

tool Mot. 1265.
Unclip the fuel pipes from the tank.
Disconnect the pipe at (9).
Position a component jack under the fuel tank.
Separate the tank from the filler neck (10).
Remove the four bolts mounting the tank.
Unclip the handbrake cables from under the tank

(11).
Tilt the tank slightly forwards, then remove it.

REFITTING

Take care not to pinch any pipes (risk of leaks).
Fit the quick release unions by hand and ensure
they connect correctly.
Take care to ensure the heat shields are correctly
refitted.
19-20
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FUEL TANK
Fuel tank
19
1 st generation Petrol version
13039R
19-21
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FUEL TANK
Fuel tank
19
1 st generation Petrol fuel tank
13037R
19-22
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FUEL TANK
Fuel tank
19
2nd generation Petrol version
13038R
19-23
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FUEL TANK
Fuel tank
19
2nd generation petrol fuel tank
13036R
19-24
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FUEL TANK
Fuel tank
19
Diesel version
13040R
19-25
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FUEL TANK
Fuel tank
19
Diesel fuel tank
13035R
The tank breathes through the top opening of the fuel breather/sender unit assembly.
19-26
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FUEL TANK
Fuel tank
Components
1
2
3
4
5
6
7
8
9
10
13
14
15
18
19
20
21
22
23
24
25
27
28
29
30
31
32
Tank
Bolt
Filler neck
Filler neck bowl
Rivet
Sleeve mounting clip
Fuel cap
Fuel supply pipe
Fuel return pipe
Clip
Cup
Canister pipe
Canister pipe
Canister
Bolt
Clip
Clip
Damper pad
Captive nut
Connection between filler neck outlet and
fuel passage pipe
Degassing - filling
Canister connection (fuel vapours)
Over-filling prevention valve
Excess pressure-under-pressure safety valve
Restriction valve
Leak prevention valve in case vehicle turns
over
Over-filling prevention valve and leak prevention valve in case vehicle turns over.
A
B
C
D
E
F
R
V
Quick-release union
Snap-fit union
Quick release union
Sleeve (not snap-fit)
Opening for air outlet during filling
Air volume allowing the fuel to expand
Fuel inlet for filling
Maximum fuel volume allowed.
19-27
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19
FUEL TANK
Fuel tank
19
PURPOSE OF THE VALVES
The tank has a sealed cap.
28 Overfill prevention valve
The filler neck for unleaded petrol has the following special features :
- a filling opening with a smaller diameter and
not compatible with a conventional filling
nozzle (the lead would have the effect of polluting the depollution system: oxygen sensor
and catalytic converter),
- a valve blocking the filing opening (30) (to
avoid fuel evaporating or the reverse passage
of fuel).
When the filler cap is removed the valve is

closed, trapping a volume of air within the
breather volume. This prevents fuel from filling this volume.
When the filler cap is replaced, the valve
opens allowing the tank to breathe through
the canister
29 Excess - vacuum safety valve
If the fuel vapour recirculation circuit is
blocked, this valve prevents the fuel tank
being subject to excess pressure (the tank
would inflate) or vacuum (as fuel is used, the
tank would be crushed).
30 Restriction valve
This valve prevents the introduction of leaded
fuel into the tank.
31 Leak prevention valve in case vehicle turns
over
If the vehicle turns over, this valve prevents
the tank from emptying, either through the
pipe leading to the canister, or through the
breather pipe (in Diesel versions).
99212R2
32 Overfill prevention valve and leak prevention

valve in case the vehicle turns over
Fitting the cap releases the overfill prevention

valve (A) allowing the tank to breathe (this feature is present only in first generation petrol versions).
The overfill prevention valve operates using

the ball at (33).
When the vehicle is stationary, during filling,
the ball rests in its seat, retaining a certain
volume of air in the reservoir .
When the vehicle is moving , the ball (33)
moves out of its seat, thus allowing the tank
to be connected to the canister.
When the tank is full, it is vital that a
sufficient volume of air to allow the fuel
contained within it to expand is retained
inside the tank, but not too much, otherwise
there is a risk of the tank exploding .
This valve has the same operating principle as
the valve (31) .
19-28
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FUEL TANK
Sender unit
In petrol versions, the pump and sender unit cannot be separated.
In diesel versions, there is no pump immersed in
the tank, and there is only a sender unit.
For the removal of the sender unit, please refer to
subsections "Tank", "Pump-sender unit".
Checking the sender unit
Indication
Value between terminals

A1 and B1 (in )
4/4
7 maximum
3/4
54.5 7
1/2
98 10
1/4
155 16
Low fuel level
300 20
Check for a variation in resistance by moving the

float.
NOTE : all the above values are given merely as
an indication.
19-29
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19
FUEL TANK
Pump- sender unit
19
Mot. 1264
Wrench for removing
Mot. 1264-01
pump-sender unit assembly nut
Mot. 1265
Pliers for removing
Mot. 1265-01
quick release unions
Disconnect, using tool Mot. 1265 or Mot. 126501:

- the fuel supply pipe (3) (which is marked by a
green quick release union),
- the fuel return pipe (4) (marked by a red quick
release union and by an arrow (B)).
Nut for pump - sender unit assembly
IMPORTANT :
During all operations on the fuel tank or on the
fuel supply circuit , it is vital :
- to refrain from smoking and handling incandescent objects in the vicinity of the working
area,
- to avoid fuel projections, due to the residual
pressure present in the pipes during removal .
REMOVAL
To remove the pump-sender unit assembly, it is

not necessary to remove the tank, as it is accessible through the inside of the vehicle. To do this :
- disconnect the battery,
- lift the rear bench seat ,
- remove the steel access cover,
- remove the electrical connection at (1),
remove the clips at (2).
96420R1
97163R5
19-30
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FUEL TANK
Pump- sender unit
Remove the mounting nut at (5) using tool
Mot. 1264 or 1264-01 (release the nut, remove
the tool, hand slacken the nut, then remove it).
19
REFITTING
Check that the seal is not deformed, and replace it

if necessary.
Extract the fuel pump-sender unit assembly.

Position the pump-sender unit assembly
(ensuring that the arrow at (F) is placed in the
longitudinal axis of the vehicle pointing to the
rear).
Position the nut and tighten it to the torque of
3.5 daN.m.
Fit the fuel pipes (it is not necessary to use the
pliers Mot. 1265 or Mot. 1265-01).
Refit the safety clips at (2).
Reconnect the electrical connection.
Refit the steel cover.
99367S
NOTE : if several hours have to pass between the

removal and refitting of the fuel pump-sender
unit assembly, refit the nut on the tank, to avoid
deforming it.
ALLOCATION OF CONNECTOR TRACKS
TRACK
ALLOCATION
A1
Earth
A2
Fuel minimum level warning light
B1
Sender unit information to instrument

panel
B2
Not used
C1
pump
C2
pump
19-31
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D7F Engine
ENGINE MOUNTING
19
13359S
12924G
19-32
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D7F Engine
ENGINE MOUNTING
19
13359R3
19-33
http://vnx.su
F8Q Engine
ENGINE MOUNTING
19
13086R2
19-34
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Transmission
CLUTCH
MANUAL GEARBOX
DRIVESHAFTS

77 11 194 244
JULY 1997
Edition Anglaise

Renault

Renault 1997
http://vnx.su
EXPLODED VIEW
PRF2000
http://vnx.su
Transmission
Contents
Page
20 CLUTCH
Mechanism- Disc
Flywheel
20-1
20-4
ENSEMBLE
GEARBOX
MOTEUR ET BAS
21 MANUAL
Identification
Ratios
Capacities-Lubricants
Consumables
Parts to be systematically replaced
Gearbox (Removal-Refitting)
21-1
21-2
21-3
21-4
21-4
21-5
29 DRIVESHAFTS
General
Front driveshaft
http://vnx.su
29-1
29-2
CLUTCH
Mechanism - Disc
Vehicle
Type
Engine
Type
Mechanism
Disc
26 splines
D = 181.5 mm
E = 6.7 mm
F/K C0A
F/K C0C
20
GA : Grey Silver
VR : Violet Red
D7F
E7J
85873S
180 CP3300
90693R8
26 splines
D = 242 mm
E = 6.8 mm
F/K C0D
F/K C0E
76906R
RR : Red Ruby
GB : Grey Blue
F8Q
85873S
200 CPOV 3250
90693R9
Cable-controlled dry-operating single disc clutch.

Constant pressure clutch thrust bearing.
20-1
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76906R
CLUTCH
Mechanism - Disc
20
REPLACEMENT (after removal of the gearbox)

Mot. 582
or
Mot. 582-01
Locking tool
REFITTING
Mechanism mounting bolt
Clean the splines of the clutch shaft and refit the

assembly without lubricant.
REMOVAL
Fit the disc (with the offset on the hub on the

gearbox side).
Fit the locking sector tool Mot. 582 or

Mot. 582-01.
Centre using the tool supplied in the kit.
Remove the mounting bolts from the mechanism

and remove the friction plate.
Check and replace any faulty parts.
95414S
Tighten progressively in a star pattern, then tightenthe mounting bolts to the correct torque.
99055R
Remove the locking sector tool Mot. 582 or

Mot. 582-01.
Coat with MOLYKOTE BR2 grease:
- the guide tube,
- the fork pads.
20-2
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CLUTCH
Mechanism - Disc
After refitting the gearbox, place the cable onto
the clutch fork, reset the notched sector and
check that the play compensation is in working order.
20
NOTE : in the case of any intervention not requiring the removal of the gearbox or after the fitting of the gearbox, DO NOT LIFT the fork, as it
would risk releasing itself from the slot (A) of the
clutch thrust bearing.
Check the travel of the clutch.

The travel of the fork must be:
X = 27.4 to 30.7 mm
99054R
97758-1R
20-3
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CLUTCH
Flywheel
REPLACEMENT
20
of the flywheel
Mot. 582
or
Mot. 582-01
Locking tool
TIGHTENING TORQUES (In daN.m)
Flywheel bolt
2 + 60
REMOVAL
After removing the friction plate, remove the

mounting bolts of the flywheel (must not be
re-used).
Regrinding of the friction face is not permitted.
REFITTING
Clean the threads of the mounting bolts of the flywheel on the crankshaft.
Remove the grease from the bearing face of the
flywheel on the crankshaft.
Refit the flywheel by immobilising it with tool
Mot. 582 or Mot. 582-01.
NOTE: the flywheel mounting bolts are to be systematically replaced.
20-4
http://vnx.su
MANUAL GEARBOX
Identification
All KANGOO vehicles are fitted with
21
JB type gearboxes.
The Workshop Repair Manual "B.V. JB. JC " deals with the complete repair of this component.
87227G
IDENTIFICATION PLATE
At A
At B
At C
At D
At E
At F
:
:
:
:
:
the gearbox type

the gearbox suffix
the fabrication number
the factory of manufacture
a slot if the gearbox is assembled with an E
type engine
: the letter preceding all fabrication numbers
greater than 999999
J B0 0 0 0
X X0 0 0 0 0
E
F
21-1
http://vnx.su
B
C
MANUAL GEARBOX
Ratios
21
JB1
Suffix
Vehicle
Differential
ratio
906
175
F/K C0D
16
55
171
172
F/K C0A
14
59
173
174
F/K C0E
16
57
Speedometer
gear
1st
2nd
3rd
4th
5th
Reverse
gear
39
31
11
41
21
19
21
43
28
39
34
35
39
32
11
39
26
37
33
JB3
Suffix
Vehicle
Differential
ratio
168
169
F/K C0C
14
59
Speedometer
gear
21
19
1st
2nd
3rd
4th
5th
Reverse
gear
11
14
21
43
28
39
34
35
39
32
11
39
169 for vehicles fitted with Air Conditioning.
21-2
http://vnx.su
26
MANUAL GEARBOX
Capacities - Lubricants
CAPACITY (in litres)
5 gear box
JB1
3.4
JB3
3.4
Viscosity grade
TRX 75W 80W
CHECKING THE LEVEL
92081S
Filling is by overflow
21-3
http://vnx.su
21
MECHANICAL GEARBOX
Consumables
TYPE
PACKAGING
PART NUMBER
21
COMPONENT
Splines of the right - hand sunwheel

MOLYKOTE BR2
Loctite 518
RHODORSEAL
5661
Eg : CAF 4/60 THIXO

LOCTITE FRENBLOC
(locking and sealing
resin)
1 kg tin
77 01 421 145
24 ml syringe
77 01 421 162
100 g tube
77 01 404 452
24 cc bottle
77 01 394 071
Fork pivot
Thrust bearing guide
Fork pads
Housing assembling faces

Threaded plugs and switches
Bearing plugs
Ends of roll pins on driveshafts
Primary and secondary shaft nuts
Fixed gear and 5th gear hub
Rear differential lock drive stud
Parts to be systematically replaced
After they have been removed :

- the lip seals,
- the O-ring seals,
- the clutch thrust bearing guide tubes,
- the secondary and differential shaft nuts,
- the speedometer drive gear and its shaft,
- the speedometer ring gear,
- the roll pins,
- the gear supporting rings.
21-4
http://vnx.su
Clutch
MANUAL GEARBOX
Gearbox (removal - refitting)
SPECIAL
21
TOOLING REQUIRED
Set of punches
Engine sub-frame carrier
B. Vi.
31-01
Mot. 1040-01
T. Av.
476
EQUIPMENT REQUIRED
Engine support tool

Component jack
TIGHTENING TORQUES (In daN.m)
Brake calliper bolt

Driveshaft gaiter bolt
Lower ball joint nut
Engine tie-bar bolt
Gearbox edge and starter motor bolt
Suspended mounting bolt on gearbox
Wheel bolts
Track rod end nut
4
2.5
5.5
18
6.5
4.5
4
9
4
REMOVAL
Place the vehicle onto a two post lift.

13083S
Remove :
- the engine cover,
- the battery.
Remove the bolts (A) of the battery protective

screen.
Disconnect the connectors on:

- the injection computer (petrol version),
- the preheating unit (diesel version),
_
the diesel fuel filter (diesel version),
- the impact sensor.
Remove the air filter sleeve.
13088R
21-5
http://vnx.su
MANUAL GEARBOX
Gearbox (Removal - Refitting)
Remove :
- the two mounting bolts (B),
On the right-hand side of the vehicle, remove the

driveshaft pins using tool B. Vi. 31-01.
13119R
91755-1R2
Disconnect the clutch cable.
Remove on both sides :

- the brake callipers and attach them together
- the mudguards,
- the track rod ends (T. Av. 476),
- the shock absorber base bolts,
- the sub-frame side member tie-rods (A),
- the stub axle carrier-driveshaft by disconnecting it from the lower ball joint
Remove :
- the upper bolts at the gearbox edge and on
the starter motor (slacken the bolt (D) as far
as possible)
- the earth strap bolts on the gearbox,
- the two bolts of the TDC sensor.
13097-2R
21
99070R1
the front wheels,

the oil collector under the gearbox.
21-6
http://vnx.su
MANUAL GEARBOX
21
Ensure that the rollers of the left driveshaft cannot be removed by hand. If they can, check if any
of the needles have fallen into the gearbox.
Disconnect and remove the starter motor.
Disconnect:
- the reversing light connector,
- the speedometer connector and remove the
gearbox sensor.
Remove :
- the entire gear control lever by removing the
bolt (E) and the three bolts of the heat shield
for access to the base of the gear lever
-
the engine tie-bar bolt,

the rear support on the gearbox.
13120S
Remove the steering box and secure it.

Fit the engine support and take the weight of
the engine and transmission assembly.
Positioning on F8Q engine
12993-1R2
13121S
Remove the engine-gearbox tie-rod.

To aid the removal of the steering box, fit, if necessary, a shim, in order to tilt the engine forward.
21-7
http://vnx.su
MANUAL GEARBOX
21
Fit the sub-frame support (Mot. 1040-01) and lower the vehicle.
Positioning on petrol engines
13122S
Remove the three mounting bolts for the support

on the gearbox.
98755R1
Remove the engine sub-frame by slackening the

four mounting bolts.
Fit the component jack under the gearbox without lifting it.
Separate the gearbox from the engine having removed the nut (E) and the engine-gearbox mounting stud.
12924R
Lower the engine as far as possible.

Remove :
- the last gearbox edge bolt at the top,
- the bumper.
85812-1R
21-8
http://vnx.su
MANUAL GEARBOX
REFITTING
Coat the walls of the guide tube and the fork pads
with MOLIKOTE BR2 grease.
Place the fork onto the slots of the clutch thrust

bearing.
Assemble the gearbox on the engine taking care
not to alter the height of the engine.
Ensure the presence and correct positioning of
the engine- gearbox centering rings .
The presence of the stud (C) aids assembly.
86308R2
Refit:
- the engine sub-frame,
- the steering,
- the engine tie-bar.
SPECIAL NOTE FOR THE E7J ENGINE
Refit the exhaust downpipe before the righthand driveshaft.

Refit the other components by proceeding in the
reverse order to removal.
21-9
http://vnx.su
21
DRIVESHAFTS
General
29
SPECIFICATION
Driveshaft seal
Vehicle type
Engines
FC0X
KC0X
Gearboxes
F8Q
JB1
D7F
JB1
E7J
JB1 / JB3
Left
Right
GE 86 + GI 69
GE 86 + RC 462
CONSUMABLES
Type
Quantity
Component concerned
RHODORSEAL 5661
Coat
Gearbox side driveshaft roll pin
MOBIL K 575 GS
180 g
GE 86
ELF GMPT89 or
MOBIL CVJ 825 BLACK STAR
110 cm3
RC 462
NOTE : the replacement of the NYLSTOP nut with the ENKO driveshaft nut means that the splines of the
stub axles must no longer be coated with Loctite SCELBLOC .
29-1
http://vnx.su
DRIVESHAFTS
Front driveshafts
29
B. Vi.
Rou.
T. Av.
T. Av.
Roll pin punch

Hub locking tool
Driveshaft extractor
31-01
604-01
476
1050-02
Driveshaft nut
Mounting bolt of gaiter on gearbox.
Wheel bolts
Shock absorber base nuts
Brake caliper mounting bolts
Track rod end nut
28
2.5
9
18
10
3.7
REMOVAL
Vehicle on a two post lift.

Drain the gearbox.
Remove :
- the brake assembly (suspend it from the
chassis),
- the driveshaft nut : tool Rou. 604-01.
99544R
REFITTING
Left side :
Left side :
Remove the three bolts on the gearbox.
Fit the driveshaft as horizontally as possible.
Right side :
Right side :
Remove the roll pin : tool B. Vi. 31-01.
Coat the splines of the joint on the gearbox side

with MOLYKOTE BR2 grease.
On both sides :
Fit the driveshaft and check its positioning : angled pin B. Vi. 31-01.
Remove :
- The track rod end nut and extract the shaft :
tool T. Av. 476,
- the upper bolt of the shock absorber base.
Fit two new roll pins : B. Vi. 31-01. Seal the roll pin
holes using RHODORSEAL 5661 .
On both sides :
Push back the driveshaft : tool T. Av. 1050-02.
Fit the driveshaft stub axle into the hub, it should

go in easily.
Remove the lower bolt of the shock absorber

base and extract the driveshaft.
Refitting is the reverse of removal. Observe the

tightening torques.
Top up the gearbox oil.
Press the brake pedal several times in order to
bring the piston into contact with the pads.
29-2
http://vnx.su
Lefthand
driveshaft
DRIVESHAFTS
Front driveshafts
29
T. Av. 1168
T. Av. 1256
T. Av. 1331
CAILLAU clip pliers

OETIKER crimping pliers
Tool for holding driveshaft bearing gaiter in position
REPLACEMENT OF THE GAITER ON THE GEARBOX

SIDE
REFITTING
For its correct positioning on the shaft, the

bearing must be pressed on to obtain a distance
of L = 118 0.2 mm between the rear part of
the bearing and the end of the shaft.
GI 69 JOINT
1
2
3
4
5
6
7
Spider
Rubber gaiter
Bearing guide
Retainer
Deflector
Circlip
Driveshaft
This measurement is obtained using the tool T.

Av. 1331 when its extremity is level with the
shaft.
85884-1R1
DI2935R
Remove the circlip.
NOTE : in order to avoid deformation of the bearing with a lip seal, and therefore any risk of leakage, do not press it on using a hammer, but using
a press, in order to apply progressive pressure.
On the press, remove the spider using an

extractor.
The driveshaft is held in the press using the slot

(G) with an extractor.
NOTE : mark the position of the spider before

extracting it.
Replace the spider in the position marked on

removal and refit the retaining circlip.
REMOVAL
Remove the gaiter and deflector - bearing

assembly in the same way as for the spider.
29-3
http://vnx.su
Lefthand
driveshaft
DRIVESHAFTS
Front driveshafts
Remove the gaiter and replace with a new one.
REPLACEMENT OF THE GAITER ON THE WHEEL

SIDE
Divide the recommended dose of grease

between the gaiter and the stub axle bowl.
GE 86 JOINT
1
2
3
4
5
6
7
8
9
10
29
Stub axle bowl

Retaining star
Spider
Yoke shaft
Thermoplastic gaiter
Clips
Spring
Pushrod
Shim
ABS target
NOTE : it is imperative to respect the volume of

grease prescribed in the consumables section.
Position the two beads of the gaiter in the

grooves of the stub axle bowl.
Set the quantity of air in the gaiter.
Fit and tighten the clips.
DI2934R
REMOVAL
Join together the two clips (6) taking care not to

damage the grooves of the stub axle bowl.
Remove as much grease as possible.
For the replacement of the thermoplastic gaiter,
it will be necessary to remove the parts on the
gearbox side (GI 69 joint) (see method previously
described).
29-4
http://vnx.su
Lefthand
driveshaft
DRIVESHAFTS
Front driveshafts
REPLACEMENT OF THE GAITER ON THE GEARBOX

SIDE
REFITTING
Slightly lubricate the driveshaft in order to facilitate the fitting of the gaiter (position the smaller
diameter of the gaiter in the groove of the driveshaft).
RC 462 JOINT
1
2
3
4
5
29
Yoke sleeve
Spider
Locking spring ring
Gaiter
Clips
Replace the spider in the position marked on

removal and replace the locking spring ring.
Make three crimping points at 120 by forcing
back the metal of the splines on the driveshaft.
Fit the yoke sleeve onto the spider.
Divide the dose of grease between the gaiter and
the yoke sleeve.
Position the gaiter correctly on its grooves.
Introduce a blunt rod with a rounded edge between the gaiter and the yoke sleeve, in order to
measure the quantity of air contained inside thejoint.
Lengthen or shorten the joint until you obtain the
measurement A = 190 mm (measurement taken
between the end of the joint and the face of the
smaller diameter of the yoke sleeve).
DI2933R
In this position, remove the rod.
REMOVAL
Cut the two clips (5) taking care not to damage

the groove of the yoke sleeve.
Remove the yoke sleeve
Remove the locking spring ring
IMPORTANT: never use solvent for cleaning the
components.
On the press, extract the spider by using a

releasing type extractor .
90392R1
NOTE : mark the position of the spider before

extracting it.
Refit the clips using the recommended tooling.
29-5
http://vnx.su
Righthand
driveshaft
DRIVESHAFTS
Front driveshafts
29
NOTE : certain righthand driveshafts are fitted

with vibration absorbers; if the thermoplastic gaiter is damaged replace the whole driveshaft .
REPLACEMENT OF THE GAITER ON THE WHEEL

SIDE
GE 86 JOINT
Remove the gaiter and replace with a new one.

1
2
3
4
5
6
7
8
9
10
Stub axle bowl

Retaining star
Spider
Yoke shaft
Thermoplastic gaiter
Clips
Spring
Pushrod
Shim
ABS target
Divide the recommended dose of grease between

the gaiter and the stub axle bowl.
NOTE : it is imperative to respect the volume of
grease prescribed in the consumables section.
Position the two beads of the gaiter into the

grooves of the stub axle bowl.
Set the quantity of air in the gaiter.
Fit and tighten the clips.
DI2934R
REMOVAL
Join together the two clips (6) taking care not to

damage the grooves of the stub axle bowl.
For the replacement of the thermoplastic gaiter,

it will be necessary to remove the parts on the
gearbox side (RC 462 joint) (see method previously
described).
29-6
http://vnx.su
Chassis
GENERAL
FRONT AXLE
REAR AXLE
WHEELS AND TYRES
STEERING ASSEMBLY
MECHANICAL ELEMENT CONTROLS
ELECTRONICALLY CONTROLLED SYSTEMS

77 11 194 253
JULY 1997
Edition Anglaise

Renault.

Renault 1997
http://vnx.su
EXPLODED VIEW
PRN3000
http://vnx.su
Chassis
Contents
Page
30 GENERAL
33 REAR AXLE
General diagram of braking circuits
30-1
Rear axle assembly
33-1
Tightening torques (in daN.m)
30-2
Brake drum
33-2
Dimensions of the main braking

components
Brake cylinder
33-4
30-7
Brake linings (drum)
33-5
Bar specifications:
- front anti-roll bar
30-8
Bearing
33-7
rear anti-roll bar
30-8
Shock absorber
33-8
rear suspension bars
30-8
Anti-roll bar, tubular rear axle
33-9
Brake unions and pipes
30-9
Half suspension arms, tubular rear

axle
33-10
Brake fluid
30-9
Bushes, tubular rear axle
33-11
Suspension bars, tubular rear axle
33-15
Four bar rear axle
33-16
Suspension arm bearings
33-20
ENSEMBLE
AXLE
MOTEUR ET BAS
31 FRONT
Lower wishbone
31-1
Lower wishbone rubber bushes
31-2
Lower wishbone ball joint
31-3
Brake pads
31-4
Front brake calipers
31-5
Brake discs
31-6
Stub axle carrier bearing
31-7
Spring and shock absorber assembly
31-9
Anti-roll bar
31-10
Engine sub-frame
31-12
35 WHEELS AND TYRES
http://vnx.su
Specifications
35-1
Wheel balancing
35-4
Contents
Page
36 STEERING ASSEMBLY
38 ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS
Axial ball joint
36-1
Manual steering rack
36-3
Power assisted steering rack
36-4
Gaiter
36-6
Steering rack pinion
BOSCH ABS
Presentation of BOSCH ABS 5.3
38-1
38-2
36-7
Presentation of the hydraulic

regulation assembly
38-3
Manual steering assistance pump
36-8
Wiring diagram
38-4
Steering column
36-12
Wiring diagram key
38-5
31 track connector
38-6
Diagnostic socket
38-7
Hydraulic assembly
38-8
Hydraulic braking test
38-9
37 MECHANICAL ELEMENT CONTROLS

Master cylinder
37-1
Brake servo
37-3
Air filter - Brake servo non-return

valve
37-5
Vacuum pump
37-6
Handbrake control lever
37-7
Handbrake control
37-8
Brake pipes
37-10
Braking compensator
37-11
Clutch control cable
37-22
Clutch automatic wear take-up

system
37-23
External gear control
37-24
http://vnx.su
GENERAL
General diagram of braking circuits
30
NOTE : the diagram below shows the general principle ; in no case should it be taken as reference for the
circuit connections and allocations. When replacing one of the components of the brake circuit on a vehicle,
always mark the pipes before removing them so that they can be connected back in their original positions.
"X" PATTERN BRAKING
with load sensitive compensator
91563S
30-1
http://vnx.su
FRONT
AXLE
GENERAL
30
DI3035R
30-2
http://vnx.su
FRONT
AXLE
GENERAL
30
DI3034R1
Fitting direction must be observed
30-3
http://vnx.su
TUBULAR
REAR AXLE
GENERAL
30
88507-1R2
30-4
http://vnx.su
4 BAR
REAR AXLE
GENERAL
30
88507-2R2
30-5
http://vnx.su
GENERAL
30
DIMENSIONS
TIGHTENING TORQUES
0.6 to 0.8
Hoses for front calipers
M 10 100
1.7
Hoses on rear suspension arm
M 10 100
1.7
Rear wheel cylinder supply
M 10 100
or
M 12 100
1.7
Master cylinder outlets
M 10 100
or
M 12 100
1.7
Compensator inlet
M 10 100
or
M 12 100
1.7
Compensator outlets
M 10 100
or
M12 100
1.7
Bleed screw
30-6
http://vnx.su
GENERAL
Dimensions of the main braking components
30
FC0X
FC0X
KC0X
KC0X
CUS
CUA
54
54
Diameter of discs
238.2
238.2
Thickness of discs
20
20
Minimum disc thickness
17.7
17.7
Pad thickness (including backing)
17.8
17,8
Minimum pad thickness (including backing)
5.5
5.5
Maximum disc run-out
0.07
0.07
22
22
Diameter of drums
203.2
228.3
Maximum drum wear diameter
204.45
229.5
Diameter of discs
Thickness of discs
Minimum disc thickness
Lining size
38
40
FRONT BRAKES (in mm)
Diameter of wheel cylinders
REAR BRAKES (in mm)
Diameter of wheel cylinders
Secondary
3.15 (ABS) - 2.8(no ABS)
Lining thickness (including backing)
4.8 (ABS) - 4.5(no ABS)

Primary
4.6 (ABS) - 4.2(no ABS)
Minimum lining thickness (including backing)
22.2
22.2
MASTER CYLINDER (in mm)
Diameter
CUS :
CUA :
Standard payload
Increased payload
30-7
http://vnx.su
GENERAL
Front anti-roll bar specifications
30
VEHICLE TYPE
FC0X
KC0X
DIAMETER (in mm)
23
Rear anti-roll bar specifications
TUBULAR REAR AXLE
4 BAR REAR AXLE
FC0X
KC0X
FC0X
KC0X
18
26.4
NUMBER OF SPLINES, BEARING SIDE
30
NUMBER OF SPLINES, SHACKLE SIDE
31
VEHICLE TYPE
DIAMETER (in mm)
Rear suspension bar specifications
TUBULAR REAR AXLE
4 BAR REAR AXLE
FC0X
KC0X
FC0X
KC0X
22.1
25.5
NUMBER OF SPLINES, BEARING SIDE
30
30
NUMBER OF SPLINES, SHACKLE SIDE
31
31
VEHICLE TYPE
DIAMETER (in mm)
30-8
http://vnx.su
GENERAL
Brake unions and pipes
30
The connection of the pipes between the master

cylinder, calipers, compensator and the hydraulic
assembly is made using threaded unions with a
METRIC THREAD.
Consequently, only parts specified in the Parts

Catalogue for this vehicle should be used.
Identification of parts
-
SHAPE of the ends of PIPES in steel or copper

(A),
SHAPE of the THREADED LOCATIONS on

components (B),
pipe UNIONS coloured GREEN or BLACK:

HEXAGONAL OUTSIDE 11 mm or 12 mm (C).
78491R
Brake fluid
BRAKE FLUID RENEWAL FREQUENCY
Braking technology, in particular for disc brakes (hollow pistons which transmit little heat, low volume of
fluid in the cylinder, sliding calipers avoiding the need for a fluid reservoir in the least cooled area of the
wheel), has allowed us to avoid the risk of vapour lock as far as possible, even if the brakes are used
intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of
humidity and replacement of the fluid is therefore recommended (refer to vehicles Warranty and Servicing
Handbook).
Topping up the level:
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should
not be compensated for since the level will rise again when the pads are changed. The level should not
however be allowed to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to
deterioration of the cups. To avoid such risks, it is important to use only those brake fluids which have been
tested and approved by our Technical Department and which conform to standard SAE J 1703 dot 4.
30-9
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FRONT AXLE
Lower wishbone
Wheel bolts
Lower wishbone nut on sub-frame
Key nut on stub-axle carrier
Anti-roll bar bearing nut
31
REFITTING
9
9
5.5
1.5
NOTE : ensure the plastic protective washer ( A ) is

present on the lower ball joint shaft.
Refit:
REMOVAL
the wishbone,
Put the vehicle on a two post lift.
the two bolts, without tightening them,
Remove both wheels.
the ball joint shaft in the stub-axle carrier and

tighten the key nut.
Remove the mounting nuts for the anti-roll bar on

the lower wishbones.
Release the anti-roll bar downwards.
Refit the anti-roll bar and fit the mounting nuts

using tool Sus. 1414 (see method in anti-roll bar
section).
Remove:
- the nut and key on the stub-axle carrier,
This tool allows the rubber mounting to be

compressed to fit the nut.
- the two mounting bolts for the wishbone on

the sub-frame,
- the wishbone.
12992R
NOTE : bounce the suspension and tighten the

wishbone and anti-roll bar bearing nuts to the recommended torque (tightening position: vehicle
unladen).
85875R2
31-1
http://vnx.su
FRONT AXLE
Lower wishbone rubber bushes
REPLACEMENT
To ensure the bushes are correctly positioned in

relation to the lower wishbone, they are replaced
one after the other.
On the press, remove one of the worn bushes
using a tube of external diameter 30 mm.
Refit the new bush, ensuring that dimension A =
146.5 mm.
Remove the second bush on the press and proceed
in the same manner as for the first bush, ensuring
the new bush is fitted so that dimension A =
146.5 mm.
90404R
31-2
http://vnx.su
31
FRONT AXLE
Lower wishbone ball joint
31
REMOVAL
If the gaiter is damaged, the complete ball joint

must be replaced.
Proceed in the same manner as for removing the
lower wishbone.
Slacken but do not remove the two mounting
bolts (3) for the wishbone on the sub-frame.
85875R1
Remove:
-
the two ball joint mounting bolts (4) ,
the ball joint.
REFITTING
Note : ensure the plastic protective washer ( A ) is

present on the lower ball joint shaft.
Fit the ball joint and torque tighten the
mountings.
Then proceed in the same manner as for refitting
the lower wishbone.
31-3
http://vnx.su
FRONT AXLE
Brake pads
31
Fre. 823
Tool for pushing piston back
REFITTING
Wheel bolts
Push back the caliper piston using tool Fre. 823.
9
4
Fit new brake pads.

The brake pad with the wear warning light wire
(if fitted) is fitted to the inside.
REMOVAL
Disconnect the wear warning light wire (if fitted).
Refit the caliper into position and fit the lower

guide bolt.
Push the piston back, sliding the caliper by hand.
Tighten the guide bolt to the recommended

torque 4 daN.m.
Remove the lower brake caliper guide bolt.
Reconnect the wear warning light wire (if fitted).

piston into contact with the pads.
12994R
Pivot the caliper around the upper bolt.

Remove the brake pads.
Check:
-
the condition and mounting of the piston dust

cover,
the condition of the guide dust cover.
31-4
http://vnx.su
FRONT AXLE
Front brake calipers
REPAIR
Wheel bolts
31
NOTE : if there are any scratches in the caliper

bore, the complete caliper must be replaced.
9
4
10
To do this:
REMOVAL
remove the brake caliper,
In the passenger compartment, fit a pedal press

(limits the amount of brake fluid which will run
out).
remove the rubber dust cover,
remove the piston using compressed air,

inserting a wooden block between the caliper
and the piston to prevent damage to the
piston: any trace of damage to the piston skirt
will render it unusable
remove the seal from the caliper groove using

a flexible rounded edge blade (eg feeler
gauge).
Release the brake pipe at the wheel cylinder end.

Remove the brake pads (see previous page).
Remove the two mounting bolts for the caliper on
the stub axle carrier.
Completely release the brake pipe by turning the
caliper.
Clean the parts using methylated spirits.
Check the condition of the pipe and replace it if

necessary.
Replace any faulty parts using original parts and

then refit the seal, piston and dust seal.
REFITTING
Fit the pipe onto the caliper.

Remove the pedal press.
To check the correct operation of the caliper
cylinder, slacken the bleed screw and wait for
brake fluid to run out.
Retighten the bleed screw.
Refit the caliper on the stub axle carrier and
tighten the bolts to the recommended torque.
Refit the pads and the wheel cylinder (follow the
method described previously).
31-5
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FRONT AXLE
Brake discs
31
Brake discs cannot be reground. If they are too

heavily worn or are scratched they must be replaced.
Wheel bolts
9
10
REMOVAL
Remove:
-
the two brake assembly mounting bolts

(attach the assembly to the spring),
the two mounting bolts securing the disc to

the hub,
the disc.
REFITTING

NOTE : when a brake disc is replaced, the pads
must also be renewed.
31-6
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FRONT AXLE
31
Rou.
15 -01
Shaft protector
Rou.
604 -01
Hub locking tool
T.Av.
476
T.Av. 1050-02
Tool for pushing driveshaft back
Remove the hub on the press.
Driveshaft nut
Wheel bolts
Remove the lower bush from the hub using an extractor with jaws and tool Rou. 15-01.
28
9
Shock absorber base nut
18
10
Track rod end nut
3.7
Key nut on stub axle carrier
5.5
REMOVAL

Remove:
-
the wheel,
the brake caliper and attach it to the spring so

the pipe is not damaged,
the track rod end using tool

T.Av. 476,
the driveshaft nut.

83348G
Push back the driveshaft using tool :

T. Av. 1050-02.
Remove the locking spring ring from the stub axle

carrier.
Remove:
On the press remove the remainder of the bearing, taking care to take the weight on the inner
bush using a tube of the same diameter.
the brake disc,
the lower ball joint nut and key,
the two shock absorber base bolts,
the hub / stub axle carrier / bearing assembly.
31-7
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FRONT AXLE
31
Fit on the press, using a tube of external diameter

48 mm and internal diameter 42 mm, taking the
weight on the inner bearing bush.
79057S
REFITTING
Fit the bearing on the press, into the stub axle carrier using a tube of external diameter
70 mm and bore 66 mm, taking the weight on the
external bush.
85902S1
Refit the hub / stub axle carrier / bearing assembly

to the vehicle.
IMPORTANT : do not take the weight on the internal bush to avoid damaging the bearing as the
force required to push the bearing on is quite
considerable.
Refitting is then the reverse of removal. Observe the

correct tightening torques.
79058-1S
Fit a new locking spring ring.

Coat each sealing lip of the bearing with multipurpose grease.
31-8
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FRONT AXLE
Spring and shock absorber assembly
31
EQUIPMENT REQUIRED
Spring compressor
Replacing a shock absorber
Shock absorber base mounting bolt

Rebound stop nut
Wheel bolts
When replacing a shock absorber, fit it in a vice

and compress the spring using the spring
compressor tool.
18
6
9
Remove the spring retaining nut.

REMOVAL
Remove the spring and the intermediate parts.
Put the vehicle on a four post lift.
If necessary, replace the shock absorber pad and

the rotating stop.
Remove:
-
the wheels,
the shock absorber base mounting bolts.
When refitting, ensure all components are

replaced in the correct location and then
decompress the spring.
NOTE : release the ABS sensor wiring if this is

fitted on the base of the shock absorber.
NOTE : apply grease between the ends of the

spring and its stops.
Remove the upper shock absorber nut in the

engine compartment.
REFITTING
Remove the shock absorber and spring assembly.
Refitting is then the reverse of removal. Observe

the correct tightening torques.
31-9
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FRONT AXLE
Anti-roll bar
31
Sus.
1413
Central bearing compressor
Sus.
1414
Rubber mounting compressor
Central bearing bolt

Rubber mounting nut
3
1.5
the two rubber mounting nuts at the ends of

the anti-roll bar,
the two bolts from the central bearings on the

bar.
Check the condition of the bearings and the

rubber mountings and replace them if necessary.
REMOVAL
Put the vehicle on a four post lift.

Remove:
REFITTING
the two lower bolts from the exhaust

downpipe,
Refit:
the two sub-frame reinforcements (4 bolts),
the rubber mounting nuts using tool

Sus. 1414,
12993-1R
12992R
31-10
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FRONT AXLE
Anti-roll bar
-
31
the central bearing bolts using tool

Sus. 1413.
12991R
the two sub-frame reinforcements,
the lower bolts on the exhaust downpipe.
Rubber bush locking position : UNLADEN .
31-11
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FRONT AXLE
Engine sub-frame
31
Mot. 1040 -01

T. Av. 476
Dummy sub-frame for removing/refitting engine/transmission assembly

Wheel bolts
Track rod end nut
Steering universal joint bolt
Sub-frame mounting bolt
9
3.7
2.5
front 10
6
rear 12
10.5
Sub-frame - side member tie rod nut
3
Key nut on stub axle carrier
5.5
Engine tie bar
6.5
Steering box mounting bolt
5
REMOVAL

12988R
Remove the wheels.
Remove:
Disconnect the track rod ends using tool T. Av.

476.
the two nuts for the steering rack heat shield,
Remove the key on the stub axle carrier.
the mounting nuts for the steering rack and

attach it to the exhaust manifold.
Release but do not remove the mudguards to

reach the upper bolt on the sub-frame - side member tie rod and remove it.
Remove:
-
the exhaust downpipe and attach the catalytic

converter,
the bolt (engine side) for the engine tie bar.
the gear control by removing the two bolts at

the ends of the control. To do this, the catalytic converter heat shield must be removed and
the gaiter on the gearbox side must also be removed.
12993-1R1
Fit tool Mot. 1040-01 under the engine sub-frame.
31-12
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FRONT AXLE
Engine sub-frame
Remove the sub-frame mounting bolts.
Carefully raise the lift.
REFITTING
Systematically renew the engine sub-frame mounting bolts and ensure they are tightened to the
correct torque.
NOTE : the engine sub-frame is fitted to the body

in the following manner.:
fit 2 pins in place of the front mounting bolts,
offer up the sub-frame,
tighten, but do not lock, the rear mounting

bolts (begin with the longest rear right hand
bolt),
replace the pins with mounting bolts at the

front,
tighten the four mounting bolts to the correct

torque, beginning at the rear,
ensure the heat shields are correctly refitted.
31-13
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31
REAR AXLE
Rear axle assembly
33
Bearing mounting nut

Wheel bolt
11
9
8.5
REMOVAL
REFITTING
Fit the pedal press.
Bleed the brake circuit.
Remove:
Adjust the handbrake (see section 37).
the two lower shock absorber mountings,
Check and if necessary adjust the braking

compensator ( see section 37 ).
the brake pipes,
the compensator control,
the central heat shield,
the handbrake cables, disconnecting them

from the central control,
Unclip the cables from the fuel tank.

Support the rear axle assembly and remove the
nuts ( 1 ).
13132R
Remove the rear axle assembly.

NOTE : the bolts can be reached under the rear
bench seat (depending on version) after
removing the blanking covers.
33-1
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REAR AXLE
Brake drum
33
The two brake drums must be of the same diameter, if one is reground, the other must also be reground.
Never exceed the diameter marked on the drum.
Emb. 880
Rou. 943
Inertia extraction tool

Hub cover plug extractor
Wheel bolts
Hub nut
9
17.5
REMOVAL
Remove the hub plug using tools Rou. 943 +

Emb. 880.
98991
Release the handbrake, slacken the secondary

handbrake cables to allow the lever to move back.
Insert a screwdriver through one of the wheel
mounting holes in the drum and push the handbrake lever to release the lug from the brake
shoe( E ).
Help the lever to slacken by pushing it towards
the rear.
98990G
Remove:
-
the nut and stub axle washer,
the drum.
33-2
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REAR AXLE
Brake drum
REFITTING
Remove all dust from the drum and the linings

using brake cleaner.
Fit:
-
the drum,
the washer and the nut, which must be torque

tightened,
the plug.
Adjust:
- the linings by repeatedly pressing the brake
pedal,
-
the handbrake (see section 37 "Controls").
33-3
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33
REAR AXLE
Brake cylinder
33
Wheel bolts
Hub nut
Bleed screw
Pipe bolt
9
17.5
0.5 to 0.8
1.7
REMOVAL
REFITTING
Remove:
Remove all dust from the drums and the linings

using brake cleaner.
the drum (see corresponding section),
the upper return spring (see paragraph

"Brake linings").

Bleed the braking circuit (see section 38).
Separate the shoes.
Adjust the linings by repeatedly pressing the

brake pedal.
Slacken:
Check the cut-out pressure (see section 37

"Controls").
the rigid pipe union on the wheel cylinder

using a pipe wrench,
the two cylinder mounting bolts on the

backing plate and remove it.
Check the condition of the shoes. If they have

traces of oil on them, renew them.
33-4
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REAR AXLE
33
Emb. 880
Rou. 943

Hub cover plug extractor
REMOVAL
Wheel bolts
Hub nut
Brake shoes must be replaced on the complete

axle - never fit shoes of differing makes or
grades.
9
17.5
Composition of RAI brake (Rattrapage Automatique Incrmental - automatic wear take up

system).
Remove:
- the brake drum (see corresponding paragraph),
- the lower spring (2) using brake shoe pliers.
Using adjustable pliers, remove the shoe side
retaining springs.
In turn, pass each brake shoe base over the fixed
point. Squeeze the bases of the shoes together to
separate the ends at the wheel cylinder end.
Separate the assembly (RAI and shoes) from the
brake backing plate then remove it, after
unclipping the handbrake cable.
98992-2R
A Leading shoe
B Trailing shoe
C Fixed point
P Base of brake shoe
F RAI wear take up system
1 Upper return spring
2 Lower return spring (for base)
3 Side retainer
4 Handbrake lever return spring
33-5
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REAR AXLE
REFITTING
Ensure:
Present the assembly to the vehicle.
- the cables slide freely,
Attach the handbrake cable to the lever.
- the handbrake levers (L) are correctly

positioned against the shoes.
33
Squeeze the bases of the shoes together and

position the other ends on the wheel cylinder
pistons. Take care not to damage the covers.
Position the shoes on the fixed point (C).
Fit the side retainers (3).
Remove the pliers from the wheel cylinder pistons
then refit the lower spring (2).
ADJUSTMENT
Using a screwdriver, adjust the brake shoe

diameter using the notched segment.
Refit the drums without tightening the nuts.
Centre the linings by repeatedly pressing the
brake pedal (approximately 20 times).
Ensure the RAI is operating correctly
(characteristic click from the drums).
Remove the drums.
98992-3R
Progressively tighten the cables at the central

adjustor so that levers (L) start to move between
the 1st and 2nd notch of the control lever travel
and remain applied from the 2nd notch.
Lock the lock nut on the central adjuster.
Refit:
- the drums and tighten the nuts to a torque of
17.5 daN.m,
- the plugs.
33-6
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REAR AXLE
Bearing
33
Emb. 880
Rou. 943

Hub plug extractor
Hub nut
Wheel bolts
17.5
9
CHECKING
REFITTING
Check the end float using a dial gauge mounted

on the drum : 0 to 0.03 mm maximum.
Using a tube and a press, fit the bearing until it

touches the shoulder.
Fit:
REMOVAL
a new clip,
the drum on the pre-lubricated stub axle,
a new lock nut and tighten to the correct

torque,
the hub plug.
Remove:
-
the hub plug using tools Rou. 943 + Emb. 880,
the brake drum (see corresponding

paragraph).
From the drum, remove:

Adjust:
-
the bearing retaining clip,
the bearing using a tube.
the brake shoes by repeatedly pressing the

brake pedal,
the handbrake (see section 37 "Controls").
33-7
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REAR AXLE
Shock absorber
PRECAUTIONS TO BE TAKEN BEFORE FITTING
Upper mounting bolt

Lower mounting bolt
11.5
8.5
Shock absorbers are stored horizontally in the

Parts Stores.
Under these conditions it is possible that the shock
absorbers, which are designed to operate in a vertical direction, will have de-primed.
REMOVAL
With the vehicle on its wheels, remove the lower

mounting bolt (1).
Before fitting the shock absorbers to the vehicle

compress them a few times by hand in the vertical
position.
Lift the vehicle and remove:

-
the wheel,
the upper mounting bolt (2),
33
REFITTING
Fit:
-
the shock absorber,
the upper mounting bolt coated with

MOLYKOTE BR2 , without tightening it,
the wheel.
Lower the vehicle.

Position the lower mounting bolt coated with
MOLYKOTE BR2.
Torque tighten both bolts.
13133R
the shock absorber.
33-8
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REAR AXLE
Anti-roll bar, tubular rear axle
Bar mounting bolt
5.5
REMOVAL
13132R
Mounting bolt
Put the vehicle on a lift with the wheels hanging

free.
On each side, remove bolts (1) and retain the
captive nuts.
Remove the bar.
REFITTING
On each side, refit the bolts (1) with the captive

nuts.
Tighten to the recommended torque.
33-9
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33
REAR AXLE
Half suspension arms, tubular rear axle
REFITTING
Bearing mounting nut

Anti-roll bar mounting bolt
Wheel bolt
33
Ensure the bearing races or the needle bearings

are in perfect condition, otherwise replace them
(see section "Bushes, tubular rear axle").
11
5.5
9
8.5
The needle bearings are greased for life and do

not require further lubrication.
NOTE : new suspension arms are supplied by the
Parts Department fitted with bearing races or
needle bearings (depending on side).
REMOVAL
Put the vehicle on a two post lift, remove:
Fit the two half suspension arms together until

dimension (B) is obtained.
the anti-roll bar,
the lower shock absorber mounting,
the secondary handbrake cable, disconnecting

at the central adjuster under the vehicle,
the brake pipe,
the two bearing mounting nuts (A).
NOTE : dimension (B) corresponds to the distance

between the same two mounting points for the
anti-roll bar on the suspension arms. It is therefore
possible to obtain this dimension by positioning
the anti-roll bar in its location and checking the
mounting bolts can be correctly positioned.
Ensure the fitting direction is observed.
86320R
13132R1
NOTE : if the half suspension arm is renewed,

bond the brake backing plate mounting bolts
with Loctite FRENBLOC.
Slacken the two nuts (A) on the other bearing so

the half suspension arm can be released from its
mountings.
Remove the half suspension arm, separating one

from the other.
Adjust the handbrake control (see section 37).
33-10
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REAR AXLE
33
This operation is carried out after removing the complete rear axle assembly and separating the two
suspension arms.
Grind the bearing races on the male suspension
arm (right hand side) using a straight grinding
wheel, taking care not to mark the tube.
T. Ar. 960-02
Bush + spacer extractor
T. Ar. 960-05
Tooling for replacing needle

bearings.
REMOVAL
Remove from the female suspension arm (left

hand side) :
-
the outer bush (6) using tool T.Ar. 960,

the inner bush (7) using the small socket of
tool T.Ar. 960.
90864S
Split the bearing races using a chisel then remove

them.
Cut and remove the seal (5).
86182R
90863R
86180R
33-11
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REAR AXLE
33
On the press, press on mandrel (A) until it touches

face (2) of mandrel (B).
REFITTING
Tool T.Ar. 960-05 must be used for fitting the

needle bearings and the bearing races.
90868R
90874R
Fit:
- the large needle bearing on mandrel (B),
Fit :
-
the small needle bearing on the mandrel (A),
the mandrel (A) into the tube, using mandrel

(B) as a guide.
90865R
90866R
33-12
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REAR AXLE
-
mandrel (B) in the tube, using mandrel (A) as a

guide.
33
The bearing races have an input chamfer on one

side.
It is important to observe the fitting direction:
chamfer (4) must be aligned as shown in the
diagram to ensure sufficient bearing surface to
press the parts on.
90868-1R
90941R
Fit:
On the press, press on until mandrel (B) touches
the tube.
the large bearing race in sleeve (D),

the assembly of sleeve (D) and (C) on the
tube.
90868-2R
90867-5R
Remove mandrels (B) and (A).

Fit the new seal (5) on the male tube.
33-13
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REAR AXLE
Press on the assembly (D) and (C) until the sleeve
(C) reaches the edge (3) of the tube.
33
On the press, press on until the sleeve (C) reaches

the edge (3) of the tube.
90867-2R
90867-4R
Fit :
Remove sleeves (C) and (D).
the small bearing race in sleeve (C),
IMPORTANT
sleeve (C) on the tube, using sleeve (D) as a

guide.
When pressing on the parts, if the weight has

been taken on the axle mounting bearings, it
must be ensured that the suspension arms are
correctly located in their mountings (risk that
they may have been moved).
Recentre them if necessary.
Assemble the two half axle sections.
NOTE : the needle bearings are greased for life
and do not require further lubrication.
Reconnect and refit the rear axle assembly to the
vehicle (see corresponding section).
90867-3R
33-14
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REAR AXLE
Suspension bars, tubular rear axle
33
Emb. 880
Inertia extractor
Preset the tool to obtain dimension "X".
Upper shock absorber mounting bolt

Lower shock absorber mounting bolt
X = 402 mm
11.5
8.5
Fit the tool in place of the shock absorber.
REMOVAL
With the vehicle raised so its wheels hang free, remove the shock absorber on the side in question.
Remove the bar from the side, using tool
Emb. 880.
REFITTING
In order to position the suspension arm so that the

bar may be correctly positioned, a tool must be
locally made.
A
Nut, diameter 14 mm
Nut, diameter 12 mm
Threaded rod, diameter 12 mm - length 660

mm
88637R2
Bracket from flat sheet 30 x 5 mm
12 x 60 mm bolt, cut to a length of 20 mm
Weld
Coat the splines of the bar with MOLYKOTE BR2 ,

fit it into the bearing and the suspension arm, and
try, by rotating the rod, to find the position where
it fits freely into the splines of the suspension arm
and the bearing.
Remove the tool and refit the shock absorber.
Return the vehicle to its wheels and measure the
underbody heights (see section "Underbody
heights - Tubular rear axle").
Check and adjust if necessary:
-
the braking compensator,
the headlights.
75505R
33-15
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REAR AXLE
Four bar rear axle
33
PRN3300
The four bar rear axle comprises:

-
two arms connected by an "L" section. This assembly (1) cannot be dismantled. Any deformation would
mean its complete replacement.
two anti-roll bars (3),
two suspension bars (4),
a shackle (2) connecting the bars.
The assembly is connected to the body by two bearings mounted on rubber bushes.
NOTE : Never take the weight of the vehicle using a jack on the "L" section (1) to lift the vehicle.
33-16
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REAR AXLE
Four bar rear axle
33
Emb. 880
Inertia extractor
Upper shock absorber mounting
8.5
Lower shock absorber mounting
11.5
Wheel bolts
REMOVAL
REFITTING
Remove:
-
the wheels,
the shock absorbers,
The anti-roll bars cannot be removed from the

vehicle when the shock absorber replacement tool
is in position. Because of this, and to make it
easier to refit the shackle, a wooden block must
be made according to the diagram below.
the suspension bar plugs.
Fit:
-
Remove using tool Emb. 880 :

-
the two suspension bars,
the two anti-roll bars, retaining the central

shackle.
the shackle on the block (locally made) in the

centre of the rear axle assembly,
Clean and lubricate the bar splines using

MOLYKOTE BR2 .
13135R
Dimensions in mm and degrees ( ).
33-17
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REAR AXLE
Four bar rear axle
-
33
the first anti-roll bar, ensuring the angle of

the block is observed, and the bar is inserted
freely.
75505-1R1
13134S
the second anti-roll bar, ensuring it engages

freely.
In order to position the suspension arm so that the

bar may be correctly positioned, a tool must be locally made.
Nut, diameter 14 mm
Nut, diameter 12 mm
Threaded rod, diameter 12 mm - length 660

mm
88637R2
Preset the tool to obtain dimension "X".

X = 430 mm
Bracket from flat sheet 30 x 5 mm
Fit the tool in place of the shock absorber.
12 x 60 mm bolt, cut to a length of 20 mm
Refit:
Weld
the bar plugs,
the shock absorbers,
the wheels.
Put the vehicle on its wheels and measure the underbody heights ( see section "values and settings" ).
33-18
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REAR AXLE
Four bar rear axle
Check and if necessary adjust:

-
the braking compensator,

the headlights.
REMINDER
When adjusting for a wheel height difference

between the right and left hand sides, always
make the adjustment on the anti-roll bars.
The adjustment for a difference in dimension " X"
between the right and left hand sides should
always be made on the suspension bars.
33-19
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33
TUBULAR REAR
AXLE
REAR AXLE
33
Saw through the inner ring taking care not to

scratch in the tube of the arm.
This operation is carried out after removing the

rear arms and the suspension bars.
REMOVAL
Totally immerse the bearing in brake fluid to

soften the rubber bush.
75362S
REFITTING
The bearing is fitted in the arm on the press,

ensuring the correct alignment is observed and
the clearance between the bearing and the arm is
correct.
DI3303
Using a two or three claw extractor, remove the

external part of the bearing by tearing off the
rubber.
Alignment
Observe dimension "X" between the bearing
pressure face and the stub axle shaft:
X = 156 mm 3.5
DI3310
85909S
33-20
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TUBULAR REAR
AXLE
REAR AXLE
33
Clearance
In this position, press on the bearing until the
dimension between the bearing centres is :
Y = 1164 mm 1
DI3311
Fit the arm to the vehicle.
33-21
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FOUR BAR REAR

AXLE
REAR AXLE
33
This operation is carried out after removing the

rear axle assembly and the suspension bars.
REMOVAL
Weld a spacer (example : nut) in the central tube

of the bush.
DI3312
Clearance
In this position, press on the bearing until the
dimension between the bearing centres is :
Y = 1164 1 mm
90241G
Remove the bush - bearing assembly on the press.
REFITTING
The bearing is fitted in the arm, ensuring the correct alignment is observed and the clearance between the bearing and the arm is correct.
Alignment
Observe dimension "X" between the bearing
pressure face and the stub axle shaft
X = 124 3.5 mm
DI3313
Fit the rear axle assembly to the vehicle and refit

the suspension bars (see corresponding section).
33-22
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WHEELS AND TYRES

Specifications
35
WHEEL RIMS
There are two forms of wheel identification marking:

-
engraved markings for steel rims,
cast marking for alloy rims.
The marking gives the main dimensional specifications of the wheel.

The marking may be complete:
Example : 5 1/2 J 14 4 CH 36
or simplified
Example : 5 1/2 J 14
A
TYPE
OF WHEEL
5 1/2 J 14
4 CH 36
WIDTH
(in inches)
5 1/2
NOMINAL DIAMETER
RIM
PROFILE
(in inches). under tyre

bead
14
Number
of holes
4
Tyre bead
profile
CH
Offset
(in mm)
36
The four wheel bolts are over a diameter of 100

mm (4 mounting bolts).
Maximum run-out: 1.2 mm measured on the rim
edge (at G).
Maximum eccentricity: 0.8 mm measured on the
pressure face of the tyre beads.
DI3501
35-1
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WHEELS AND TYRES

Specifications
35
TYRES
Examples of identification marking

165/70 R 13 83 S
165
70
13
83
85920R2
165
Tyre width in mm ( l ) section
70
Ratio h/l
height
width
Radial structure
13
Inner diameter expressed in inches. Corresponds to the diameter of the rim.
83
Load index
Speed index 180 km/h maximum

Some speed symbols :
Maximum speed
R
S
T
U
H
V
ZR over
Types of structure :
Diagonal
Radial
Bias belted
No marking
R
B
35-2
http://vnx.su
170
180
190
200
210
240
240
km/h
WHEELS AND TYRES

Specifications
Type
Rim
Wheel bolt
torque
(daN.m)
5 B 13
FC0X
KC0X
5 B 13
Tyres
35
Inflation pressure
(bar) cold
Front
Rear
165/70 R 13 C 88/86
2.8
3.6
165/70 R 13 83 (1)
2.6
2.9
165/70 R 14
2.4
3.0
5,5 J 14
The tyre inflation pressures are values for a fully laden vehicle or motorway use.
The tyre inflation pressure must be checked when cold. The increase in temperature during driving increases
the pressure by 0.2 to 0.3 bar.
If the inflation pressures are checked when the tyres are warm, take this pressure increase into consideration.
Never deflate a warm tyre.
(1) Reinforced tyre.
Chains
For safety reasons, chains may NEVER be fitted to the rear axle.
"Snow" or "thermorubber" tyres: all four wheels must be fitted with these tyres to retain vehicle adhesion as
far as possible.
35-3
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WHEELS AND TYRES

Wheel balancing
35
BALANCE WEIGHTS
Only use weights provided by the Parts

Department:
-
fitted using hooks to steel wheels (hook is part

of the weight),
fitted using hooks (flat hooks) or self adhesive

for alloy wheels.
A
B
Steel wheel rim

Alloy wheel rim
88659R
35-4
http://vnx.su
STEERING ASSEMBLY
Axial ball joint
36
Dir. 1305-01
Tool for removing - refitting

axial ball joint
Dir. 1306
Tool for retaining SMI unit rack
T.Av. 476
Turn the wheels so the rack teeth are freed on the

valve side.
Wheel bolts
Track rod end nut
3.7
Bolt on parallelism adjustment sleeve
1.7
Axial ball joint
Fit tool Dir. 1306.

In this position, release the axial ball joint using
tool Dir. 1305-01.

REMOVAL
Disconnect the track rod end using tool T.Av. 476.

Slacken the bolt on the parallelism adjustment
sleeve and slacken the track rod end while
holding the axial ball joint using an open wrench.
97469R1
Make a mark or count the number of turns of

thread taken up so the parallelism can be preadjusted on refitting.
Remove the plastic retaining clip for the gaiter
and remove the gaiter.
36-1
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STEERING ASSEMBLY
Axial ball joint
REFITTING
Assembly (2) MUST be renewed systematically.
83510-1R3
Refit to the rack (3) :

- the stop washer assembled with the locking
ring (2),
- the new axial ball joint (1) having lightly coated
the threads with LOCTITE FREN-BLOC, ensuring
that the air evacuation opening is not blocked.
Before finally tightening the axial ball joint using
tool Dir. 1305-01, check that the tabs on the
locking ring (2) align with the flats (B) on the rack.
Tighten the axial ball joint to the recommended
torque.
Centre the steering to equalise the air in the
gaiters.
Fit a new gaiter and secure it with a new clip
(after greasing the gaiter bearing surface on the
axial ball joint).
Checking
Gently press on the gaiter to check the other
gaiter inflates which indicates the air is circulating
correctly.
36-2
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36
STEERING ASSEMBLY
Manual steering rack
36
T.Av. 476
REFITTING
Wheel bolts
Track rod end nut
Steering rack mounting bolts
Universal joint eccentric bolt

recommended tightening torques.
9
3.7
5.5
2.5
If a new steering rack is being fitted, fit the track

rod ends in the position noted on removal.
To do this, slacken the bolt on the parallelism
adjustment sleeve and slacken the track rod end
while holding the axial ball joint using an open
wrench.

REMOVAL
Remove the front wheels.

Cut the rubber gaiter retaining clip and push the

gaiter back towards the bulkhead.
Check the parallelism.
Disconnect the ball joints using tool T.Av. 476.
NOTE : the markings on the track rod ends M U S T

BE OBSERVED (one mark on right hand joint, two
marks on left hand joint).
Remove:
-
the universal joint eccentric bolt,
the steering rack mounting bolts on the subframe.
Remove the steering rack.
36-3
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STEERING ASSEMBLY
36
Mot. 453-01
T.Av. 476
Hose clamp pliers

Cut the rubber gaiter retaining clip and push the

gaiter back towards the bulkhead.
Wheel bolts
Track rod end nut
Steering rack mounting bolt
Disconnect the ball joints using tool T.Av. 476.
3.7
Remove the universal joint eccentric bolt.
Universal joint eccentric bolt
2.5
Engine tie bar bolt
6.5
Disconnect the oxygen sensor.

Remove the exhaust downpipe.
Remove the bolt (engine side) from the engine tie
bar and pivot the engine and transmission
assembly forwards.
Insert a retaining block.

REMOVAL
Remove the front wheels.

Fit a clamp Mot. 453-01 to each of the pipes from
the oil reservoir.
NOTE : never clamp the high pressure pipes.
Special notes for F8Q engine

Remove (from above) :
-
the battery,
the battery mounting,
the high and low pressure pipes from the

steering valve.
13120S
36-4
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STEERING ASSEMBLY
Disconnect the high and low pressure pipes on the
steering rack (take precautions to catch the oil)
and the nut on the pipe retaining bracket.
36
REFITTING

recommended tightening torques.
Fill the circuit with oil.
Turn the wheels from left to right (engine not
running) to distribute the oil in the circuit.
Repeat the operation with the engine running
then top up the level.
If a new steering rack is being fitted, fit the track
rod ends in the position noted on removal.
To do this, slacken the bolt on the parallelism
adjustment sleeve and slacken the track rod end
while holding the axial ball joint using an open
wrench.
12997R
Check the parallelism.

Remove:
-
the two nuts on the heat shield for the right

hand steering rack bearing,
the steering rack mounting nuts and remove it

from the timing side.
NOTE :
- do not remove the pipes between the valve
and cylinder,
fit plugs to the steering rack openings to

prevent the introduction of impurities.
36-5
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STEERING ASSEMBLY
Gaiter
The gaiter MUST be renewed with a new gaiter
whenever an axial ball joint is removed.
Fitting the gaiter
Use an ogive on the axial ball joint to prevent
damage to the gaiter during fitting.
Coat the gaiter bearing face on the axial ball joint
with grease to prevent the gaiter twisting.
Secure the gaiter with a new clip (supplied with
the gaiter).
NOTE : the steering MUST be at the centre point
to equalise the air.
36-6
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36
STEERING ASSEMBLY
Steering pushrod
36
ADJUSTMENT
If the steering rack pinion is noisy, before considering replacing the steering rack, check that the pinion is
correctly adjusted.
1.
Determining the source of the noise
Hold the steering rack on the pinion side and

check for transverse play (up and down).
Movement followed by a click is caused by the
pinion.
2.
Adjusting for SMI steering racks
Release the adjusting nut (1) by straightening the

bent over edges (A) on the nut collar.
Check when driving that the steering returns to
the centre point.
Maximum adjustment allowed : 1 notch.
Lock the nut again in the two lugs opposite the
housing by bending over the nut collar.
83920R
36-7
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STEERING ASSEMBLY
REPLACING THE PULLEY (D7F-F8Q engine without
AC)
36
REMOVAL
With the pump removed (see removal method on

following pages), set it in a vice and extract the
pulley using tools B.Vi. 22-01 + B.Vi. 47.
REMOVAL
Remove:
-
the PAS pump belt.
the pulley (three bolts).
REFITTING

procedure for tensioning the belt (see section 07).
REPLACING THE PULLEY ( E7J engine without AC)
Dir. 1083
B.Vi. 22-01
+
Tool for refitting the PAS pump

pulley
12995R
Tool for removing the PAS pump

pulley
REFITTING
B.Vi. 47
Refit the pulley using tool Dir. 1083.

Press the pulley on to dimension:
X=
12996R
36-8
http://vnx.su
34.7 0.2
D7F engine
without AC
STEERING ASSEMBLY
Mot. 453-01
Hose clamp pliers
T. Ar. 1094
Extractor

REMOVAL
Remove:
-
the PAS pump belt,
the pulley.
Fit a clamp Mot. 453-01 to the supply pipe.

Disconnect the supply and high pressure pipes.
Take precautions to catch the PAS fluid (protect
the alternator).
Remove the three pump mounting bolts and
remove the pump.
REFITTING

Fill and bleed the circuit, moving the steering
from lock to lock.
36-9
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36
STEERING ASSEMBLY
F8Q engine
without AC
REFITTING
Mot. 453-01
36
Hose clamp pliers


from lock to lock.
REMOVAL
Remove:
-
the right hand wheel,
the right hand mudguard,
the bumper (10 bolts).
the accessories belt,
the pulley.

Take precautions to catch the PAS fluid.
remove the pump.
36-10
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STEERING ASSEMBLY
E7J engine
without AC
REFITTING
Mot. 453-01
Hose clamp pliers


from lock to lock.
REMOVAL
Remove:
-
the alternator belt,
the PAS pump belt,
the alternator.
36

Take precautions to catch the PAS fluid.
remove the pump.
13296R
36-11
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STEERING ASSEMBLY
Steering column
Steering wheel bolt

Steering column universal joint
eccentric bolt
Steering column mounting nuts
36
Remove:
4.5
- the drivers airbag cushion by the two Torx T30

bolts (tightening torque 0.5 daN.m) located
behind the steering wheel and disconnect the
connector ( D ),
2.5
2
REMOVAL

Set the vehicle wheels straight.
Remove the steering wheel in the following
manner.
Without airbag option

Remove the plastic cover.
Remove:
- the steering wheel bolt (this MUST be renewed
on refitting),
- the steering wheel after noting its position.
12973S
- the horn connector, if fitted,

With airbag option
- the steering wheel bolt (this MUST be renewed
on refitting),
REMOVAL
IMPORTANT: pyrotechnic systems (airbags and
pretensioners) must not be handled near to a heat
source or flame - they may be triggered.
- the steering wheel after setting the wheels

straight,
- the half cowlings ( three bolts).
IMPORTANT : whenever the steering wheel is

removed, the airbag connector ( D ) MUST be
disconnected. The airbag is fitted with a
connector which short circuits when it is
connected to avoid any incorrect triggering.
Disconnect the rotary switch connector and

remove it after removing the three mounting
bolts ( E ).
When removing the switch, its position must be
noted:
either by ensuring the wheels are straight when
removing it so that the track may be positioned
centrally,
or by immobilising the rotary switch rotor with
adhesive tape.
36-12
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STEERING ASSEMBLY
Steering column
If the switch is being replaced, the new part is
supplied ready-centred, held in place by an
adhesive label which tears off when the steering
wheel is moved for the first time (fit with the
wheels straight).
36
Remove:
-
the half cowlings (three bolts),
12971R
12970S
the stalk - switch assembly (one bolt).
12967-1R
Disconnect the connectors.
36-13
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STEERING ASSEMBLY
Steering column
36
Remove:
-
the instrument panel visor ( six bolts).
12968S
the lower protector ( four bolts).
12970-1R1
the four mounting bolts for the instrument

panel and disconnect the connectors.
12966R
12969-1R1
36-14
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STEERING ASSEMBLY
Steering column
Remove the mounting bolts for the dashboard on
the steering column.
36
Release:
-
the steering column after disconnecting the

ignition switch,
the gaiter from the bulkhead ( 1 ) and remove

it with the steering column.
REFITTING
Refit the steering column.

Fit the gaiter on the bulkhead, having tied the
flaps and the universal joint together with string.
12964R2
Under the vehicle, cut the retaining clip for the

rubber gaiter and push it back towards the
bulkhead.
Remove the eccentric bolt from the universal
joint.
Remove the two bolts and the two nuts mounting
the steering column.
13116S

Check the instrument panel connectors are
correctly reconnected.
12965-1R2
36-15
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STEERING ASSEMBLY
Steering column
SPECIAL NOTES FOR VEHICLES FITTED WITH A
DRIVERS AIRBAG
36
IMPORTANT
Before reconnecting the drivers airbag cushion,

check to see if the system is operating correctly as
follows:
Ensure that the wheels are still straight.

Check that the rotary switch is still immobilised
before refitting.
If it is not, follow the method for centring
described in section 88 "drivers airbag".
check the airbag warning light on the

instrument panel is illuminated when the
ignition is on,
Renew the steering wheel bolt each time it is

removed ( pre-bonded bolt).
connect a dummy ignition module to the

drivers airbag connector and check that the
warning light extinguishes,
Observe the correct tightening torque ( 4.5

daN.m).
switch the ignition off, connect the airbag

cushion in place of the dummy ignition module
and secure the cushion to the steering wheel,
switch the ignition on. Check the warning light
illuminates for three seconds when the ignition
is switched on then extinguishes and remains
extinguished.
If the warning light does not operate as described
above, refer to the fault finding section and check
the system using the XRBAG (El. 1288).
IMPORTANT : if these instructions are not

followed exactly the system may not operate
normally and could even be triggered incorrectly.
36-16
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Master cylinder
37
Hydraulic pipe unions

Mounting nut on brake servo
1.7
1.8
REMOVAL

Disconnect the brake fluid level detector
connector.
Remove the injection computer (depending on
version).
Release the PAS reservoir and move it to the side,
towards the engine.
91101R
Drain and remove, by pulling up, the brake fluid

reservoir (take care to catch the fluid which will
run out).
NOTE : these vehicles have a master cylinder

which is integral to the brake servo. Sealing of the
brake servo is directly linked to that of the master
cylinder. During any operation, a new seal (A)
must be fitted.
Remove:
Fit the master cylinder in alignment with the

brake servo so that pushrod pin (P) enters
correctly into the master cylinder housing.
- the pipes and note their positions,

- the two mounting nuts on the brake servo.
REFITTING

Check the length of the pushrod.
Dimension X = 22.3 mm.
Depending on model, adjust using pin (P).
DI3718
37-1
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Master cylinder
Fill the brake fluid reservoir and bleed the brake
circuit.
MASTER CYLINDER (EXCHANGE)
The kit sold by the Parts Department comprises :

- one master cylinder (4 outlets or 2 outlets for
ABS),
- two plugs (A),
- two mounting nuts (B).
DI3719
37-2
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37

Brake servo
Mounting nut on brake servo

Brake servo on bulkhead
1.8
2.3
the air filter,
the non-return valve.
remove the 4 brake servo mounting nuts,
remove the brake servo.
REFITTING
The brake servo cannot be repaired. Operations

are only allowed on:
-
37
Before refitting, check:

-
dimension L = 104.8 mm ,
dimension X = 22.3 mm .
REMOVAL
Disconnect and remove the battery.

Remove:
-
the master cylinder (following the method

described previously),
the battery protection plate (4 bolts, 1 nut),
the two mounting nuts for the expansion

bottle and move it towards the engine.
Disconnect the flexible vacuum hose from the

brake servo.
In the passenger compartment:

-
91101R2
remove the pin ( A ) from the clevice

connecting the brake pedal to the pushrod by
moving the clip,

97860R
37-3
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Petrol engine

Brake servo
37
Mot
453 -01
Hose clamp pliers
EQUIPMENT REQUIRED
Vacuum pump
CHECKING SEALING
When checking the sealing of the brake servo, ensure the seal between the brake servo and the master
cylinder is perfect. If there is a leak, replace the seal (A).
DI3701
The sealing of the brake servo is checked on the

vehicle when the hydraulic circuit is in operating
condition.
If the vacuum drops by more than 33 mbar (25

mm/Hg) in 15 seconds, there is a leak located
either :
Connect the vacuum pump between the brake

servo and the vacuum source (inlet manifold)
using a "T" union and the shortest possible pipe.
at the non-return valve (replace it),
or at the pushrod diaphragm (replace the

brake servo).
Run the engine at idle speed for one minute.

Clamp the pipe (clamp Mot. 453-01) between the
"T" union and the vacuum source.
If the brake servo is not operational the braking

system will operate but the force required at the
pedal to obtain the equivalent deceleration as for
assisted braking is considerably higher .
Turn the engine off.
37-4
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Air filter - Brake servo non-return valve
REPLACING THE AIR FILTER
37
REPLACING THE NON-RETURN VALVE
This operation may be carried out on the vehicle.
REMOVAL
Disconnect the brake servo vacuum inlet pipe.

Pull the non-return valve while twisting it to
release it from the rubber sealing washer.
83 212
74883S
75 564
91101G
To replace the air filter (F), the brake servo does

not need to be removed.
REFITTING
Check the condition of the rubber sealing washer

and the non-return valve.
Under the pedal mounting, use a screwdriver or a

metal hook to remove the worn filter (F). Cut the
new filter at A (see diagram) and fit it around the
rod, then press it into position, checking that it
fills the complete opening to prevent any nonfiltered air from passing through.
Replace any faulty parts.

Refit the assembly into position.
37-5
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Diesel engine

Vacuum pump
REMOVAL
Drain the cooling circuit.

Remove the air tube and its mounting.
Disconnect the quick release vacuum pipe.
Remove the thermostat mounting (2 bolts).
Remove the vacuum pump (2 bolts, 2 nuts).
13097-1S
Systematically renew the drive dog when replacing the pump.
REFITTING

CHECKING
Engine warm, at 4000 rpm, the minimum vacuum

should be 700 mbar (525 mm/Hg) in 3 seconds.
37-6
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37

Handbrake control lever
37
Note the handbrake adjustment dimension,between the end of the nut (1) and the rod.
REMOVAL
Release the handbrake.

Remove the lower bolts from the exhaust
downpipe.
Remove the rear rubber mounting for the exhaust
pipe.
NOTE : attach the exhaust pipe to the body.
Remove the heat shields.
98826-2R
Slacken nut ( 1 )to release the two cables.

Remove the linkage from the clip (2).
Remove the two handbrake control lever
mounting nuts.
Remove the handbrake lever and disconnect the
connector.
12998S
REFITTING

Refit the heat shields.
Remember to reconnect the handbrake
connector.
Reset the handbrake control linkage to the
dimension noted on removal.
If necessary, adjust the lever travel (see section
"Adjusting the control").
37-7
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Handbrake control
ADJUSTMENT
Remove:
Incorrect adjustment of the handbrake where the

cable is too tight:
- the two rear wheels,
37
- the two drums.
- prevents the correct operation of the automatic compensation system for the brake shoes ,
Check the operation of the compensation system

by rotating the notched sector (D) (ensure it turns
in both directions), then turn it back by 5 to 6
teeth.
- causes long brake pedal travel.
The cables should not be re-tensioned to correct

this fault since it will quickly occur again.
The handbrake should not be used to adjust play,
it should only be adjusted when replacing :
- brake linings,
- cables,
- the control lever.
Any other adjustment except in the above cases is
not permitted.
With the vehicle on a lift supported under the body, slacken the nut (1) so the central adjuster is
completely free.
98992-1R3
98826-1R
37-8
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Handbrake control
Ensure :
- the cables slide correctly,
- the handbrake levers (B) are in the correct
position against the brake shoes.
98992-1R2
Progressively tighten the cables at the central

adjuster so that levers (B) start to move between
the 1st and 2nd notch of the control lever travel
and remain applied from the 2nd notch.
Tighten the lock nuts.
Fit the drums.
With the vehicle on its wheels, adjust the brake
linings by pressing the brake pedal firmly and
progressively for a number of times while
listening for the automatic compensation system
clicking.
37-9
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37

Brake pipes
37
These vehicles have brake pipes without a copper seal. The seal is by contact "at the bottom of the cone" of
the shoulder (Y) on the pipe.
X = 1.5
Z= 1.3
96118R
PRECAUTIONS TO BE TAKEN WHEN REMOVING - REFITTING A BRAKE CYLINDER OR A BRAKE PIPE.
For safety reasons and to ensure that the brake pipe is not twisted and is not liable to touch a suspension
component the following order of operations must be observed:
REMOVAL
REFITTING
Slacken the union (1) (pipe wrench) between the

rigid pipe and the hose (2) until the spring (3)
becomes slack which releases the hose from the
splines (4).
Fit the caliper to the brake and screw the hose

onto it, then torque tighten to
1.5 daN.m.
The brake pipes are fitted when the axle assembly
is in position:
Wheels suspended (suspension in place)
Axle assembly aligned (wheels straight)
Position the female end of the hose on the
retaining bracket (5), without twisting it and
check that the end piece (4) fits freely into the
splines of the bracket, then fit:
- the spring (3),
- the rigid pipe to the hose, checking that the
hose does not turn when the assembly is
screwed together.
Torque tighten the union.
85536R
Remove the hose from the caliper and if necessary

remove the caliper.
37-10
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Braking compensator
37
CHECKING PRINCIPLE
These vehicle are fitted with a load sensitive

braking compensator.
The pressure is read in an X pattern, by comparing
the pressure at the rear wheels with a given
pressure at the front wheels.
The dual compensator has two totally separate
bodies which act in an X pattern on one front
wheel and one rear wheel.
Both circuits must be checked.
I : front right/ rear left.
II : front left/ rear right.
Load sensitive compensators
For load sensitive compensators, the adjustment
allows alteration of the rear pressure depending
on the front pressure.
The adjustment is made simultaneously in both
bodies. If the pressure is incorrect for one of the
two bodies, replace the compensator.
85925S
37-11
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Braking compensator
37
NOTE
the braking compensators differ depending on the type of rear axle:

- standard load rear axle: red reference mark,
- increased load rear axle: green reference mark,
TIGHTENING TORQUES
CHECKING
(in daN.m)
Hydraulic unions
1.7
Compensator mounting bolt
1.8
Rod adjustment bolt
Fre. 244 -03

or
Fre. 1085-01
Pressure gauge for checking

compensator rating
REMOVAL
Connect two pressure gauges Fre. 244-03 or

Fre. 1085-01 :
Disconnect the brake pipes.
- one at the front right hand side,
Disconnect rod ( 2 ) from the compensator by

slackening bolt ( 1 ).
- one at the rear left hand side.
Remove the compensator (two bolts).
Bleed the pressure gauges via screw (P).
12865-1R
98828R
NOTE : do not alter the position of nut (3).
Progressively press the brake pedal until the

pressure at the front wheels is the setting
pressure (see table of values). Read the
corresponding pressure at the rear wheels;
correct it if necessary.
REFITTING

Bleed and check the circuit (see section "Checking
- Adjusting").
37-12
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Braking compensator
37
Carry out the same operation on the other circuit:
ADJUSTMENT
- one at the front left hand side,
The method for adjusting the compensators used

today in After Sales is simple and only involves
using two pressure gauges which must be
connected to the braking circuit (front right
wheel and rear left wheel, then front left wheel
and rear right wheel).
- one at the rear right hand side.

If there is a large difference (values exceed
tolerance ranges), replace the compensator since
no repair is permitted.
Checking and adjustment is carried out with the

vehicle unladen, the fuel tank full and the driver
on board.
After imposing a certain pressure at the front by
pressing the brake pedal, just read off the
pressure at the rear and compare the value with
that given in section 07. Then move the
compensator rod by releasing the bolt ( 1 ), so rod
( 2 ) may be adjusted.
NOTE : do not alter the position of nut (3).
12865-1R
This method is difficult to carry out when the

vehicle is loaded, as is often the case for a utility
vehicle fitted out with shelves full of spare parts
and tools.
The special case of utility vehicles has led to the
development of a different method for
adjustment which uses a deflection calculation
(index of crushing) for the tyres (this is
inexpensive but must be carried out with care).
The graphs for rear pressure as a function of tyre
deflection must be consulted.
37-13
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Braking compensator
37
Tooling required:
3 Adjusting the rear tyre pressure:
- one measuring tape mounted on a base (used

for measuring underbody heights),
- the pressure must be adjusted with the wheels

on the ground and one person in the drivers
seat,
- an accurate pressure gauge.

- deflate the two rear wheels so that the pressure
is brought to 1.2 bar (use an accurate pressure
gauge which has been correctly calibrated),
1 Preparation of the vehicle:
- wait a few minutes for the air in the tyres to
return to ambient temperature since it is
cooled when the tyres are deflated and the
pressure will therefore have changed,
- the vehicle must be left loaded,

- the person in charge of pressing the brake
pedal when the compensator is being adjusted
must be in the vehicle when the radius under
load is measured at the rear wheels,
- adjust the pressure to 1.2 bar as accurately as

possible.
- the vehicle must be on a flat horizontal surface,

which is smooth and clean (use a four post lift if
possible).
4 Measuring the radius with the vehicle
unladen:
- lift the rear wheels so that the tyres are no
longer crushed by the load on the axle (as soon
as the wheels leave the ground),
2 Marking the centre of the rear wheels:

- lift the rear of the vehicle so the rear wheels
may be turned,
- measure the distance between the ground and

the wheel centre using the measuring tape.
- apply a chalk stick to the hub cover or the

wheel embellisher at the approximate centre of
the wheel,
- turn the wheel by hand fairly quickly, pressing
hard on the chalk. This allows concentric circles
to be drawn around the real rotation centre of
the wheel,
5 Measuring the radius with the rear wheels

loaded:
- mark the centre using a pencil on the chalk,
- return the vehicle to its wheels,
- carry out the same operation on the second

rear wheel.
- measure the distance between the ground and

the wheel centre using the measuring tape.
37-14
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Braking compensator
6 Calculating the tyre deflection:
- subtract the two measurements made to obtain
the tyre deflection.
7 Carry out stages 4, 5 and 6 for the other rear

wheel.
8 Calculate the average deflection for both

tyres:
- add the two values for the two deflections
noted for the two rear wheels and divide the
result by two to give the average deflection.
9 Reading the graphs:

- On the first graph, read off the load on the rear
axle as a function of the average deflection
noted.
- On the second graph, read off the output
pressure P2 (corresponds to the pressure
applied to each rear wheel) as a function of the
load value noted from the first graph.
IMPORTANT : each graph corresponds to a
particular make and type of tyre.
10 Adjusting the compensator :

- Follow the current method described for After
Sales if the compensator is incorrectly set.
37-15
http://vnx.su
37

Braking compensator
37
Load on rear axle / tyre deflection (pressure 1.2 bars)
DUNLOP 165/70 R13C
Deflection ( mm )
Load on rear axle ( Kg )
PRN3700
37-16
http://vnx.su

Braking compensator
37
KLEBER 165/70 R13
Deflection ( mm )
PRN3704
37-17
http://vnx.su

Braking compensator
37
MICHELIN 165/70 R13C XC4S
Deflection ( mm )
PRN3700
37-18
http://vnx.su

Braking compensator
37
MICHELIN 165/70 R13C Agilis 61
Deflection ( mm )
PRN3700
37-19
http://vnx.su

Braking compensator
37
Adjustment for compensator outlet pressure / Load on rear axle
KANGOO standard payload
Outlet pressure P2 ( bars ) for 100 bars at the front
PRN3702
37-20
http://vnx.su

Braking compensator
37
Adjustment for compensator outlet pressure / Load on rear axle

KANGOO increased payload
Outlet pressure P2 ( bars ) for 100 bars at the front
PRN3703
37-21
http://vnx.su

Clutch control cable
37
Remove the end of the cable from its location on

the wear compensation sector.
REMOVAL
In the engine compartment, disconnect the cable

from the fork.
Remove the cable sleeve stop from the bulkhead.

Remove the complete cable via the engine
compartment.
REFITTING
From the engine compartment, thread the cable

through the bulkhead.
Fit the cable end piece into position on the wear
compensation sector.
Refit the clutch pedal.
Check the wear compensation ratchets return to
the rest position.
In the engine compartment, fit the cable onto the
clutch fork.
89204S
Check the cable sleeve stop is correctly aligned on

the bulkhead.
Press the pedal to pull the cable through.
Press the clutch pedal to clip the cable sleeve stop

into position on the bulkhead. The adjustment is
carried out automatically.
In the passenger compartment, remove:

- the bolt ( 1 ),
- the stiffener ( 2 ),
- the nut from the pedal mounting shaft ( 3 ).
12986R
37-22
http://vnx.su

Clutch automatic wear take-up system
SPECIAL NOTES
In order to ensure the assembly operates correctly,

check that:
- the notched sector pivots correctly about its
pin,
- the ratchets return to the rest position freely,
- the cable is always taut on the fork and there is
at least 2cm of slack,
- the fork travel is between:
X = 27.4 and 30.7 mm
91830R1
These components should be checked before any

operation on the clutch itself.
37-23
http://vnx.su
37

Under the vehicle:
Mounting nut for unit on body

Linkage mounting clip bolt on clevice
Linkage mounting bolt on clevice
Linkage - lever mounting nut
37
- release the primary exhaust pipe,
1.5
2
3
3
- remove the bolts from the heat shield cover.
REMOVAL

In the vehicle, remove the gaiter from the console
and remove the two mounting bolts.
12988R
Remove:
- the lever - linkage mounting nut,
- the four nuts mounting the control unit.
12985R
12987R
37-24
http://vnx.su

REMOVAL of the control linkage
After removing the lever - linkage connecting nut,
remove the linkage - selector connecting bolt.
PRG37.6R
REFITTING

Coat the lever joints and the linkage pin with 33
Mdium grease.
Ensure the clevice is fitted correctly : offset on
gearbox side.
37-25
http://vnx.su
37

37
B.Vi. 1133
Shim for locking the gearbox input lever in 1st

Linkage mounting clip bolt on clevice
ADJUSTMENT
Slacken bolt (V).
Remove the collector.
Fit shim B.Vi. 1133 to take up any play.
93856-1S
92450-2R
At the same time pull the end of the shim

downwards and pivot it through approximately
45 until it touches the lug on the housing.
Engage 1st gear.
92450-3S
37-26
http://vnx.su

37
Press the lower lever gate against the gearbox

ramp , inserting a 9 mm shim.
93910S1
In this position, tighten bolt (V).

Check the resulting play ( Y ) which must be
between 7 and 10 mm.
Remove shim B. Vi. 1133.
Check the gears engage correctly.
Refit the collector.
DI3705
37-27
http://vnx.su

BOSCH ABS
38
This vehicle is fitted with BOSCH ABS 5.3 of the four channel additional type; the conventional braking
equipment and the ABS equipment are separate.
SPECIAL NOTES
The system comprises four speed sensors. Each hydraulic braking channel is associated with a sensor at each
wheel. The front wheels are therefore regulated separately. The rear wheels however are regulated at the
same time and in the same way according to the select low principle (the first wheel which tends to lock
causes immediate regulation on the complete axle assembly). The compensator fulfils its normal function.
38-1
http://vnx.su

BOSCH ABS
38
LOCATION OF THE BOSCH ABS COMPONENTS
PRN3818
Hydraulic assembly
Brake fluid level warning light
Master cylinder
Braking compensator
Brake servo
38-2
http://vnx.su

BOSCH ABS
38
PRESENTATION OF THE HYDRAULIC REGULATION ASSEMBLY
PRN3819
Inlet from master cylinder
Rear left wheel
Rear right wheel
D Front right wheel

E
Front left wheel
38-3
http://vnx.su

BOSCH ABS
38
WIRING DIAGRAM
PRN3817
38-4
http://vnx.su

BOSCH ABS
WIRING DIAGRAM KEY
104
Ignition switch
118
ABS computer
150
Rear right wheel sensor
151
Rear left wheel sensor
152
Front right wheel sensor
153
Front left wheel sensor
160
Stop switch
225
Diagnostic socket
247
Instrument panel
260
Fuse box
777
Power feed fuse board
R2
Dashboard / rear left
R36
ABS / Dashboard
R101 Right hand side member / Right hand

headlight
38-5
http://vnx.su
38
38

BOSCH ABS
31 TRACK CONNECTOR
PRN3813
Micro-spring connecting earth (terminal 19) to pins 20 and 21 (ABS and NIVOCODE warning lights) if the
connector is disconnected.
Allocation of connector tracks

Track
Description
Track
Description
Sensor earth - RRH
15
+ after ignition computer feed
Sensor information - RRH
16
Pump motor earth
Sensor earth - FRH
17
+ BAT (solenoid valves and pump

motor)
Not connected
18
Sensor information - FRH
+ BAT (solenoid valves and pump

motor)
Sensor earth - FLH
19
Electronic earth
Sensor information - FLH
20
Not connected
Sensor earth - RLH
21
ABS warning light
Sensor information - RLH
22
Not connected
10
Not connected
25
Not connected
11
Diagnostic line K
26
Not connected
12
Diagnostic line L
27
Not connected
13
Not connected
31
Not connected
14
Stop lights switch information
38-6
http://vnx.su

BOSCH ABS
DIAGNOSTIC SOCKET
PRN3807
Chassis earth
Electronic earth
Diagnostic line K
15
Diagnostic line L
16
+ battery
38-7
http://vnx.su
38

BOSCH ABS
38
From below:
HYDRAULIC ASSEMBLY
Remove:
Pipe unions
M10 100
M12 100

1.7
1.7
- the exhaust manifold heat shield ( 3 bolts),

- the two lower mounting bolts for the hydraulic
assembly,
REMOVAL

Remove the front right hand wheel.
Fit a pedal press to limit the amount of brake
fluid which will run out.
From above:
Disconnect the computer connector.
Remove the two earth bolts.
Disconnect the six pipes from the hydraulic assembly, marking their position for refitting.
13139R
the hydraulic assembly via the wheel arch.
REFITTING

13138R
NOTE : the computer must not be removed. If

there is a fault, replace the complete hydraulic assembly.
Remove the upper hydraulic assembly mounting

bolt ( 1 ).
38-8
http://vnx.su

BOSCH ABS
38
HYDRAULIC BRAKING TEST
This section describes the test to be carried out using the XR25, to check the mounting of the ABS system in
the vehicle and, in particular, the hydraulic circuit.
NOTE: for this test, two persons are required and the vehicle must be on a two post lift, if possible.
Principle of the test

Put the vehicle on the lift with the wheel to be tested raised. One of the operators must be in the passenger
compartment in the drivers position with the XR25. Switch the ignition on, vehicle in neutral, in fault finding
mode and press the brake pedal. The second operator must apply a torque to the wheel to try and rotate it.
The operator generates an appropriate command on the XR25 which carries out the following cycle ten
times: alternate decrease then increase in pressure at the wheel to be checked. These actions in the ABS will
be noted at the wheel as ten alternate locking and releasing operations. The jerky movement of the wheel,
noted qualitatively by the operator, signify that the hydraulic circuit for this wheel is correctly connected.
The programme for the XR25 for this sequence is as follows:
-
Cycle on the wheel to be tested:

- a drop in pressure for 200 ms where the pump starts at the same time,
- an increase in pressure for 300 ms where the pump starts at the same time (ten cycles are carried out
for the wheel in question).
The pressure increases to master cylinder pressure for all four wheels.
The hydraulic pump motor stops.
The operator releases the brake pedal.
The hydraulic test for the wheel in question is complete - begin the test for the three other wheels.
BLEEDING PROCEDURE
NOTE : the hydraulic assembly is pre-filled.
This bleeding procedure must be used when one of the following components has been removed:
-
the hydraulic assembly,
the master cylinder,
the pipework (between the hydraulic assembly and the master cylinder).
1) Bleed the braking system conventionally using the pedal.

NOTE : if, after a road test with ABS regulation, the pedal travel is not correct, bleed the hydraulic assembly.
38-9
http://vnx.su

BOSCH ABS
38
2) Bleeding the hydraulic assembly.

IMPORTANT : the bleeding order must be observed, beginning with the
left and then front right.
rear right , then the rear left, front
a) Bleed the rear right brake by bleeding the hydraulic assembly secondary circuit using the XR25:
-
position the bleed container and the hose, open the brake bleed screw,
pump the brake pedal (approximately ten times),
start the bleed command on the XR25,
pump the brake pedal during the diagnostic bleed phase,
at the end of the bleed cycle on the XR25, continue to pump the brake pedal and close the brake
bleed screw.
b) Carry out the procedure described at a) for the rear left, front left and front right brakes.
c)
Check the pedal travel and if it is incorrect, restart the bleeding procedure.
IMPORTANT : ensure there is sufficient brake fluid in the reservoir.

CHECKING THE WHEEL SPEED SENSORS
a) Check the resistance of the sensor connections (from the computer connector to the 2 track speed sensor
connector).
b) Visually inspect the teeth ( 26 teeth) on the target and if they are faulty, replace the target.
c)
Check the air gap using a set of shims. Only the front sensors can be checked.
Front: 0.13 < Z < 1.96 mm
PRN3820
38-10
http://vnx.su
Sheet Metal Work

GENERAL
LOWER STRUCTURE
UPPER FRONT STRUCTURE
UPPER SIDE STRUCTURE
UPPER REAR STRUCTURE
TOP OF BODY
SIDE OPENING ELEMENTS
NON-SIDE OPENING ELEMENTS
77 11 194 280
JULY 1997
The repair methods given by the manufacturer in this document are based on the
Edition Anglaise

Renault.
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB4008
http://vnx.su
Sheet metal work

Contents
Page
40 GENERAL
Dimensions
Engine and equipment
Identification
Means of lifting
Towing
Using symbols
Key to symbols
Description of Parts (exploded)
Opening clearances
Collision fault finding
Sub- frame dimensions
Repair bench
Special tooling
Part Number of special tooling
Page
42 UPPER FRONT STRUCTURE

40-1
40-2
40-4
40-6
40-8
40-9
40-11
40-12
40-15
40-22
40-25
40-27
40-38
40-38
A
B
C
D
E
F
G
H
I
J
Front wing
Headlight carrier panel
Cowl side panel (pillar lining)
part section
Upper reinforcement of cowl side
panel
Wheel arch, front section
Wheel arch
Plenum chamber
Windscreen aperture lower cross
member
Steering column mounting
Bulkhead
42-1
42-2
42-5
42-8
42-12
42-17
42-24
42-28
42-32
42-34
43 UPPER SIDE STRUCTURE

41 LOWER STRUCTURE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Front end lower cross member

Front side member, front section
Front side member closure panel
Front half unit
Front side cross member
Front side member, rear section
Front mounting of sub frame
Sill panel closure panel
Cross member under front seat
Side floor
Tunnel
Rear floor, front section
Rear floor, rear section (part
section)
Front cross member of rear floor,
front section
Rear floor stiffener
Rear end cross member
Rear absorber reinforcement
Rear side member extension
Rear side member, part section
Complete rear side member
Rear floor centre cross member
Seat anchoring reinforcement
Rear floor unit
41- 1
41- 5
41-10
41-13
41-17
41-21
41-26
41-29
41-33
41-36
41-39
41-41
41-44
41-51
41-53
41-55
41-58
41-60
41-62
41-63
41-67
41-68
41-71
A
B
C
D
E
F
G
Front pillar
Windscreen pillar
Front pillar lining/Cowl side panel
Centre pillar / sill panel
Centre pillar lower reinforcement /
door pillar
Sill panel reinforcement
Left hand side sill panel
43-1
43-6
43-9
43-14
43-19
43-23
43-25
44 UPPER REAR STRUCTURE

A
B
C
D
E
F
G
H
Rear wing panel

Side panel
Side panel lining
Roof stretcher lining
Rear inner wheel arch
Lights mounting side panel rain
channel
Rear wing panel extension
Rear end panel
http://vnx.su
44-1
44-9
44-17
44-26
44-30
44-33
44-38
44-41
Contents
45 TOP OF BODY
A
B
C
D
Roof
Roof front cross member
Roof centre cross member
Roof rear cross member
45-1
45-7
45-8
45-9
47 SIDE OPENING ELEMENTS

A
B
C
D
E
F
Front door
Front door panel
Front door stiffener
Side door
Side door panel
Side door stiffener
47-1
47-2
47-6
47-8
47-11
47-14
48 NON-SIDE OPENING ELEMENTS

A
B
C
D
E
Bonnet
Bonnet hinge
Rear opening doors
Tailgate
Roof flap
http://vnx.su
48-1
48-2
48-3
48-4
48-5
GENERAL
Dimensions
40
12333R
(1) Unladen
(2) Laden
Dimensions in metres.
40-1
http://vnx.su
GENERAL
40
Engine
Vehicle type
Clutch type
Gearbox type
manual and automatic
Type
Capacity
(cm 3)
FC0A
KC0A
D7F
1149
180 CP 3300
JB1
FC0C
KC0C
E7J
1390
180 CP 3300
JB3
FC0D
KC0D
FC0E
KC0E
F8Q
1870
200 CPOV 3250
JB1
40-2
http://vnx.su
GENERAL
40
SPECIFIC BODYWORK FEATURES
Pay load 600 kg
Drivers airbag
Pay load 625 to 710 kg depending on

engine/equipment
Passengers and drivers airbag

Height adjustable front head restraint
Pay load 800 kg
Height adjustable and tiltable front head restraint
Glazed, sliding side door and rear opening doors

or glazed tailgate
Rear parcel shelf
Sliding side door (reflective glass)
Luggage compartment net
Sliding side door (panel)
Electric one touch windows
Rear door, panel
Heated electric rear view mirrors
Rear door, glazed
Heated screen + timed windscreen wiper
Opening doors, panels
Heated front seats
Opening doors, glazed
Front seat driver emergency exit
Tailgate
Rear bench seat 1/1
Opaque roof flap (excluding tailgate)
Rear bench seat 1/3 - 2/3
Glazed roof flap (excluding tailgate)
Cabin rack without stop
Fixed side window (meaning glazed side door)
Headlining
Sliding side window
Boot carpet
Fixed rear quarter panel (meaning the glazed

sliding side door )
Parcel shelf luggage cover

Two front fog lights in bumper
(excluding F8 AC PAS)
Heat insulating windscreen (with air conditioning)

2 point rear centre seat belt
3 point rear centre seat belt
40-3
http://vnx.su
GENERAL
Identification
POSITIONING OF VEHICLE IDENTIFICATION PLATE
It is located at the bottom of the right hand side

centre pillar.
13187R
40-4
http://vnx.su
40
GENERAL
Identification
40
6
7
8
RENAULT S.A.
9
e0-00/00-0000-000-000-00
1
VF000000000000000
0000 kg
0000 kg
1 - 0000 kg
2 - 0000 kg
11
12
13
000000000000000
Numbers given on the manufacturers plate and on the engine plate should be quoted in all letters or
orders.
1
2
3
4
5
6
7
8
9
10
11
12
13
10
The type mines of the vehicle and the chassis number

The total all up weight(P.T.M.A.)
The maximum permitted total train weight (P.T.R. - vehicle loaded with trailer)
The maximum permitted weight on the front axle (P.T.M.A. front axle)
The maximum permitted weight on the rear axle (P.T.M.A. rear axle)
The technical features of the vehicle
The paint reference
The equipment level
The vehicle type
The trim code
The additional equipment definition
The fabrication number
The interior matching trim code
40-5
http://vnx.su
GENERAL
Means of lifting
40
Safety symbol (special precautions to be taken when carrying out operations).
Cha. 280 -02

Cha. 408 -01
or
Cha. 408 -02
Adaptable cross piece for trolley

jack
Adaptable socket for trolley jack
AXLE STANDS
If a trolley jack is used, appropriate axle

stands must always be used.
To place the vehicle on axle stands, they MUST be

placed:
- either under the reinforcements provided for
lifting the vehicle with the jack which forms
part of the vehicle equipment,
- or under the points behind the reinforcements.
Rear positioning of the axle stands can be carried
out by lifting the vehicle from the side.
The vehicle MUST NOT be lifted by supporting its

weight under the front suspension arms, or under
the V section rear axle.
According to the type of trolley jack, use sockets
Cha. 408-01 or Cha. 408-02 to position the cross
piece Cha. 280-02.
To lift at the front or rear, take the weight under
the vehicle jacking points.
LIFTING FROM THE SIDE WITH A TROLLEY JACK
Use cross piece Cha. 280-02.

Take the weight under the valance at the front
door.
Position the flange correctly in the cross member
groove.
12274-1R
85679-1G15
40-6
http://vnx.su
12333-2G
GENERAL
Means of lifting
40
There are several examples :
These absolutely MUST be placed to the right of

the jacking points. They must be clipped into the
sill panel flange openings.
1 - WHEN REMOVING PARTS
2 - SPECIAL CASE OF THE REMOVAL - REFITTING
SAFETY SYMBOL
OF THE ENGINE AND TRANSMISSION

ASSEMBLY
Generally speaking, never use a 2 post lift if a

four post lift would be more suitable.
In this specific case, the body of the vehicle must

be attached to the arms of the two post lift with
special pads.
If this is not possible, position the lifting pads

below the body flange at the jacking points for
the jack supplied with the vehicle.
FOG Company
Part number FOG 449 8111 - 449 8411

or
FRONT
CHEMICO Company
Part number 39 2550 0001

or
SCHENCH Company
Part number 776 684
98703S
REAR
98704S
40-7
http://vnx.su
GENERAL
Towing
40
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the vehicle from a ditch or for any other similar breakdown operation or to lift the vehicle, either directly or indirectly.
FRONT
REAR
13189S
13366S
40-8
http://vnx.su
GENERAL
Using symbols
40
The following indications are found in the section

diagrams :
The part in black is the one which will

be removed in the operation
are the part numbers corresponding to
and 7 the list on the introduction page
e = 1 + 1
are the thicknesses (in mm) of the

panels for electrical spot welding
This arrow on the diagram designates

the access point for the unpicking of
spot welds (see specific cases)
11644R1
The above diagram shows parts on the vehicle for

which a section of the panel butt welding joint is
shown by the diagrams which follow.
It also indicates the logical sequence of operations

in the symbols which follow each diagram.
This dashed line shows the centre line

of the sections
The point shows the exact position of
the weld join
Example :
place of operation and logical sequence
This letter designates the drawing
F - G - corresponding to the section (It is giH - I - J ven in one of the upper corners of
each drawing )
spot welding
weldable mastic
unpicking with grinder
CAA11538R8
e = 1+1
40-9
http://vnx.su
GENERAL
Using symbols
40
SPECIFIC CASES
Under diagram I
site of operation and order of operations
1
1st operation
2
chisel the edge
2
unpicking
with grinder
apply weld fillet
2nd operation
CAA11537-1R6
In this example, there is no direct access for removing part 1. The spot welds should be unpicked
through part 2, which should be kept.
10354R
In this particular case, the arrow indicates that

the joint is made by arc welding (MIG).
E
CAQ11697-1R5
2
This arrow indicates that it is necessary
to cut the part it crosses before accessing the joint.
The references which follow indicate different

operations :
1
2
10349R
In this example, the joint is

made by bonding.
unpicking
welding
40-10
http://vnx.su
GENERAL
Key to Symbols
40
Plug welding.
Under MAG gas protection.
Chiselling
Grind back beads or spot welds.

Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.
Crimping of exterior door panels.
Safety symbol.
This means that the welding operation
in question concerns one or more of the
vehicles vital safety components.
Grind back spot welds.

20 000 rpm straight grinder with 10 or 16
mm diameter spherical burr.
Drill spot welds.
Hardened steel bit. Speed of rotation 800
to 1 000 rpm.
Body solder - lead fill.

Hot air torch.
Nozzle output temperature 600 min.
Slipper+ 33 % tin solder + tallow.
Note : to a large extent, body solder
filling compensates for the heat
distortion caused by welding.
Unpicking
Application of weldable mastic.

This mastic conducts electricity, applied
between two panels to be spot welded,
it ensures the seal between the panels
and avoids corrosion of the spot welds.
Cleaning surfaces to be welded.

100 mm diameter fibre disc.
Cutting with a saw.

Pneumatic power hacksaw.
Application of aluminium paint.

This is to be applied to the joint faces of
each of the parts to be plug welded.
The paint conducts electricity and is is
resistant to high temperatures. It
provides anti-corrosion protection
around the plug welds.
- Cutting out part by grinding off flange

or grinding back remaining traces of
spot weld.
- Finish surface after welding.
- Angle grinder equipped with a rubber
pad and a 120 to 180 mm diameter
fibre disc grain size P36.
Unsoldering.
Apply a fillet of extruded mastic

from a manual or pneumatic spray
gun.
one or two pot mastic for crimped
and butt joints.
MAG stitch weld

Note : to obtain a good quality weld we
recommend the use of a gas consisting
of argon + 15 % CO2. This is
considered to be an active gas (MAG).
Spray on sealer
spray gun.
two pot anti-gravel and anticorrosion mastic.
Spot weld
40-11
http://vnx.su
GENERAL
Description of parts (exploded view)
40
SUB-FRAME
PRB4002
1
2
3
4
5
6
7
8
9
10
11
12

Rear floor unit
Rear floor, rear section
Rear end panel
Rear absorber reinforcement
13
14
15
16
17
18
19
20
21
22
23
24
40-12
http://vnx.su
Rear floor front cross member

Front mounting of front sub-frame
Front half unit
Tunnel
Side floor
Sill panel closure panel (side door)
GENERAL
40
UPPER STRUCTURE
PRB4003
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Body side, rear section, panel

Body side , rear section, glazed
Rear wing panel lining
Roof
Roof rear cross member (with roof flap)
Roof rear cross member (without roof flap)
Roof flap mounting reinforcement
Roof stretcher lining (with roof flap)
Roof stretcher lining (without roof flap)
Side panel lining
Side panel rain channel (lights mounting)
Rear wing panel stiffener
Stiffener spacer on rear wing panel
Side panel, panel
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Side panel, glazed

Centre pillar/door pillar reinforcement
Windscreen pillar lining
Front pillar
Cowl side panel reinforcement, rear section
Upper reinforcement of cowl side panel
Wheel arch, complete
Plenum chamber
Bulkhead
Windscreen aperture lower cross member
Centre pillar / right hand side sill panel
Rear wing panel ( glazed )
40-13
http://vnx.su
GENERAL
40
REMOVABLE COMPONENTS
PRB4004
61
62
63
64
65
66
67
68
69
70
Hinged roof flap

Tailgate
Rear opening door, right hand side
Rear opening door, left hand side
Front door panel
Front door
Front wing
Bonnet
Side door
Side door panel
40-14
http://vnx.su
GENERAL
Opening clearances
40
12333R1
12333-2R
40-15
http://vnx.su
GENERAL
Opening clearances
40
12333-3R
12333R2
40-16
http://vnx.su
GENERAL
Opening clearances
40
1
3
12848R
12850R
12849R
12853R
40-17
http://vnx.su
GENERAL
Opening clearances
40
12854R
12852R
12851R
12906R
40-18
http://vnx.su
GENERAL
Opening clearances
12
12905R
10
12856R
13
12861R
11
12858R
12855R
40-19
http://vnx.su
40
GENERAL
Opening clearances
14
40
16
12857R
12860R
17
15
12864R
12859R
40-20
http://vnx.su
GENERAL
Opening clearances
40
18
12863R
19
12862R
40-21
http://vnx.su
GENERAL
40
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is necessary to carry
out a series of tests :
VISUAL INSPECTION
This inspection involves the examination of the sub-frame of the vehicle where mechanical components
are mounted and in the crumple zones or vulnerable areas in order to detect folds where materials have
been deformed.
INSPECTION USING TRAMMEL GAUGE

The visual inspection may be completed using a trammel gauge which will allow measurement of certain
deformations by symmetrical comparisons (for more detail on each point to check, refer to the repair
bench paragraph below).
INSPECTION OF AXLE ASSEMBLY GEOMETRY

It is the only check which determines whether the impact suffered by the vehicle has or has not affected
its road holding.
Important : In borderline cases, it is essential not to neglect checking the axle assembly components which
may also have been subject to deformation.
On principle, no welded component in the body shell may be replaced without ensuring that the subframe was not affected by the impact.
12664-1R
40-22
http://vnx.su
GENERAL
GAUGE POINTS
Point G :
Point G1 :
Rear end of front side member.
40
Rear section of front side member.
12842R
12670R
The starting reference point for checking points

(C) and (C1).
The starting point for checking points (A) and (B).
Points C and C1 :
Sub-frame front mounting and front end of side
member.
12843R
40-23
http://vnx.su
GENERAL
Point B :
40
Left hand side
Front point of rear axle assembly.
12846R
12844R
Requires partial removal of the fuel filler neck

mounting.
Point J :
Rear end of rear side member.
Right hand side
12847R
Requires the partial removal of the silencer securing clip.
40-24
http://vnx.su
GENERAL
Sub-frame dimensions
DESCRIPTION
40
205
402.5
DIAMETER
SLOPE %
71
18.5
Front sub-frame rear mounting
Rear axle assembly front mounting
1 999.3
657
71.3
2020
X : 820
Front left sub-frame front mounting
- 418
447
130
1010
(squared)
Front right sub-frame front mounting
- 418
465
130
1010
(squared)
Rear shock absorber upper mounting
2 333.13
545.75
184
12.5
Front shock absorber upper mounting
18.5
545.50
657
48
G1
Rear section of front left side member
600
- 375
2020
(squared)
Rear section of front right side member
600
351.6
2020
(squared)
2 918
497.5
151
12.216.2
575
315
280
14.25
X : 302
Y : 1
Rear point of rear side member
Front end cross member
Rear end cross member (end panel)
3 121
- 497.5
151
M8
Front engine mounting
- 247
483.5
514
M10
Rear engine mounting
- 113
483.5
514
M10
40-25
http://vnx.su
X : 3
X : 430
Z : 5
GENERAL
40
12664R
40-26
http://vnx.su
GENERAL
Repair Bench
40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
A - FRONT SUB-FRAME REAR MOUNTING
1 - Front mechanical units removed
It is the principle front reference point.
The bracket rests against the rear section of the

side member and is centred in the sub-frame
mounting hole.
Right hand side
NOTE :
on the left hand side, the hole is round,

on the right hand side it is a slot.
12666R
Left hand side
12893R
40-27
http://vnx.su
GENERAL
Repair Bench
40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL (cont)
12845R
2 - Front mechanical units in place

The bracket covers the sub-frame mounting bolt
and rests against the mounting bolt washer.
NOTE : The two sides are not symmetrical, on the
right hand side the mounting is set on the rubber

mounting.
If the rear of the vehicle is being rebuilt, these
two points alone may be used to align and support the front of the vehicle.
40-28
http://vnx.su
GENERAL
Repair Bench
40
I - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL (cont)
B - FRONT POINT OF REAR AXLE ASSEMBLY
Rear mechanical units in place or removed
It is the main rear reference point.
The bracket rests under the side member and is

centred in the hole (square).
If the front section is being rebuilt, these two
points alone can be used to align and support the
rear of the vehicle.
12669R
Without mechanical units
12844R1
With mechanical units
40-29
http://vnx.su
GENERAL
Repair Bench
II - ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
These are the provisional reference points which

replace the main ones, when they have been affected by the impact.
G - FRONT SIDE MEMBER, REAR SECTION
12666R1
This point is also used as a positioning reference

when replacing a rear section of the front side
member.
On the impact side, this point allows the vehicle
to be additionally supported with a reference
point on the opposite side.
NOTE : these points should only be used in the cir-
cumstances quoted, there is no need to use them

when the main reference points (points A and B)
are correct.
This additional reference function may also be filled by the front side member ends check points
for a rear impact and vice versa.
40-30
http://vnx.su
40
GENERAL
Repair Bench
40
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS
C - FRONT SUB-FRAME FRONT MOUNTING
12668R

The bracket rests under the sub-frame front
mounting and is centred in the hole with the
mounting bolt.
12843R1
It is used when replacing :

- a front end cross member,
- a side member, part section,
- a half unit.

The bracket covers the sub-frame mounting bolt
and washer.
It is used:
- following a frontal collision for a slight impact,
- for fault finding for the gauge inspection of
the front section .
40-31
http://vnx.su
GENERAL
Repair Bench
40
III - REFERENCE POINTS FOR POSITIONING REPLACED PARTS (cont)
E-
F-
REAR SHOCK ABSORBER UPPER MOUNTING
FRONT SHOCK ABSORBER UPPER

MOUNTING
12665R
12841S
The bracket is fitted at the shock absorber clevis

location and positions this mounting for replacing :
- a rear side member,
- the rear floor unit.
The bracket rests under the shock absorber cup

and is centred in the shock absorber mounting
hole.
It is used when replacing :
- wheel arches,
- a front half unit.
It is also used when straightening.
It is also used when straightening.
40-32
http://vnx.su
GENERAL
Repair Bench
40
P - FRONT AND REAR ENGINE MOUNTING
J - REAR SIDE MEMBER REAR END
12841S
12667R
The bracket is positioned from above the engine

mounting, and is centred in the mounting holes of
the engine mounting.
The bracket touches below the side member and

is centred in the pilot hole (slot).
It may be used for a slight rear impact without removing the rear axle, but requires the removal of
the exhaust mounting.
It is used with the mechanical units removed for

replacing a front half unit.
40-33
http://vnx.su
GENERAL
Repair Bench
40
K - FRONT END CROSS MEMBER
L - REAR END CROSS MEMBER (REAR END)
12668R1
The bracket helps with the fitting of the cross

member and rests vertically against the front end
cross member, then it is centred by a centring bolt
at (K).
12667R1

The bracket helps with the fitting of the cross
member and rests vertically against the rear end
cross member, then centres itself in the mounting
hole of the absorber mounting.
It is used for replacing the front end cross member, with or without mechanical units.
NOTE : The operation for replacing the front end
It is used for replacing the whole rear end, with or

without mechanical units.
cross member can be carried out without the removal of the engine and transmission assembly,
but requires the removal of the radiator.
The bracket helps with fault finding on the front
cross member.
40-34
http://vnx.su
GENERAL
Repair Bench
40
CELETTE REPAIR BENCH
PRB4005
40-35
http://vnx.su
GENERAL
Repair Bench
40
BLACKHAWK REPAIR BENCH
PRB4006
PRB4007
40-36
http://vnx.su
GENERAL
Repair Bench
40
IV - SPECIAL TOOLING
BLACKHAWK
CELETTE
Photo
Photo
Special heads for Blackhawk System MS
Special heads for CELETTE System MS
Order from :Consult your After Sales Head Office
Order from: Consult your After Sales Head Office
Suppliers Part Number : REN 88200
Suppliers Part Number : 760 300
40-37
http://vnx.su
GENERAL
Special tooling
40
13470R
Points (A) and (B) are the references for the positioning of the jig on the
vehicle.
Before fitting, when fault finding is carried out, the user must ensure that
these points are correct.
Points (E), (F) and (G) and their symmetry help with the mounting and positioning of the replaced components.
When points (A) or (B) can no longer be used as a reference (detected during a fault finding inspection), the points on the opposite side of the impact fulfil the function of positioning reference.
Special Tooling Part Number
Drawing
Manual Part
Number
Car. 1439
Parts Department
Number
00 00 143 900
Description
Front face jig.
40-38
http://vnx.su
LOWER STRUCTURE
INTRODUCTION
JOINTS WITH:
The replacement of this part is a basic operation

for a frontal impact .
Cowl side panel

Front right wheel arch
Side member
Side member closure panel
The repair bench does not have to be used, on

condition that the side members have not been
affected by the impact.
41 A
PARTS CONCERNED (thickness in mm) :
1
2
3
4
5
6
7
8
COMPOSITION OF THE PART FROM THE PARTS

DEPARTMENT
Part assembled with :

- closure panel,
- towing ring,
- reinforcement on the front end lower cross
member (left hand side).

Bonnet hinge mounting
Cross member partition reinforcement
Cowl side panel
Front right wheel arch
Towing ring
PRB4121
41-1
http://vnx.su
1.5
1.5
1.5
1
0.8
1.5
1.2
2.5
LOWER STRUCTURE
41 A
CAR11700-1R3
12899R
C
1
CAS13025-1R1
CAQ11697R7
41-2
http://vnx.su
LOWER STRUCTURE
41 A
Left hand side
D
3
CAI11550-3R1
12900R
Right hand side
E
1
6
1
CAA11538-1R4
CAR11700-1R1
41-3
http://vnx.su
LOWER STRUCTURE
12902R
F
8
CAS13025-1R5
41-4
http://vnx.su
41 A
LOWER STRUCTURE
41
INTRODUCTION
The replacement of this part can be done in two

ways :
A Front side member, complete front section .
B Front side member, partial front section (cut
to be made in front of the front mounting of
the sub-frame), see the following diagram.
In the two cases these are complementary operations to the replacement of the front end lower
cross member and the headlight carrier panel. As
a result, the joints with these parts will not be
considered here, they will be dealt with in the respective sections.
PRB4122
The repair bench must be used.
or
The replacement of this part also requires the replacement of the side member closure panel
which will have to be ordered separately.
JOINTS WITH:

Front wheel arch
Shock absorber cup height adjuster
Engine mounting *

DEPARTMENT
1 -Side member
Part assembled with:
- engine mounting height adjuster (only on the
right hand side),
- sub-frame front mounting.
1
2
3
4
5
6
7
2 - Front side member closure panel

Part on its own.

Front wheel arch
Engine mounting height adjuster*
Engine mounting reinforcement *
* Only the right hand side.
41-5
http://vnx.su
1.5
2.5
0.8
0.8
1.2
1.8
1.5
LOWER STRUCTURE
41
C
4
1
5
CAS13028-6R1
12903R
1
5
CAA11537-3R2
CAS13028-6R1
E
5
6
4
1
5
1
CAS13028-6R1
CAE11546-4R7
41-6
http://vnx.su
LOWER STRUCTURE
13005R
F
2
1
CAB11539R8
41-7
http://vnx.su
41
LOWER STRUCTURE
41
H
1
CAA11538R3
12896R
2
CAG11548-6R1
CAA11536R3
41-8
http://vnx.su
LOWER STRUCTURE
12894R
13010R
41
3
2
1
1
5
CAN11689R3
CAS13028-6R2
41-9
http://vnx.su
LOWER STRUCTURE
INTRODUCTION
JOINTS WITH:
The replacement of this part may be done in two

ways :
A Complete front side member closure panel.
B Partial front side member closure panel (see
diagram below).

Front sub-frame front mounting
41
This operation is carried out by straightening or

replacing the front side member. It is complementary to the front end lower cross member and to
the wheel arch.
1
2
3
4

reinforcement
As a result, joints with these parts will not be

considered here, they will be dealt with in the respective section.
DEPARTMENT
Part on its own.
PRB4123
41-10
http://vnx.su
1.5
1.2
1.2
1
LOWER STRUCTURE
41
B
3
1
CAB11539-1R7
12903R3
C
3
4
2
4
1
CAT13323R3
CAT13322R7
41-11
http://vnx.su
LOWER STRUCTURE
41
D
4
CAB11539-1R1
12902R1
or
F
3
CAS13033R2
CAS13033R2
41-12
http://vnx.su
LOWER STRUCTURE
Front half unit
41 D
INTRODUCTION
The operation for the replacement of this part is

complementary to :
- the front end lower cross member,
- the headlight panel
- the cowl side panel.
This operation requires the replacement of the
cowl side panel (pillar lining) and of the cowl side
panel upper reinforcements, which have to be ordered separately.
In the operation described below there are only
descriptions of the specific joints to the part
concerned, information concerning the parts to
be ordered separately is not considered here. This
will be dealt with in the respective sections.
PRB4124
or

DEPARTMENT

1
2
3
JOINTS WITH:
Front side member , rear section

- engine mounting height adjuster (right
hand side)
- engine mounting reinforcement (right
hand side),
- engine mounting plate (right hand side),
- sub-frame front mounting,
- front side member closure panel ,
- wheel arch,
- shock absorber cup,
- shock absorber cup height adjuster,
- ABS mounting (right hand side),
- injection unit mounting and impact sensor
(left hand side).
Plenum chamber
Injection unit mounting and impact sensor (left
hand side)
1 Plenum chamber
2 Injection unit mounting and impact
sensor (left hand side)
3 Front side member, front section
4 Front side member, rear section
5 Shock absorber cup height adjuster
6 Shock absorber cup
7 Cowl side panel (pillar lining)

Cowl side panel upper reinforcement
41-13
http://vnx.su
1
2
1.5
1.8
1
2
1.5
LOWER STRUCTURE
Front half unit
13007R1
41 D
13000R2
B
6
5
1
5
1
CAA11536R8
CAS13024-3R3
Right hand side special feature.
41-14
http://vnx.su
LOWER STRUCTURE
Front half unit
13010R4
12894R1
41 D
1
3
CAA11538R8
CAN11689R3
41-15
http://vnx.su
LOWER STRUCTURE
Front half unit
41 D
CAA11536-4R2
13005R4
G
5
4
4
3
3
CAB11539R3
CAS13029-4R1
41-16
http://vnx.su
LOWER STRUCTURE
INTRODUCTION
JOINTS WITH:
The replacement of this part is a complementary

operation to the replacement of a front pillar or a
sill panel with a lining for a side impact.
Bulkhead
Floor
Windscreen wiper motor mounting
Rear side member, front section
Rear side member, rear section
Sill panel

descriptions of the joints specific to the part
concerned.
Information concerning the other parts will be
dealt with in the respective sections.
41
1
2
3
4
5
6

DEPARTMENT
Part assembled with jack support.
7
8
9
10
PRB4125
41-17
http://vnx.su

Bulkhead
Floor
Front side member
reinforcement, rear section
Sill panel
1
1
1
1.5
1.8
2.5
1.2
0.7
1
2.5
LOWER STRUCTURE
41
B
5
3
1
CAG11548-2R8
12893R2
3
1
CAT13321-2R3
CAF11547-2R1
41-18
http://vnx.su
LOWER STRUCTURE
41
F
6
10
CAM11557-5R6
12904R
9
8
7
1
CAT13329-1R8
CAA11538R5
H
8
6
7
1
CAS13024-1R5
CAE11546-2R8
41-19
http://vnx.su
LOWER STRUCTURE
41
J
1
2
1
7
CAA11538-2AR8
1
13020R
CAA11538R5
41-20
http://vnx.su
LOWER STRUCTURE
41
INTRODUCTION
JOINTS WITH:

operation to the replacement of the front half
unit.
Bulkhead
Floor
In the operation described below, there are only

concerned.
PARTS CONCERNED (thickness in mm):
Bulkhead
Floor
Sill panel
reinforcement
8 Front side cross member
1
2
3
4
5
6
7


DEPARTMENT

- sub-frame front mounting,
- front side cross member,
- side member reinforcement.
PRB4126
41-21
http://vnx.su
1
1
1.8
1.2
0.7
1
2.5
1
LOWER STRUCTURE
41
B
2
CAT13324R1
12898R1
1
2
CAD11545R3
CAA11538R5
41-22
http://vnx.su
LOWER STRUCTURE
41
CAA11538R5
12893R3
8
CAT13321R4
CAF11547-2R2
41-23
http://vnx.su
LOWER STRUCTURE
12904R1
41
13020R
6
5
4
8
CAT13329-1R8
CAA11538R5
J
6
4
8
8
4
CAE11546-2R8
CAA11538-2aR8
41-24
http://vnx.su
LOWER STRUCTURE
41
CAA11538R5
12897R
CAF11547-2R23
41-25
http://vnx.su
LOWER STRUCTURE
Front mounting of sub-frame
INTRODUCTION
JOINTS WITH:

for a sub-frame impact .


concerned.
41 G


Front mounting of front sub-frame
Front mounting reinforcement of
front sub-frame
5 Bonnet hinge mounting
1
2
3
4

DEPARTMENT
Part assembled with sub-frame front mounting

reinforcement.
PRB4127
41-26
http://vnx.su
1.5
1.2
1.2
1
1.5
LOWER STRUCTURE
41 G
C
1
CAA11538R6
1
12901R
A
5
D
3
2
CAR11700R4
4
CAT13322-1R4
B
2
CAA11536R5
41-27
http://vnx.su
LOWER STRUCTURE
41 G
F
4
CAB11539R1
12903R4
E
3
4
CAU13323-3R3
41-28
http://vnx.su
LOWER STRUCTURE
INTRODUCTION
JOINTS WITH:
The replacement of this part is an operation for a

side impact and is complementary to:
Front pillar lining

Side floor
Seat cross member
Rear side member
1 - For a frontal side impact :

the front pillar
Replace part section along cut A (see following diagram)
41 H
2 - For a rear side impact :

the side panel lining
the centre pillar reinforcement
the sill panel
Replace part section along cut A (see following diagram)
1
2
3
4
5
6
7

concerned.

Cowl side panel pillar lining
Side floor
Front seat cross member
Sill panel closure panel , rear section
Sill panel

The sill panel reinforcement must be ordered as
an extra .

DEPARTMENT
1 - Sill panel closure panel

2 - Sill panel reinforcement
PRB4128
or
41-29
http://vnx.su
1.2
1
0.8
1
1.5
1
0.8
LOWER STRUCTURE
12898R
41 H
13015R1
B
6
CAT13326R2
CAA11537-1R3
41-30
http://vnx.su
LOWER STRUCTURE
41 H
D
1
4
CAA11538-1R3
13011R
C
1
3
CAA11538-1R3
41-31
http://vnx.su
LOWER STRUCTURE
13018R1
13232R
41 H
CAA11536-1R7
CAN11690-4R1
F
1
CAA11536-1R7
41-32
http://vnx.su
LOWER STRUCTURE
41
INTRODUCTION
JOINTS WITH:
The replacement of this part is an operation following a side impact, complementary to the replacement of the sill panel closure panel .
Side floor

concerned.
1
2
3
4
5


Floor
Tunnel

DEPARTMENT
Part assembled with front seat spacer.
PRB4129
41-33
http://vnx.su
1
1
1.8
1.2
1.2
LOWER STRUCTURE
41
B
1
3
CAF11547-2R5
13017R
A
1
2
CAA11538R2
41-34
http://vnx.su
LOWER STRUCTURE
41
4
CAF11547-2R1
13011R1
C
1
CAA11538R3
41-35
http://vnx.su
LOWER STRUCTURE
Side floor
41
INTRODUCTION
JOINTS WITH:

operation to the replacement of:
Tunnel
Rear floor
1 - For a frontal impact :

- the front side member, rear section ,
- the bulkhead
1 Tunnel
2 Side floor
3 Rear floor
2 - For a side impact :

- the front pillar with lining
- the sill panel closure panel
In the operation below, there are only descriptions of the joints specific to the part concerned.

DEPARTMENT

- side member closure panel reinforcement,
- cross member under front seat.
PRB4130
41-36
http://vnx.su
1.2
0.8
1
LOWER STRUCTURE
Side floor
41
B
2
CAA11538R3
13019R
2
1
CAA11538-1R5
41-37
http://vnx.su
LOWER STRUCTURE
Side floor
41
D
3
CAB11540R1
13016R
C
3
CAT13325R1
41-38
http://vnx.su
LOWER STRUCTURE
Tunnel
INTRODUCTION
JOINTS WITH:

operation to the replacement of :
Rear floor
Side floor
Bulkhead
41
1 - For a frontal impact :

- the bulkhead

- the side floor
1
2
3
4
3 - For a rear impact :

- the rear floor unit
Rear floor
Side floor
Tunnel
Bulkhead

concerned.

DEPARTMENT

- impact sensor unit mounting,
- front reinforcement of tunnel,
- seat anchoring reinforcement ,
- cable sleeve stop mounting,
- centre reinforcement of tunnel.
PRB4131
41-39
http://vnx.su
1
0.8
1.2
0.7
LOWER STRUCTURE
Tunnel
41
13016R1
13019R1
C
4
1
2
3
3
CAT13325-1R1
CAA11536-2R8
B
1
CAB11540R1
41-40
http://vnx.su
LOWER STRUCTURE
41
INTRODUCTION
JOINTS WITH:
For a side impact, the replacement of this part is a

complementary operation to the replacement of :
- the sill panel closure panel,
- the rear floor unit,
- the rear floor front cross member.

Tunnel
Side floor

concerned.
1
2
3
4
5
6


Tunnel
Side floor
Sill panel closure panel extension,
rear section

DEPARTMENT

- floor reinforcement,
- nuts .
PRB4132
41-41
http://vnx.su
0.8
1
1.2
0.8
1.2
1.5
LOWER STRUCTURE
41
B
1
CAA11538R2
1
13347R
CAA11538R2
CAN11690R5
41-42
http://vnx.su
LOWER STRUCTURE
41
E
5
CAA11538R7
13348R
D
6
1
1
CAR11700R5
CAF11547-2R8
CAR11700R5
41-43
http://vnx.su
LOWER STRUCTURE
Rear floor, rear section (part section)
41
INTRODUCTION
JOINTS WITH:

operation to the replacement of:
Side floor
Upper shock absorber gusset
Rear axle assembly mounting unit
Shock absorber mounting upper reinforcement
Sill panel closure panel, rear section
Rear floor front cross member, front section
Rear side member
Wheel arch
Spring bumper mounting
Centre cross member

- the sill panel reinforcement ,
- the rear inner wheel arch,
- the rear wing panel lining.
Replace part section along cut A (see diagram
and method below).
2 - For a rear impact
- the rear end panel,
- the rear side member, part section or
complete.
Replace part section along cut B (see diagram
and method below).
1
2
3
4
5
6

concerned.
7
8
9
10
11
12

DEPARTMENT
Part assembled with towing ring reinforcement.
13
14
15
PRB4133
or
41-44
http://vnx.su

Side floor
Upper shock absorber gusset
Rear axle assembly mounting unit
Shock absorber mounting
upper reinforcement
Rear side member
Wheel arch
reinforcement
Centre cross member
1
0.8
1.5
1.2
1.2
1.2
1.5
0.8
1.5
1
1.5
1.5
1
1.5
0.8
LOWER STRUCTURE
41
1 - ALONG CUT A
CAA11538R4
C
13018R2
6
1
or
CAN11690R6
D
CAS13028R4
10
1
CAN11690R6
41-45
http://vnx.su
LOWER STRUCTURE
1
9
CAA11538-1R5
CAH11549R1
41-46
http://vnx.su
41
LOWER STRUCTURE
41
11
CAH11549R1
13001R
G
12
10
9
11
CAF11547-2R4
CAH11549R1
J
1
10
CAA11538R3
41-47
http://vnx.su
LOWER STRUCTURE
41
2 - ALONG CUT B
13001R1
13018R3
K
1
CAS13033R1
CAA11536-2R2
or
41-48
http://vnx.su
LOWER STRUCTURE
1
13
CAA11538-1R6
1
14
CAA11538-1R6
41-49
http://vnx.su
41
LOWER STRUCTURE
INTRODUCTION
Below you will find special details for vehicles fitted with a rear floor, front section .
13348R1
1
1
1
8
CAT13329R1
1
2
41-50
http://vnx.su
41
LOWER STRUCTURE
41 N
INTRODUCTION
JOINTS WITH:

operation to the replacement of the sill panel closure panel for a side impact.
Rear floor
Sill panel closure panel, front section

concerned.
1 Rear floor front cross member,

front section
2 Rear floor
3 Sill panel closure panel, front section
4 Sill panel closure panel, rear section

This part may be replaced partially (see diagram
and method below).

DEPARTMENT
Part only.
PRB4134
or
41-51
http://vnx.su
0.8
1
1.2
1.5
LOWER STRUCTURE
41 N
B
2
CAA11538R7
13232R1
or
A
4
2
1
CAS13033R1
1
CAA11538-2aR3
1
2
41-52
http://vnx.su
LOWER STRUCTURE
41 O
INTRODUCTION

operation to the replacement of the rear floor for
a rear impact.
concerned.

DEPARTMENT
Part only.
PRB4135
JOINTS WITH:
Rear floor
Rear side member
1 Rear floor stiffener

2 Rear floor
3 Rear side member
1
0.8
1.5
41-53
http://vnx.su
LOWER STRUCTURE
41 O
CAF11547-2R2
13221R
C
3
1
2
2
1
CAA11538-2aR4
CAA11538R5
1
2
41-54
http://vnx.su
LOWER STRUCTURE
INTRODUCTION
JOINTS WITH:

operation to the replacement of the rear end panel for a rear impact.
Rear shock absorber reinforcement

Towing ring (left hand side)
Side panel rain channel
Side panel lining
Rear floor
Side member
The side member extensions must be replaced

(11) and (12) , and must be ordered separately.
concerned.
41

1
2
3
4
5
6
7
8

DEPARTMENT
10 - Part assembled with rear shock absorber

reinforcement

Side panel lining
Rear floor
Side member
11 and 12 - Side member extension
PRB4136
41-55
http://vnx.su
1.2
1
1.5
1.5
1.5
0.7
0.8
1.5
LOWER STRUCTURE
41
C
6
CAA11536-1R3
13225R
D
6
1
2
CAB11539R7
CAT13327R3
2
6
1
CAB11539R7
41-56
http://vnx.su
LOWER STRUCTURE
41
CAT13328R1
13221R1
2
1
7
1
4
CAA11538R5
CAT13327R5
CAH11549-1R1
41-57
http://vnx.su
LOWER STRUCTURE
INTRODUCTION
For a rear impact, the replacement of this part is a

complementary operation to the replacement of
the rear end panel.
concerned.

DEPARTMENT
Part only.
PRB4137
JOINTS WITH:

1
2
3
4

41-58
http://vnx.su
1
1.2
1.5
1.5
41 Q
LOWER STRUCTURE
13351R1
41 Q
13352R
1
CAT13327R5
CAT13327R6
41-59
http://vnx.su
LOWER STRUCTURE
INTRODUCTION

operation to the replacement of the rear end
cross member .
concerned.
Use of the repair bench is advised, to ensure that
the rear cross member is correctly geometrically
positioned.
DEPARTMENT
Part assembled with towing ring (left hand side).
PRB4138
JOINTS WITH:
Rear side member
1 Rear side member extension

2 Rear side member
3 Towing ring (left hand side)
41-60
http://vnx.su
1.5
1.5
1.5
41
LOWER STRUCTURE
41
13221R2
13225R1
2
CAA11536R7
CAA11536R7
CAA11538R5
41-61
http://vnx.su
LOWER STRUCTURE
41
INTRODUCTION

operation to the replacement of the rear end
cross member for a rear impact
This part may be replaced partially (see cut and
diagram below).
concerned.
13221R3

DEPARTMENT
or

- side member rear reinforcement
- towing ring (left hand side),
- rear side member extension .
CAS13033R1
PRB4139
or
1 Rear side member
1.5
41-62
http://vnx.su
LOWER STRUCTURE
41
INTRODUCTION
JOINTS WITH:

operation to the replacement of the side panel
with lining and the inner wheel arch for a rear
side impact.

Centre cross member
It requires the partial replacement of the rear

floor, rear section and the front cross member of
the rear floor .
Rear side member

Rear floor
Centre cross member
Sill panel closure panel,
rear section
6 Rear floor stiffener
7 Rear shock absorber lower gusset
1
2
3
4
5

concerned.

DEPARTMENT

- side member rear reinforcement,
- towing ring (left hand side),
- rear side member extension ,
- upper shock absorber gusset,
- rear axle assembly mounting unit,
- upper gusset of rear axle assembly mounting,
- side member reinforcement,
- sill panel closure panel, rear section.
PRB4140
41-63
http://vnx.su
1.5
1
1.5
1.2
1.5
1
1.5
LOWER STRUCTURE
13012R
41
13232R2
B
4
4
CAA11536R6
CAO11694R1
41-64
http://vnx.su
LOWER STRUCTURE
41
D
1
6
CAA11538-1R8
13237R
C
1
3
CAA11538-1R8
41-65
http://vnx.su
LOWER STRUCTURE
41
CAS13024-2R5
13235R
E
1
3
CAA11538-1R1
41-66
http://vnx.su
LOWER STRUCTURE
Centre cross member of rear floor
41 U
INTRODUCTION

operation to the replacement of the rear side
member for a rear side impact.
concerned.

DEPARTMENT

- brake limiter mounting,
- emergency spare wheel mounting bearing.
13237R1
A
1
CAA11538R4
PRB4141
JOINTS WITH:
Seat mounting reinforcement

3
1 Rear floor centre cross member

2 Rear side member
3 Rear axle assembly mounting unit
closure panel
1.5
1.5
1
CAS13024-1R5
41-67
http://vnx.su
LOWER STRUCTURE
41
INTRODUCTION
JOINTS WITH:

operation to the replacement of the rear floor
centre cross member, for a rear impact.
Rear floor

concerned.
1 Seat anchoring reinforcements

2 Seat mounting reinforcement
3 Rear floor front cross member,
front section
4 Rear floor
5 Rear floor centre cross member


DEPARTMENT
Part assembled with seat mounting reinforcement.
PRB4142
41-68
http://vnx.su
1.2
1.5
0.8
1
1.5
LOWER STRUCTURE
41
B
3
CAA11538R7
13222R
C
3
1
CAA11538R5
CAF11547-2R2
D
4
2
1
CAN11690-3R4
41-69
http://vnx.su
LOWER STRUCTURE
41
F
2
CAR11700R1
13237R2
CAA11538R6
41-70
http://vnx.su
LOWER STRUCTURE
Rear floor unit
INTRODUCTION
JOINTS WITH:

operation to the replacement of the rear end panel for a rear impact.
Side floor
Tunnel
Side panel lining
Rear wheel arch

concerned.
41

1
2
3
4
5
6
7
8
9
10

DEPARTMENT

- rear end cross member,
- rear floor centre cross member,
- rear floor front cross member,
- rear floor,
- rear floor stiffener ,
- complete rear side members
11
12
PRB4143
41-71
http://vnx.su
Side floor
Tunnel
Side panel lining
Wheel arch
Side panel
reinforcement
Shock absorber mounting upper
reinforcement
0.8
1.2
1
1.2
0.7
1
1.5
0.8
0.8
1.5
1.5
1.2
LOWER STRUCTURE
Rear floor unit
13012R1
13232R3
41
5
3
CAB11540-1R1
CAN11690-3R1
F
4
3
CAB11540-1R1
CAA11536R6
41-72
http://vnx.su
LOWER STRUCTURE
Rear floor unit
41
12
6
CAA11536R8
13018R4
7
5
CAA11536R7
41-73
http://vnx.su
LOWER STRUCTURE
Rear floor unit
41
H
6
10
11
CAF11547-2R7
13001R2
I
10
CAF11547-2R4
CAA11538R4
41-74
http://vnx.su

Front wing
42 A
INTRODUCTION
The replacement of this part is a basic operation for a frontal impact.

It is a removable bodywork component.
COMPOSITION OF THE PART FROM THE PARTS DEPARTMENT

- mudguard skirt,
- bumper mounting support .
13330R
Remove :
- the plastic cover at (A) on the wing side (see section 55),
- the wheel arch plastic mudguards (see section 55),
- the bumper and its mounting blade (see section 55),
- the indicator repeater,
the front wing : 8 hexagonal-head bolts 6 mm and a torx bolt 6 mm.
42-1
http://vnx.su

INTRODUCTION

for a frontal impact.
The fitting jig should be used.

DEPARTMENT
Part assembled with bonnet hinge mounting.
PRB4209
JOINTS WITH:

Front sub-frame mounting
1
2
3
4
5
6
7

Front sub-frame mounting
42-2
http://vnx.su
1
1.5
1.5
1
1
1.5
1.5
42

42
B
5
CAG11548R6
13002R
C
5
1
4
CAC11541-1R6
CAA11538-1R2
42-3
http://vnx.su

42
F
5
4
1
3
7
CAN11690-2R8
CAA11536R7
G
4
1
CAA11538-1R1
CAP11696R6
42-4
http://vnx.su

Cowl side panel (pillar lining), part section
42
INTRODUCTION

operation for a frontal impact to a headlight carrier panel.
It will be partially replaced according to the cut on
the diagram and the method below.
The replacement of this part also requires the replacement of the cowl side panel upper reinforcements.
descriptions of joints specific to the part concerned.

DEPARTMENT
PRB4210
1 - Cowl side panel , part assembled with :

- front wing mounting,
- impact retainer reinforcement (bonnet),
- dashboard mounting support,
- shock absorber cup height adjuster reinforcement .
or
JOINTS WITH :
Engine support plate

Shock absorber cup
Plenum chamber
2 - Cowl side panel upper reinforcement, front

section.
3 - Cowl side panel upper reinforcement, rear
section.
1
2
3
4
5

Engine support plate
Shock absorber cup
Plenum chamber
42-5
http://vnx.su
1.5
2
2
1
1

Cowl side panel (pillar lining) , part section
42
5
1
CAA11538-1R4
12895R
A
1
2
CAA11538-1R3
42-6
http://vnx.su

Cowl side panel (pillar lining) , part section
42
D
1
CAG11548-7R3
12999R
or
C
1
CAA11536-1R3
CAS13033R2
42-7
http://vnx.su

INTRODUCTION
42 D
The replacement of this part is complementary to

the headlight carrier panel for a frontal impact.

2 Cowl side panel upper reinforcement,
front section
3 Cowl side panel upper reinforcement,
rear section
4 Engine support plate
5 Shock absorber cup
6 Shock absorber cup height adjuster
7 Windscreen wiper mounting
8 Front pillar

descriptions of joints specific to the part concerned.

DEPARTMENT
1
1
1
2
2
1
1
1.5
Parts only :
1 - Cowl side panel upper reinforcement, front
section.
2 - Cowl side panel upper reinforcement, rear
section.
12892R
PRB4211
JOINTS WITH :

Cowl side panel upper reinforcement, front
section
Cowl side panel upper reinforcement, rear
section
Front pillar
2 / 3
CAA11538R4
42-8
http://vnx.su

42 D
C
2
CAS13026R7
12903R1
B
2
1
2
CAF11547-2R8
CAA11536R4
42-9
http://vnx.su

42 D
G
1
CAA11538R7
12891R
CAF11547-2R8
CAF11547-2R8
I
8
3
5
CAN11690R2
CAR11700R1
42-10
http://vnx.su

42 D
K
3
7
8
CAF11547-2R3
12890R
L
3
1
2
1
7
CAS13022R1
CAN11690R5
42-11
http://vnx.su

42
INTRODUCTION
JOINTS WITH :
The replacement of this part is an operation for a

frontal impact and is complementary to the replacement of the cowl side panel (pillar lining).
Engine mounting height adjuster (right hand side)

Front end lower cross member (right hand side)
It can be carried out partially from the right hand

side (see diagram and method below).
concerned.
1
2
3
4
5
6
7
Information concerning other parts will be dealt

with in the respective section.

DEPARTMENT
Engine mounting
Side member, front section
Front wheel arch
1 - Part only (right hand side).

2 - Part only (left hand side).
PRB4212
or
42-12
http://vnx.su
2
2
1
1.5
1
1.5
1.5

42
B
5
CAQ11697R5
13009R
CAR11700R5
CAI11550-2R5
42-13
http://vnx.su

42
E
5
4
CAS13028R1
12903R2
or
D
1
5
CAS13028R8
42-14
http://vnx.su

42
G
7
CAC11541R7
13010R1
H
5
4
2
CAB11540R1
CAS13028R2
42-15
http://vnx.su

13005R3
2
5
CAP11696-1R4
42-16
http://vnx.su
42

Wheel arch
42
INTRODUCTION

operation to the replacement of the cowl side panel (pillar lining) for a frontal impact.
It also requires the replacement of the cowl side
panel upper reinforcements (pillar lining), and
the use of the repair bench.
In the operation below there are only descriptions
of the joints specific to the part concerned.

DEPARTMENT
PRB4213

- engine mounting height adjuster (right hand
side),
- engine support plate (right hand side),
- wheel arch ,
- shock absorber cup ,
- shock absorber cup height adjuster ,
- ABS mounting (right hand side),
- injection unit and impact sensor mounting
(left hand side).
JOINTS WITH :
Plenum chamber
Front side member
1
2
3
4
5
6
7
8
9
10
11
42-17
http://vnx.su

Engine mounting height adjuster
Engine mounting reinforcement
Shock absorber cup
Plenum chamber
Front wheel arch
Injection unit and impact sensor
mounting (left hand side)
1
1.5
1.5
2
1
1
1.5
2.5
1
1.5
2

Wheel arch
42
B
9
CAQ11697R5
13009R
10
9
CAR11700R5
CAI11550-2R5
42-18
http://vnx.su

Wheel arch
42
E
1
7
CAA11538-1R3
12895R1
F
1
3
7
CAA11536-1R3
CAS13029R1
42-19
http://vnx.su

Wheel arch
42
CAA11536R2
13005R1
H1
G1
1
1
8
CAA11537-2R5
CAA11536-4R2
CAA11537-1R5
42-20
http://vnx.su

Wheel arch
42
J
1
6
7
CAE11546R7
13005R2
K
9
7
I
1
6
7
CAS13028R1
CAB11539-1R8
L
2
CAA11538R7
42-21
http://vnx.su

Wheel arch
13007R
42
13000R
N
4
1
5
1
5
CAA11536R8
CAS13024-1R3
42-22
http://vnx.su

Wheel arch
42
P
9
7
CAS13028R2
13010R2
O
5
11
CAA11538R8
42-23
http://vnx.su

Plenum chamber
42 G
INTRODUCTION
JOINTS WITH :

- the wheel arch for a frontal impact,
- cowl side panel for a side impact.
Wheel arch
Injection unit and impact sensor mounting (left
hand side)
Bulkhead
Pillar lining (cowl side panel)
This operation may be carried out partially (see

diagram and method below).
The Parts Department only provides chambers of
the (1) "air conditioning" type, as a result, the
closure panel must also be ordered (2).
1
2
3
4
In the following operation there are only descriptions of the joints specific to the part concerned.
Information concerning other parts is dealt with
in the respective section.
5
6
7
8

DEPARTMENT
Plenum chamber
- bonnet lock mounting,
- windscreen wiper motor mounting.
Partition closure panel.
Plenum chamber
Shock absorber cup
Injection unit and impact sensor
mounting (left hand side)
Bulkhead
Windscreen wiper mounting
member
PRB4214
or
42-24
http://vnx.su
1
1
2
2
1
1.5
1.5
1.2

Plenum chamber
13007-1R
42 G
13000R1
C
1
2
3
2
1
CAA11536R8
CAS13024R3
CAB11540R6
42-25
http://vnx.su

Plenum chamber
42 G
13003-1R
13013R
D
6
E
1
CAA11538R7
CAS13033R2
F
5
CAA11538R7
42-26
http://vnx.su

Plenum chamber
13010R3
G
1
CAA11538R8
42-27
http://vnx.su
42 G

42 H
INTRODUCTION

- the wheel arch with the cowl side panel for a
frontal impact,
- the front pillar with lining for a side impact.
This operation may be carried out partially (see
diagram and method below).
PRB4215
The Parts Department supplies the windscreen

aperture lower cross member (1) without the steering column mounting (2), which must be ordered
separately.
or

JOINTS WITH :
Bulkhead
reinforcement
Steering column mounting height adjuster

DEPARTMENT
Windscreen aperture cross member

- steering column mounting height adjuster,
- lower reinforcement of windscreen aperture cross member.
Steering mounting
Part only.
1 Bulkhead
2 Windscreen aperture lower cross
member
3 Windscreen aperture lower cross
member reinforcement
4 Steering column mounting height
adjuster
5 Steering column mounting
7 Windscreen wiper mounting
42-28
http://vnx.su
1
1.2
1.2
1.5
2
1.5
1.5

42 H
2
6
CAB11539R3
13014R1
C
7
2
1
6
CAB11539-1R5
CAF11547-2R7
or
42-29
http://vnx.su

42 H
D
6
CAA11538R8
13224R
E
F
3
2
4
CAS13030R6
CAF11547-4R1
42-30
http://vnx.su

42 H
G
1
CAA11536-3R1
13014R2
or
2
1
2
CAS13025R3
CAB11539-1R5
42-31
http://vnx.su

42
INTRODUCTION
JOINTS WITH :

operation to the replacement of the windscreen
aperture lower cross member.

Steering column mounting height adjuster
Bulkhead
1 Steering column mounting

2 Steering column mounting height
adjuster
3 Bulkhead

DEPARTMENT
Steering mounting:
Part only.
PRB4216
42-32
http://vnx.su
2
1.5
1

42
1
2
CAA11536R7
13224R1
C
3
CAA11538-1R8
CAA11536-3R1
42-33
http://vnx.su

Bulkhead
INTRODUCTION
JOINTS WITH :

Floor
Windscreen pillar
1 - for a frontal impact :

- the wheel arch with the cowl side panel,
- the plenum chamber ,
2 - for a side impact:
- the front pillar with lining,
- the windscreen aperture lower cross member,
- the plenum chamber .
42
1
2
3
4
5
6
7
8
This part may be partially replaced (see diagram

and method below).
Bulkhead
Floor
Windscreen pillar
Rear side member, front section
Front pillar


DEPARTMENT

- windscreen wiper mounting,
- windscreen wiper mounting reinforcement.
PRB4217
or
42-34
http://vnx.su
0.7
0.8
1.5
1
1
2.5
1
0.8

Bulkhead
42
B
1
CAA11536-1R8
12893R1
C
1
1
7
6
2
2
CAG11548-1R8
CAS13031R7
42-35
http://vnx.su

Bulkhead
42
E
1
CAD11545-3R2
13003R
or
D
1
CAA11536-2R1
2
or
CAA11536-2R4
42-36
http://vnx.su

Bulkhead
42
CAS13033R2
12890R1
or
CAB11540-1R6
42-37
http://vnx.su

Bulkhead
13008R1
I
4
5
CAS13028-1R7
1
2
42-38
http://vnx.su
42

Front pillar
43 A
INTRODUCTION
JOINTS WITH:

for a front side impact.
concerned.
Inner reinforcement
Pillar lining


DEPARTMENT
1
2
3
4

- pillar reinforcement,
- welded hinges,
- hinge reinforcement,
- welded nuts,
- upper reinforcement of cowl side panel.
5
6
7
8
Front pillar
Inner reinforcement
member
Pillar lining
PRB4311
NOTE : to carry out the operation below, it will be
necessary to separate the inner reinforcements

and the cowl side panel reinforcement from the
pillar on the Parts Department part. These
reinforcements will be rewelded during the
operation (operations A and B described below).
For the operation to the upper reinforcement of
cowl side panel part (C), refer to the section
concerned.
43-1
http://vnx.su
1
1.2
1
1.2
1.2
1.2
1.2
1.2

Front pillar
43 A
CAV13465R1
13234R
C
1
5
2
CAV13466R7
CAE11546-5R1
43-2
http://vnx.su

Front pillar
43 A
E
5
2
1
CAN11690-3R4
13233R
or
1
X = 220 mm
D
1
5
CAS13033R8
CAO11694R4
43-3
http://vnx.su

Front pillar
43 A
2
5
CAI11550-3R4
13231R
X = 400 mm
1
4
5
2
1
CAC11541-2R1
CAN11690-3R4
43-4
http://vnx.su

Front pillar
43 A
CAE11546-5R3
CAE11546-5R3
N
1
1
CAE11546-5R8
CAS13033R5
or
L
1
CAE11546-5R8
43-5
http://vnx.su

Windscreen aperture pillar
INTRODUCTION
JOINTS WITH:

operation to the replacement of the front pillar

Roof
Body side
Roof stretcher

concerned.
43

1
2
3
4
5
6
7

DEPARTMENT

Roof
Body side
Roof stretcher
Centre pillar upper reinforcement
Body side lining
Part assembled with aerial cable guide.
PRB4312
43-6
http://vnx.su
1
0.8
0.7
1
0.7
1.2
0.7

13214R
A
6
1
CAS13028R8
43-7
http://vnx.su
43

43
C
3
4
1
CAI11550-2R4
13213R
1
CAV13469R5
CAQ11697R1
CAA11537R6
43-8
http://vnx.su

Front pillar lining / Cowl side panel
43
INTRODUCTION
JOINTS WITH:

operation to the front pillar with reinforcement
of cowl side panel for a front side impact.

Bulkhead
Plenum chamber
Windscreen wiper connecting bracket
The cowl side panel reinforcement must be ordered separately.

concerned.
1
2
3
4
5

Cowl side panel / front pillar lining

Bulkhead
Plenum chamber

DEPARTMENT
Part assembled with dashboard mounting reinforcement.
PRB4313
or
43-9
http://vnx.su

43
3
1
CAA11538-1R4
13014R
A
1
CAA11536-1R8
43-10
http://vnx.su

43
D
1
CAA11537R3
13015R
3
1
CAA11538-1R4
43-11
http://vnx.su

43
CAS13033R1
12999-2R
E
5
1
CAS13028R7
43-12
http://vnx.su

43
CAS13024R6
13008R
CAA11536-1R6
43-13
http://vnx.su

INTRODUCTION
JOINTS WITH:

Body side lining

Centre pillar reinforcement
Sill panel lining

concerned.
43 D

1
2
3
4
5

DEPARTMENT
Centre pillar
Body side lining
Part assembled with side door rail guides.
PRB4314
or
43-14
http://vnx.su
1
1.2
1.2
1.2
0.8

43 D
B
1
4
CAI11550R1
13231R1
or
X = 400 mm
A
3
4
1
CAI11550R6
43-15
http://vnx.su

43 D
D
1
CAS13033R8
13226R
or
C
5
2
1
CAI11550R7
CAI11550R8
43-16
http://vnx.su

43 D
G
3
5
1
CAI11550R6
13230R
CAI11550R1
CAI11550R6
I
1
2
CAI11550R1
43-17
http://vnx.su

13229R
or
J
1
CAS13033R8
43-18
http://vnx.su
43 D

Centre pillar lower reinforcement / door pillar
43
INTRODUCTION

operation to the replacement of the centre pillar
concerned.

On the part supplied by the Parts Department,

the pillar upper reinforcement will need to be unpicked.
CAA11538-1R4

DEPARTMENT
Part assembled with seat belt mounting nut.
CAB11539R6
PRB4315
43-19
http://vnx.su

JOINTS WITH:

Body side lining
NOTE : welding of the joint with the body side
lining will be carried out when the centre pillar is

refitted.
1
2
3
4
Centre pillar lower reinforcement

Body side lining
43-20
http://vnx.su
1.2
1.2
0.8
1.2
43

43
B
3
CAI11550R8
13355R1
2
1
CAA11538-1R4
43-21
http://vnx.su

43
D
1
3
5
CAE11546R7
13353R
1
4
CAF11547R4
CAA11537R2
F
3
CAA11536R6
43-22
http://vnx.su

INTRODUCTION

operation to the replacement of the sill panel for
a side impact.
concerned.

DEPARTMENT
Part only.
PRB4316
LIST OF JOINTS :

Centre pillar lower reinforcement
Body side lining
Front pillar reinforcement (identical to the centre
pillar reinforcement)
1 Sill panel reinforcement

2 Sill panel closure panel
3 Centre pillar lower reinforcement
43-23
http://vnx.su
1.2
1.2
1.2
43

43
B
2
CAB11539-1R3
13353R1
C
1
1
2
CAA11537-1R2
CAB11539-1R8
43-24
http://vnx.su

43 G
INTRODUCTION
LIST OF JOINTS :

for a rear side impact.
Body side lining

This part can be partially replaced (see diagram

and method below).

concerned.
1
2
3
4


Body side lining
This part may be replaced in two ways :

1 - Cut A-A (described below)
2 - Cut B-B (refer to operation N for the front pillar)

DEPARTMENT
Part only.
PRB4317
or
43-25
http://vnx.su
0.8
0.7
1.2
1.2

43 G
B
2
1
2
CAV13468R3
or
13219R
2
or
C
1
2
1
1
CAA11537-1R4
CAS13033R5
or
or
43-26
http://vnx.su

43 G
CAN11691R7
13609R
F
or
3
2
1
D
1
CAE11546-2R8
CAS13033R7
4
or
2
1
CAE11546-2R8
43-27
http://vnx.su

Rear wing panel
44 A
INTRODUCTION
JOINTS WITH :

Lights mounting side panel rain channel

Body side lining

concerned.

dealt with in the respective section.
1
2
For the panel version, this part may be replaced in

two ways (see cuts marked on the diagram below) :
3
4
5
1 - complete replacement with cut A.A

2 - partial replacement with cut B.B
6
7
8
9
10
11
12
13
At the end of the section there are special details

for the glazed version and for the version with
roof flap.

DEPARTMENT
Part assembled with sliding door rail units and

striker plate mounting.
PRB4413
44-1
http://vnx.su
Rear wing panel (right hand side)

(right hand side)
channel
upper reinforcement
Centre rail mounting
Stretcher lining
Roof
Sill panel rear closure panel
Seat belt mounting reinforcement
Roof flap rain channel
0.8
0.7
1.2
1
1.2
1
0.7
0.7
1.2
1.2
1.5
1.2
0.7

Rear wing panel
44 A
B - C
2
CAI11550-2R1
13226R1
or
CAS13033R1
44-2
http://vnx.su

Rear wing panel
44 A
E
2
CAQ11697R3
13227R
F
2
2
12
1
CAI11550-2R1
CAI11550-2R4
44-3
http://vnx.su

Rear wing panel
44 A
H
11
2
1
CAE11546-2R7
13229R1
or
G
1
2
11
CAE11546-2R4
CAS13033R1
44-4
http://vnx.su

Rear wing panel
44 A
13216R
13212R1
or
CAB11540-1R1
CAV13468R1
K
5
CAB11540-1R7
44-5
http://vnx.su

Rear wing panel
13356R
2
1
2
44-6
http://vnx.su
CAN11691R7
44 A

Rear wing panel
GLAZED
VERSION
13218R1
44 A
13217R1
or
A
1
A
1
CAS13033R8
CAS13033R8
44-7
http://vnx.su

Rear wing panel
VERSION WITH
ROOF FLAP
44 A
INTRODUCTION
Below there are special details for vehicles fitted

with a roof flap.
CAC11541-1R6
13475R
13
CAC11541-1R6
44-8
http://vnx.su

Side panel
44
INTRODUCTION
JOINTS WITH :


Body side lining
Door pillar reinforcement
Wing panel stiffener spacer

concerned.

1
2
3
For the panel version, this part may be replaced in

two ways (see cuts on the diagram below) :
4
5
1 - complete with cut A.A on the upper section

2 - partial with cut B.B for the glazed version
6
7
8
9
10
11
12
13
14
15
At the end of the section there are also special details for the glazed version and the version with a
roof flap.

DEPARTMENT
Part assembled with sliding door rail units and

striker plate mounting.
PRB4414
44-9
http://vnx.su
Rear wing panel

channel
upper reinforcement
Centre rail mounting
Stretcher lining
Roof
Door pillar upper reinforcement
Door pillar reinforcement
Sill panel pillar reinforcement
Wing panel stiffener spacer
Wing panel stiffener
0.8
0.7
1.2
1
1.2
1
0.7
0.7
1.2
1.2
1.5
0.7
1.2
0.7
0.7

Side panel
44
B - C
1 - COMPLETE WITH CUT A-A
CAI11550-2R1
13218R2
or
CAS13033R1
44-10
http://vnx.su

Side panel
44
E
11
2
1
CAE11546-2R7
13219R1
or
1
13
11
CAE11546-2R4
7
1
CAI11550-2R3
CAS13033R1
44-11
http://vnx.su

Side panel
44
H
11
10
1
CAE11546-2R7
13216R
J
1
10
11
CAE11546-2R4
CAB11540-1R1
K
5
CAB11540-1R7
44-12
http://vnx.su

Side panel
13212R1
44
12665R1
or
2
1
2
CAV13468R1
1
2
44-13
http://vnx.su
CAN11691R7

Side panel
13018R
13210R
44 B
15
1
14
CAA11538-1R8
CAV13463R7
44-14
http://vnx.su

Side panel
GLAZED
VERSION
44
2 - DETAILS OF CUT B-B
13218R1
or
13217R1
or
A
1
A
1
1
1
CAS13033R7
CAS13033R7
44-15
http://vnx.su

Side panel
VERSION WITH
ROOF FLAP
44
INTRODUCTION
Below are special details for vehicles fitted with a

roof flap.
CAC11541-1R6
13475R
CAC11541-1R6
44-16
http://vnx.su

Side panel lining
44
INTRODUCTION
JOINTS WITH :

operation to the wing panel or a side panel for a
rear side impact.
Door pillar upper reinforcement or centre pillar

reinforcement
Rear wheel arch
It also requires replacement of the centre pillar

reinforcement, the door pillar will need to be ordered separately.
concerned.

1
2
3
This part is replaced in three ways (see cuts on the

diagram below) :
4
5
1 - complete
2 - partial by cut A-A
3 - partial by cut B.B for glazed version
6
7
8
9
10
11
12
13

DEPARTMENT
Part assembled with welded nuts.
PRB4415
44-17
http://vnx.su

0.7
Stretcher lining
0.7
channel
1.2
1
upper reinforcement
1.2
1.5
1.5
Door pillar upper reinforcement
1.2
Door pillar lower reinforcement
1.2
Inertia reel mounting reinforcement 1.5
Inner wheel arch
1
Seat mounting reinforcement
1.5
1.2

Side panel lining
1
44
COMPLETE
2
1
CAA11538-1R1
C
13220R
A
2
CAO11694-1R1a
CAA11537R8
44-18
http://vnx.su

Side panel lining
44
CAA11538R6
13211R
D
5
1
CAN11690R3
44-19
http://vnx.su

Side panel lining
44
H
8
CAO11694R1
13355R
F
1
1
8
9
CAJ11551-4R7
CAO11694-1R7
J
8
2
1
9
CAN11690-2R8
CAQ11697R8
44-20
http://vnx.su

Side panel lining
44
L
1
6
CAA11538-1R8
13353R2
1
7
6
CAF11547-3R3
CAA11538-1R8
44-21
http://vnx.su

Side panel lining
44
O
12
1
11
CAK11552-4R2
13354R
P
10
11
11
CAW13601-3R1
CAQ11697R6
44-22
http://vnx.su

Side panel lining
44
11
CAQ11697R2
13351R
Q
1
13
CAA11536-2R4
44-23
http://vnx.su

Side panel lining
2 - PART SECTION CUT A-A
44
2 - PART SECTION CUT B-B
13354R1
13215R
or
1
CAB11540R1
or
CAS13033R1
44-24
http://vnx.su

Side panel lining
44
13210R1
13354R2
or
or
CAS13033R1
CAS13033R1
44-25
http://vnx.su

44 D
INTRODUCTION
JOINTS WITH:

operation to the wing panel with lining for a side
impact with rollover.

Wing panel upper rain channel

concerned.

Wing panel upper rain channel
Roof rear cross member reinforcement
Centre pillar / door pillar
upper reinforcement
7 Upper reinforcement of side
panel rain channel
8 Roof flap rain channel
1
2
3
4
5
6


DEPARTMENT
Part assembled with welded nuts.
PRB4416
44-26
http://vnx.su
0.7
1
1.2
0.8
1.2
1.2
1.2
0.7

44 D
B
1
6
CAA11538-1R8
13214R1
CAA11537-1R5
44-27
http://vnx.su

44 D
CAP11696-2R6
13211R2
C
1
5
4
1
CAJ11551-1R3
CAA11537R5
F
7
CAO11694-1R3
44-28
http://vnx.su

VERSION WITH
ROOF FLAP
44 D
7
CAO11694R6
13475R1
1
CAO11694R6
44-29
http://vnx.su

44
INTRODUCTION

operation to the wing panel with lining and rain
channel for a rear side impact.
concerned.

DEPARTMENT
Part assembled with bumper reinforcement.
PRB4417
JOINTS WITH:
Rear floor
Rear side member

Bumper
Bumper reinforcement
Sill panel rear closure panel
Rear shock absorber mounting
reinforcement
6 Floor
1
2
3
4
5
44-30
http://vnx.su
1
1.5
1.5
1.5
1.5
0.8

44
3
1
2
CAE11546-3R7
13471R
2
1
7
CAF11547-3R4
CAA11538-1R3
D
1
CAN11690-2R6
44-31
http://vnx.su

E
1
CAA11537-1R7
F
1
5
4
CAP11696-2R7
44-32
http://vnx.su
44

INTRODUCTION
JOINTS WITH:
The replacement of this part may be carried out in

two ways :
Panel upper rain channel

Side panel lining
Rear floor
Roof
1 - Complete replacement, complementary to the

side panel with lining.
2 - Partial replacement, complementary to the
rear end panel and rear end cross member
(see cut in the diagram below).
44

concerned.
1
2
3
4
5
6
7
8
9
10


DEPARTMENT

- side panel extension,
- lights mounting with studs and welded nuts,
- bumper counter blade,
- tailgate counter balance reinforcement,
- welded nuts,
- upper hinge reinforcement.
PRB4418
or
44-33
http://vnx.su

channel
Panel upper rain channel
Panel lining
Rear floor
Roof stretcher
Roof
Wheel arch
Side panel
1.5
1.2
0.7
0.8
1.02
0.7
0.7
1
1
1

44
1 - COMPLETE REPLACEMENT
CAO11694R4
13211R1
CAW13605-1R2
44-34
http://vnx.su

44
D
1
CAA11536-3R2
13212R
E
1
CAA11536-3R2
CAA11536-5R2
44-35
http://vnx.su

44
G
3
CAU13326R1
13223R
H
4
1
10
CAQ11697R4
CAL11554-2R1
44-36
http://vnx.su

2 - PARTIAL REPLACEMENT
13223R1
13351S
Appearance after cutting.
or
I
10
10
CAV13467R3
44-37
http://vnx.su
44

44 G
INTRODUCTION
JOINTS WITH:
The replacement of this part is carried out partially following a rear side impact and is complementary to the rear wing panel (see diagram and method below).
Wing panel lining

Bumper mounting
The bumper side mounting must also be replaced

and is sold separately.
1
2
3
4

concerned.

Wing panel lining
Acoustic insert
Bumper mounting


DEPARTMENT
Part only.
PRB4419
44-38
http://vnx.su
1
0.7
0.7
1.2

44 G
CAN11689R5
13223R2
or
2
A
1
CAA11536-1R3
CAA11536-3R2a
or
2
4
CAA11538R7
44-39
http://vnx.su

3
1
CAA11538-1R4
44-40
http://vnx.su
44 G

Rear end panel
INTRODUCTION
JOINTS WITH:

for a rear impact.
Rear end panel

Floor
Rear pillar lower gusset

concerned.
44 H
1
2
3
4
5

diagram below).
Rear end panel

Floor

DEPARTMENT
Part only.
PRB4420
or
44-41
http://vnx.su
1
1.2
1.5
0.8
1

Rear end panel
44 H
B
1
3
2
CAE11546R8
13223R3
C
or
1
3
2
1
CAB11539-1R7
CAS13030-1R2
CAA11538R5
44-42
http://vnx.su

Rear end panel
44 H
3
1
CAA11536-4R8
13223R4
or
E
1
4
5
CAS13033R1
CAE11546-8R2
44-43
http://vnx.su
TOP OF BODY
Roof
45 A
INTRODUCTION
JOINTS WITH :

for a rollover, or a complementary operation to a
side panel for a side impact.

Body side
Side panel
Side panel rain channel (lights mounting)

concerned.
1
2
3
4
5

DEPARTMENT
Part assembled with stiffeners.

6
7
8
9
10
11
PRB4503
45-1
http://vnx.su
Roof
reinforcement
Side panel
Upper reinforcement of side
panel rain channel
Centre pillar door pillar
reinforcement
Stretcher lining
0.8
0.8
1
0.8
1.2
0 .8
1.2
1.2
1
0.7
0.7
TOP OF BODY
Roof
45 A
B
1
CAA11536-4R2
1
13228R
A
1
2
CAG11548-2R5
CAQ11697R7
D
1
CAQ11697R7
45-2
http://vnx.su
TOP OF BODY
Roof
45 A
13213R1
13214R2
F
1
CAC11544-1R1
CAC11544-1R1
45-3
http://vnx.su
TOP OF BODY
Roof
45 A
13211R3
13212R2
H
1
1
5
4
CAC11544-1R2
CAE11546-6R1
45-4
http://vnx.su
TOP OF BODY
Roof
45 A
K
1
6
CAS13025-4R2
J
1
1
CAG11548-2R5
10
CAS13025-4R2
1
2
45-5
http://vnx.su
TOP OF BODY
Roof
VERSION WITH
ROOF FLAP
45 A
INTRODUCTION

roof flap.
CAA11536-4R1
1
2
13475R1
A
11
CAA11536-4R1
11
1
CAJ11551-1R5
45-6
http://vnx.su
TOP OF BODY
45
INTRODUCTION

operation to the roof.
concerned.

DEPARTMENT
Part only.
13213R2
PRB4504
CAA11537-1R6
JOINTS WITH :
1 Roof front cross member

2 Windscreen pillar lining
0.8
1
45-7
http://vnx.su
TOP OF BODY
45
INTRODUCTION

concerned.

DEPARTMENT

- roof bar mounting reinforcement,
- partition mounting nuts.
13214R3
PRB4505
CAA11537-1R6
JOINTS WITH :
1 Roof centre cross member

2 Centre pillar upper reinforcement
0.8
1.2
45-8
http://vnx.su
TOP OF BODY
INTRODUCTION
JOINTS WITH :

Side panel upper rain channel


concerned.
45 D

1
2
3
4

Side panel upper rain channel

DEPARTMENT

- cross member reinforcement,
- tailgate hinge mounting reinforcement,
- opening door lock mounting reinforcement,
- partition mounting nuts.
PRB4506
45-9
http://vnx.su
0.8
1.2
0.7
0.7
TOP OF BODY
45 D
B
2
3
1
CAJ11551R3
13211R4
CAA11537-1R5
45-10
http://vnx.su
VERSION WITH
ROOF FLAP
TOP OF BODY
INTRODUCTION

roof flap.
13473R
CAA11537-1R5
45-11
http://vnx.su
45 D

Front door
47 A
PRB4706
REMOVAL
13021R1
Remove the door hinge pins using tool Car. 1415

Parts Department number 00 00 141 500 (operation must be carried out by two people).
13021R
Disconnect the connection of the door wiring by

pushing the clip upwards.
REFITTING
Remove the door handle bolt (A).
Refit in the opposite way to the to removal and

refer to the section on opening clearances, to
make any adjustments.
47-1
http://vnx.su

Front door panel
INTRODUCTION
JOINTS WITH:

Door box section

Anti-intrusion reinforcement
Stiffener
47
This operation also requires the stiffener to be replaced and this must be ordered separately.

method below).
1
2
3
4

concerned.
Door box section

Door panel
Stiffener


DEPARTMENT
Part assembled with soundproofing pads.
PRB4707
or
47-2
http://vnx.su
0.8
1.2
0.8
1.2

Front door panel
47
B
1
CAQ11697R4
13343R
or
1
3
CAT13318R1
1
CAS13033R3
47-3
http://vnx.su

Front door panel
47
E
3
2
1
CAT13318R2
1
13343-1R
2
or
D
3
CAS13033R3
47-4
http://vnx.su

Front door panel
47
G
3
2
1
CAT13318R2
1
13344R
F
2
CAN11689R1
CAV13463R1
47-5
http://vnx.su

INTRODUCTION

operation to the front door panel.
concerned.

DEPARTMENT
Part only.
PRB4710
JOINTS WITH:
Door box section

Stiffener
1 Door box section

2 Stiffener
3 Lock striker plate reinforcement
47-6
http://vnx.su
0.8
1.2
1.2
47

47
13472-1R
13472R
B
1
CAA11538R7
CAA11538R3
47-7
http://vnx.su

Side door
47 D
PRB4709
REMOVAL OF THE SLIDING DOOR
13105R
12978R
pin.
Remove :
- the rear stop,
47-8
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Side door
47 D
REMOVAL OF UPPER RUNNER MOUNTINGS
12979R
12976R
REMOVAL OF INTERMEDIATE RUNNER

MOUNTINGS
12977R
Remove the inner trim.
47-9
http://vnx.su

Side door
REMOVAL THE LOWER RUNNER MOUNTINGS
47 D
REFITTING
Refit in the opposite way to removal and refer to

section 51 - sliding door mechanism, to make adjustments.
12975R
13106R
Remove the lower trim according to version.
47-10
http://vnx.su

Side door panel
INTRODUCTION
JOINTS WITH:

for a side impact.
Door box section

Stiffener
47

method below).

concerned.
1
2
3
4

Door box section

Door panel
Stiffener

DEPARTMENT
Part assembled with soundproofing pads.
PRB4708
or
Only for the glazed version.

NOTE : for panel versions, the whole panel should
be replaced.
47-11
http://vnx.su
0.8
1.2
0.8
1.2

Side door panel
47
B
3
2
1
CAT13318R2
1
13346R
A
2
CAN11689R1
CAV13463R1
47-12
http://vnx.su

Side door panel
47
D
3
CAQ11697R5
13345R
E-G
or
1
3
CAT13318R1
1
CAS13033R3
47-13
http://vnx.su

Side door stiffener
INTRODUCTION

operation to the side door panel.
concerned.

DEPARTMENT
Part only.
PRB4710
JOINTS WITH:
Door box section

Stiffener
1 Door box section

2 Stiffener
3 Rail roller reinforcement
47-14
http://vnx.su
0.8
1.2
1.2
47

Side door stiffener
47
B
3
CAB11539-1R1
13608R
A
1
CAA11538R7
47-15
http://vnx.su

Bonnet
48 A
REFITTING

section 40 (opening clearances) to correctly make
adjustments.
ADJUSTMENT
The height adjustment is carried out using strut

mounting bolts (B) on the headlight carrier panel.
The front and rear adjustments are carried out
using mounting nuts (A) on the bonnet .
PRB4808
REMOVAL
13238R
Remove the bonnet nuts (A) (operation must be

carried out by two people).
48-1
http://vnx.su

Bonnet hinges
48
REFITTING
Refer to the preceding section, to make adjustments to the bonnet.
PRB4809
REMOVAL
13238R
Remove:
- the bonnet nuts at (A) (operation must be carried out by two people),
- the bonnet,
- the strut mounting bolts (B) on the headlight
carrier panel.
48-2
http://vnx.su

Rear opening doors
48
REFITTING

section 40 (opening clearances) to correctly make
adjustments.
ADJUSTMENT
The height and clearance adjustment is carried

out by means of the mounting bolts (A).
The tilt adjustment is carried out using a a B.H.A.
type clip from Z International, by deforming at (B)
the welded hinges on the rear pillar.
PRB4810
REMOVAL
13101R
Remove the mounting bolts (A) on the door edges

(this operation should be carried out using two
people).
48-3
http://vnx.su

Tailgate
48 D
REFITTING

section 40 (opening clearances) to make correct
adjustments.
ADJUSTMENT
Height and tilt adjustment are made by fitting

shims under the mounting bolts (A).
Clearance adjustment is carried out by adjusting
the play of the same bolts in their mounting holes.
PRB4811
REMOVAL
13474R
After removal of trim and wiring, remove the balancers then the mounting bolts (A) from the roof
rear cross member (this operation should be carried out with two people).
48-4
http://vnx.su

Roof flap
48
REFITTING

section 40 (opening clearances) to make the correct adjustments.
ADJUSTMENT
Adjustment of edge clearances can only be made

by adjusting the play of the mounting hinges on
the roof.
PRB4812
REMOVAL
13247R
Remove the blanking cover and the mounting nut

(A).
Move the linkage from its position (B) .
Remove the cross member mountings (C).
48-5
http://vnx.su
Sheet Metal Work

GENERAL INFORMATION
LOWER STRUCTURE
TOP OF BODY
77 11 292 482
JANUARY 2000
EDITION ANGLAISE
The methods may be modified as a result of changes introduced by the manufacturer

in the production of the various component units and accessories from which his
vehicles are constructed."
reference numbering system is forbidden without the prior written authority of Renault.
RENAULT 2000
http://vnx.su
EXPLODED VIEW
http://vnx.su
Sheet Metal Work

Contents
Page
40 GENERAL INFORMATION
Dimensions
Towing
Key to symbols
Fitting the extension elements
Description of parts
Repair bench
Tools and specific products
40-1
40-2
40-3
40-4
40-5
40-6
40-8
40-9
40-12
41 LOWER STRUCTURE
P
X
Semi-extreme rear cross member

Rear floor extender
41-1
41-8

A
Aa
B
Bb
G
I
J
K
Basic body rear wing panel

Added rear wing panel
Basic body side panel
Added side panel
Side panel extender
Side inner panel extender
Upper rear corner stiffener
44-1
44-3
44-12
44-14
44-24
44-28
44-30
44-33
45 TOP OF BODY
Aa Grand volume added roof
E
Roof inner panel extender
http://vnx.su
45-1
45-5
GENERAL 140
INFORMATION
Dimensions
(1) Empty
(2) Laden
Dimensions in metres.
40-1
http://vnx.su
40
GENERAL INFORMATION
40
BODY AND EXTENDED PASSENGER COMPARTMENT
Engine
Vehicle type
Type
Capacity
Clutch type
Gearbox type
manual and automatic
(cm3 )
FC0HHF
E7J
1390
180 CP 3300
JB3
FC0EHF
F8Q
1870
200 COPV 3250
JB1
EXTENDED
PASSENGER
COMPARTMENT
BODY
Petrol
Diesel
Petrol
Diesel
Pay load (kg)
550
600
580
580
Weight (kg) when empty and ready for operation

(basic vehicle)
1175
1220
1195
1240

on front
610
660
610
655

on rear
565
560
585
585

(all options)
1227
1270
1246
1291
40-2
http://vnx.su
GENERAL INFORMATION
Towing
40
SPECIAL FEATURES OF THE KANGOO GRAND VOLUME
This vehicle does not have a rear towing eye.
REAR
FRONT
Under no circumstances should the rear towing ring of

the basic body be used for towing.
The towing eye may only be used for towing on the

road.
40-3
http://vnx.su
GENERAL INFORMATION
Key to Symbols
40
Chiselling
Crimping of exterior door panels.
Grind back beads or spot welds.

Straight grinding wheel with 75 mm
diameter bakelite impregnated disc,
thickness 1.8 to 3.2 mm.
Safety symbol.
This means that the welding operation in
question concerns one or more of the
vehicle's vital safety components.
Grind back spot welds.

Straight grinding wheel 20 000 rpm fitted
with a spherical burr 10 or 16 mm.
Body solder - lead fill.

Hot air torch.
Nozzle output temperature 600 min.
Slipper+ 33 % tin solder + tallow.
Note: to a large extent, body solder filling
compensates for the heat distortion
caused by welding.
Drill spot welds.

Hardened steel bit.
Speed of rotation 800 to 1 000 rpm.
Unpicking
Application of weldable mastic.

This mastic is a conductor, interposed
between two spot welding sheets, it
ensures the seal between the sheets and
avoids corrosion of the spot weld
Cleaning surfaces to be welded.

Fibre disc 100 mm
Cutting with a saw.

Pneumatic power hacksaw.
Cut out part by grinding off flange or
grinding back remaining traces of spot
weld.
Finish surface after welding.
Angle grinder fitted with a rubber pad
and a 120 to 180 mm diameter fibre disc
grain size P36.
Application of aluminium paint.

This is to be applied to the joint faces of
each of the parts to be plug welded. This
paint is conductive and can withstand high
temperatures; it gives anti-corrosion
protection around welds
Unsoldering.
Apply a fillet of extruded mastic

from a manual or pneumatic spray gun
one or two pot mastic for crimped and
butt joints.
MAG stitch weld

Note: to obtain a good quality weld we
recommend the use of a gas consisting of
argon + 15% CO2 which is considered an
active gas (MAG)
Apply mastic by spraying

spray gun.
anti-chipping and anti-corrosion in two
parts
Apply a bead of extruded adhesive mastic
from a manual or pneumatic spray gun
adhesive mastic in one or two parts
Resistance spot welding
Plug welding.
Under MAG gas protection.
Thermal cleaning of extruded or spray

mastic
40-4
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GENERAL INFORMATION
Fitting extension elements
1
2
3
4
5
Roof
Rear ring
Side panel
Wing panel
Basic body
40-5
http://vnx.su
40
GENERAL INFORMATION
40
UPPER STRUCTURE
PRF4011
1
2
3
4
5
6
7
8
9
Roof added
Rear wing panel (panel and glazed version)
Side panel rain channel support
Side panel added (panel and glazed version)
Side panel extender
40-6
http://vnx.su
GENERAL INFORMATION
40
SUB-FRAME
PRF4012
10 Rear floor extender

11 Demi-rear end cross member
12 Rear end panel
40-7
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GENERAL INFORMATION
40
DESCRIPTION
DIAMETER
SLOPE %
Rear end cross member (end panel)
3 446
- 497.5
151
M8
40-8
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GENERAL INFORMATION
Repair Bench
CELETTE REPAIR BENCH
40-9
http://vnx.su
40
GENERAL INFORMATION
Repair Bench
BLACKHAWK BODY JIG BENCH
PRF4013
40-10
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40
GENERAL INFORMATION
Repair Bench
SPECIAL TOOLING PART NUMBER
BLACKHAWK
CELETTE
Special heads for MS System
Specific plates for MZ System
Order at:
Order at:
BLACKHAWK S.A.
Centre Eurofret
Rue de Rheinfeld
67100 STRASBOURG
CELETTE S.A.
B.P. 9
38026 VIENNA
Suppliers part number: 760 308

Suppliers part number: REN 88222
40-11
http://vnx.su
40
GENERAL INFORMATION
40
MATERIAL
FITTING ADDED ELEMENTS

PRODUCTS
It is VITAL to fit the elements added to the KANGOO
Grand Volume with:
the glue cartridge
part number 56 89 330 053 used by RENAULT
Industrial Vehicles,
its grip primer part number 56 89 330 052,
the vents with blades (sold singly)
part number 77 11 172 866,
degreaser, heptane
part number 77 11 170 064,
SPECIAL NOTES
In the areas where the original paintwork has been
altered (to the sheet), it will be necessary to apply
anticorrosion impression type "ALPHA"
(part number 77 01 423 933).
PHOTO 14342 (SHOWN IN REPAIR MANUAL 338 SECTION 5)
The grip primer (part number 56 89 330 052) is applied

on the cataphoresis after sanding with a grey buffer on
the areas treated for "ALPHA" impression without
sanding after drying.
NOTE: for all additional instructions, refer to the
technical sheets for each product.
40-12
http://vnx.su
GENERAL INFORMATION
3M ADHESIVE FINISHING SEAL
(Part number 77 11 212 385)
It is applied before the paint, on a degreased primer.

Refer to section type (section 44-Aa, 44-Bb).
16595R4
40-13
http://vnx.su
40
LOWER STRUCTURE
141
Semi-rear end cross member
41
INTRODUCTION
This part is changed in addition to changing the rear
end panel. It may be performed in two ways:
Cut 1
order a right or left demi-cross member,
Cut 2
order the two demi-cross members

then fit them in (A) or (B). For this
operation, the use of the body jig bench
is vital.
The separation operation should be carried out last,

when all the other links have been unhooked.
In the operation described below, only descriptions of
the joints specific to the part concerned are given.

1
2
3
4
5
6
7
8
9
Connections associated with the additional parts are

not taken into consideration. These connections will be
dealt with in their respective section (refer to contents).

DEPARTMENT
extreme rear cross member.
lower central extender,
striker support absorber,
lower side extender,
side cross member,
side cross member stiffener,
counter blade absorber.
Side panel rain channel light support

Lights lower bracket
Side cross member stiffener
Extreme rear cross member
Side cross member
Side panel extender
Rear floor extender
Lower central extender
Basic body rearend panel
41-1
http://vnx.su
1.5
1
1
1.2
1
1
0.8
1
1
LOWER STRUCTURE
SPECIAL FEATURE OF THE FOLLOWING
REPLACEMENT CUT 1
41-2
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41
LOWER STRUCTURE
41-3
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41
LOWER STRUCTURE
41-4
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41
LOWER STRUCTURE
J = two hexagonal screws 8 mm
41-5
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41
LOWER STRUCTURE
SPECIAL FEATURES OF THE FOLLOWING
REPLACEMENT CUT 2
761P4-16604-1
L = two hexagonal screws 8 mm
41-6
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41
LOWER STRUCTURE
41-7
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41
LOWER STRUCTURE
Rear floor extender
41
INTRODUCTION
For a rear impact, replacing this part is an additional

operation to replacing:
the rearend panel,
the demi-extreme rear cross member.
1
2
3
4
5
6
7
8
9
IMPORTANT: the separation operation should be

carried out last, when all the other links of the part
have been released, in order to move the part to
separate it.
Rear floor extender

Rear section rear floor
Lights support lower bracket
Central lower extender
Side cross member
Seal contour

Connections associated with the additional parts are
not taken into consideration. These connections will be
dealt with in their respective sections (refer to
contents).

DEPARTMENT
seal contour,
striker stiffener,
towing ring plate.
41-8
http://vnx.su
X
0.8
1
1.2
1
1.5
0.8
1
1
1
LOWER STRUCTURE
Rear floor extender
H = two hexagonal screws 8 mm
41-9
http://vnx.su
41
LOWER STRUCTURE
Rear floor extender
CAA11536-1R5A
CAA11538-1R5
41-10
http://vnx.su
41
TOE14621-5R7

INTRODUCTION
The basic body sheet wing panel of the Kangoo Grand
Volume may be replaced partially by following the
method given below.

DEPARTMENT

1 Basic body wing panel
44-1
http://vnx.su
0.8
44

44
CAS13033R7
764A1-16607
or
SPECIAL FEATURE
Only operations related to the partial cut are dealt with
in this method. Other operations are described in
Repair Manual 326.
CAS13033R7
44-2
http://vnx.su

Rear wing panel fitted
INTRODUCTION
The replacement of this part is a basic operation for a
rear side impact.
It also requires the replacement of the Grand Volume
added roof, which is fitted on top at their common
contact (refer to section 45Aa).
Information on additional parts will be dealt with in their
respective sections (refer to the contents).

DEPARTMENT
Part 1.
PRF4417
IMPORTANT: in order to aid refitting, the panel

mounting on the body during repair is different from the
original mounting (refer to the method described
below).
44-3
http://vnx.su
44
Aa

ORIGINAL MOUNTING
44
Aa

1
2
3
4
5
6
Added rear wing panel

Basic body roof
Side panel extender
16619S
MOUNTING FOR REPAIR
16619-1S
Moulding 7 mm
Moulding 5 mm
44-4
http://vnx.su
0.8
0.8
0.8
1.5
1
1

44
Aa
REMOVAL (ORIGINAL MOUNTING)
16586-1R1
16619R1
16595R1
16584-1R1
44-5
http://vnx.su

16589R1
44
Aa
16691R
A
B
Masking tape width 5 cm

Adhesive moulding
16596R1
16593R1
44-6
http://vnx.su

44
Aa
16592R1
16588R1
16590R1
16587R1
44-7
http://vnx.su

44
Aa
REFITTING
We recommend that you follow the order given below:
position the panel on the body,
bond the panel,
fit and adjust it,
strap the part (refer to section 44Bb),
solder.
NOTE: the panel should be stuck and fitted to the body
as quickly as possible.
The adhesive moulding diameters change depending
on the glue course (see below).
16584-1R1
Adhesive moulding 5 mm
between sheets (1) and (2)
16619-1R1
16586-1R1
44-8
http://vnx.su

44
16595R1
Aa
16596R1
A adhesive moulding 7 mm
B adhesive moulding 5 mm
16589R1
44-9
http://vnx.su

44
Aa
SPECIAL FEATURE
Wide masking tape should be applied to the basic
body wing panel at the adhesive moulding position
(section 6), which will prevent the mounting body wing
panel being damaged when the part is removed once
more.
16593R1
16691R
A
B

Between sheets (1) and (A)
16592R1
44-10
http://vnx.su

16590R1
44
Aa
16587R1
Example of plating for stuck parts

(refer to section 44Bb Refitting).
16588R1
44-11
http://vnx.su

44
INTRODUCTION
The basic body side panel of the Kangoo Grand
Volume may be partially replaced by following the
method given below.
This is made possible by masking the connection
when the Grand Volume added panel is in place.
IMPORTANT: this method cannot be used on a series
Kangoo.

DEPARTMENT
Part assembled with sliding door rail units and striker
plate mounting.

1 Basic body side panel
44-12
http://vnx.su
0.8

44
CAS13033R7
764B1-16606
or
SPECIAL FEATURE
Only operations related to the partial cut are dealt with
in this method. Other operations are described in
Repair Manual 326.
CAS13033R7
CAA11536-2R7
44-13
http://vnx.su

Added side panel
INTRODUCTION
rear side impact.
It also requires the replacement of the Grand Volume
added roof, which is fitted on top at their point of
contact (refer to section 45AA).
Information on parts will be dealt with in their
respective sections (refer to contents).

DEPARTMENT
IMPORTANT: in order to aid refitting, the panel

mounting on the body during repair is different from the
original mounting (refer to the method described
below).
44-14
http://vnx.su
44
Bb

Added side panel
ORIGINAL MOUNTING
44
Bb

1
2
3
4
5
6
Added side panel

Basic body roof
Side panel extender
MOUNTING FOR REPAIR
Moulding 7 mm
Moulding 5 mm
44-15
http://vnx.su
0.8
0.8
0.8
1,5
1
1

Added side panel
REMOVAL (ORIGINAL MOUNTING)
44-16
http://vnx.su
44
Bb

Added side panel
A
B

Adhesive moulding
44-17
http://vnx.su
44
Bb

Added side panel
44
Bb
16587R3
44-18
http://vnx.su

Added side panel
44
Bb
REFITTING
We recommend that you follow the order given below:
bond the panel,
adjust and strap the part (refer to section 44Bb),
solder.
ATTENTION: The adhesive moulding diameters
change depending on the glue course (see below).
A
B
16620-1R
16584-1R3
44-19
http://vnx.su

Added side panel
44
Bb
SPECIAL FEATURE
Wide masking tape should be applied to the basic
body wing panel at the adhesive moulding position
(section 6), which will prevent the mounting body side
panel being damaged when the part is removed once
more.
16595R3
A
B
16691R
A
B

Between sheets (1) and (A)
44-20
http://vnx.su

Added side panel
44
Bb
16591R1
16593R3
16592R3
16590R3
44-21
http://vnx.su

Added side panel
44
Bb
Example of plating for the stuck parts
Fit the weather-strip for the front door in the

opposite direction on the door. Close the door,
then position the straps (see below).
16588R3
ATTENTION: protect the seals from glue spillages

using masking tape.
16587R3
16631S
44-22
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Added side panel
3
Use bolts and nuts of 6 mm and wide washers

for plating the panel at the side strip clampingholes.
16632S
44-23
http://vnx.su
44
Bb

Side panel extender
44
INTRODUCTION
This part may be replaced in two ways:

1 total replacement complementary to the side panel,
2 partial changing complementary to the skirt and
lights mounting side panel rain channel.
1
2
3
4
5
Side panel extender

Side cross member
Lower lights bracket
Basic body side panel extender

Information on parts to which this is additional, will be
contents).

DEPARTMENT
Part on its own.
44-24
http://vnx.su
G
1
1
1
1,2
1

Side panel extender
44
1 - COMPLETE REPLACEMENT
TOA14581R7
764G1-16608
TOH14634R7
TOA14581R7
TOB14593R6
44-25
http://vnx.su

Side panel extender
Moulding 5 mm
44-26
http://vnx.su
44

Side panel extender
2 - PARTIAL CHANGING SPECIAL FEATURES
764G2-16646
CAA11536-2R7
44-27
http://vnx.su
44

44
INTRODUCTION
Replacing this part is an additional operation to the
rain channel lights support after a rear impact.
This operation may be carried out partially.

DEPARTMENT
Assembled part with hinge stiffener.
16629R
or
PRF4413
CAS13033R7

1
2
3
4

Lights support side panel rain channel
Rear floor extender
Basic body side panel lining
0.8
1.5
0.8
0.7
44-28
http://vnx.su

44
CAB11539-1R1
CAA11536-2R6
Moulding 5 mm
CAA11536-2R3
44-29
http://vnx.su

44
INTRODUCTION
This part is changed in addition to changing roof with
cross member and inner panel.

DEPARTMENT
Part on its own.
764J1-16628

CAA11536-2R4
1
2
3
4
5
6
7
8

Basic body roof rear cross member
Basic body roof
Inner panel stiffener
1
0.8
0.8
1.5
0.8
0.8
0.8
0.8
44-30
http://vnx.su

44
CAA11536-2R5
CAA11536-2R2
Moulding 5 mm
CAW13605-4R1
CAA11536-2R2
Moulding 5 mm
44-31
http://vnx.su

44
CAA11538-1R4A
764J2-16643-1
I = two hexagonal screws 8 mm.
CAA11536-2R5
44-32
http://vnx.su

44
INTRODUCTION
This part is changed in addition to changing the
rearend panel. It is carried out partially.
contents).

DEPARTMENT
side panel extension,
lights mounting with studs and welded nuts,
bumper counter blade,
tailgate counter balance reinforcement,
welded nuts,
upper hinge reinforcement.
16715S

1 Lights support side panel rain channel
2 Bolt diameter 8 mm key of 13
3 Steel rivet
IMPORTANT: the Parts Department part should be cut

out before fitting at the level of the assembled side
panel extender (refer to diagram below).
44-33
http://vnx.su
1.5

REMOVAL - REFITTING
16627R
1
2
Remove the two bolts

Bore the rivet
CAS13033R5
44-34
http://vnx.su
44
TOP OF BODY
145
Grand volume added roof
45
INTRODUCTION
side impact.
Information on additional parts will be dealt with in their
respective sections (refer to the contents).

DEPARTMENT
Part provided with luggage grid spacer extractors and
blanking covers.

1
2
3
4
5
6
Added roof
Added side panel
Basic body roof
Luggage grid spacer extractor
45-1
http://vnx.su
0.7
0.8
0.8
0.8
15
1
Aa
TOP OF BODY
45
Aa
REMOVAL - REFITTING
16584R
Between sheets (1)

and (2)
765A2-16625
Moulding 5 mm
Moulding 5 mm
16582R
Between sheets (1)

and (3)
Moulding 5 mm
45-2
http://vnx.su
TOP OF BODY
45
765A1-16626
Aa
16583R
Between sheets (1)

and (4)
Moulding 5 mm
16586R
Between sheets (1)

and (2)
Moulding 5 mm
Between the sheet

(1) and the part (5)
Moulding 5 mm
45-3
http://vnx.su
TOP OF BODY
45
Aa
16829R
16633S
Apply a coating of glue to the spacer extractor on (1),

tighten it manually until the two sheets are plated, then
finish by tightening with a key - tightening torque
2.37 da N.m.
Example of plating method for refitting the added roof.
Apply a coating of glue on (2) before refitting the

added roof.
45-4
http://vnx.su
TOP OF BODY
45 E
REMOVAL
INTRODUCTION
This part is changed in addition to changing roof with
cross member.
contents).

DEPARTMENT
Part on its own.
765E1-16643
F = bolt of 8 mm

1
2
3
4
5

Side panel lining
1
0.8
1.5
0.8
0.7
CAA11538R8
45-5
http://vnx.su
TOP OF BODY
45 E
CAA11536-2R5
CAA11536-2R5
CAB11539-1R1
between sheets (1)

and (5)
Moulding 5 mm
45-6
http://vnx.su
Mechanisms and Accessories

GENERAL
SIDE OPENING ELEMENT MECHANISMS
NON-SIDE OPENING ELEMENT MECHANISMS
WINDOWS
EXTERIOR PROTECTION
EXTERIOR ACCESSORIES
LOWER INTERIOR ACCESSORIES
UPPER INTERIOR ACCESSORIES
INTERIOR SAFETY ACCESSORIES
77 11 194 289
JULY 1997
Edition Anglaise
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".
RENAULT.
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB5000
http://vnx.su
Mechanisms and
accessories
Contents
Pages
50 GENERAL
Safety
Tooling
Pages
54 WINDOWS
50-1
50-2
51 SIDE OPENING ELEMENT
Tilting or fixed windows in sliding

door
Fixed or moving side window
Window in rear door and window in
tailgate
Moving window/latch
54-4
54-5
54-6
54-7
MECHANISMS
Window winder handle on front
door
Door opening handle - interior,
front door
Door opening handle - exterior,
front door
Front door lock
Front door window riser
Door barrels
Interior handle for opening the
sliding door
Exterior handle for sliding door
Locking warning light and sliding
door lock
Sliding door runners
Adjusting the sliding door
51-1
55 EXTERIOR PROTECTION
51-2
Roof protection strip

Bumpers
Side protection strips
Protective panel at rear
51-3
51-4
51-5
51-6
51-7
51-8
56 EXTERIOR ACCESSORIES
51-9
51-10
51-12
Exterior rear view mirror

Rear view mirror
Rear screen washer jet
Number plate light
52 NON-SIDE OPENING ELEMENT

52-1
52-2
52-3
52-4
52-5
52-6
54 WINDOWS
Windscreen
Front door window
56-1
56-2
56-3
56-4
57 LOWER INTERIOR ACCESSORIES
MECHANISMS
Exterior handle for rear door
Rear screen wiper motor
Rear door lock
Rear door latches
Exterior handle for tailgate
Hinged rear roof flap cross member
55-1
55-3
55-4
55-5
Dashboard
57-1
58 UPPER INTERIOR ACCESSORIES

Upper storage compartment in cab
58-1
59 INTERIOR SAFETY ACCESSORIES

54-1
54-3
Front seat belts

Rear seat belts
http://vnx.su
59-1
59-2
GENERAL
Safety
50 A
AIR BAG AND PRETENSIONERS
96310-1S
98718R1
IMPORTANT: All operations on the air bag and

pretensioner systems must be carried out by qualified personnel who have been appropriately
trained.
The Air bag Workshop Repair Manual, section 88
MUST be consulted.
Each time the steering wheel is removed, the steering wheel bolt MUST be renewed. Refer to sections 88 and 57A.
IMPORTANT : Whenever the steering wheel is removed, the air bag connector (B) MUST be disconnected.
The air bag has a connector which short circuits
when it is disconnected to prevent incorrect triggering.
ATTENTION: When working under the vehicle do

not subject the underside of the floor to impacts
without removing the pretensioner fuse and waiting 5 minutes for the reserve capacity to discharge.
Refer to section 88 "Fuse allocation".
HEAT SHIELDS
Heat shields must be refitted, whether they are

for bodywork or mechanical components.
TIGHTENING TORQUES
The recommended tightening torques MUST be

observed.
PRODUCTS
Read the precautions for use with care and observe the safety instructions by using the appropriate protection (gloves, mask, etc.).
50-1
http://vnx.su
GENERAL
Tooling
50 A
Door window winder handles may also be removed. (First affix a small piece of masking tape to
the door panel to avoid damaging it during removal.)
The pliers have one flat and one bent nose, giving
easy access to remove clips without damaging
them. The heads of the clips are not deformed,
enabling them to be re-used when refitting.
99331S
Tool for removing the external rear view mirror

glass Car. 1363 - Part Number 00 00 136 300.
This tool may also be used for removing roof trim
and exterior door weatherstrips.
12776S
Tool for removing door hinge.

Car. 1415 - Part Number 00 00 141 500
99799S
SODICAM clip removal pliers.

Using these pliers it is easy to remove "fir-tree"
clips and interior trim clips such as on door panels,
soundproofing mats and mudguard mountings.
50-2
http://vnx.su
GENERAL
Tooling
50 A
This tool has been specifically adapted for the

opening elements of utility vehicles. It can take
the weight of one door with all components fitted
so that the assistance of a second person is no longer required.
Renault approval number: 661 000.
Supplier: Z INTERNATIONAL
Part Number: SUP 01
13411S
TOOL FOR SUPPORTING DOOR
This frame assists the operator when removing or

refitting swing-out or sliding doors.
13412S
50-3
http://vnx.su

Window winder handle on front door
92221R
Insert cloth (1) to protect the trim and position a

block between the cloth and the tool. Then use a
locally made fork or tool FACOM D115 as a lever
to remove the window winder handle.
NOTE: The unpicking tool may be used for this
operation.
51-1
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51

Door opening handle - interior, front door
PRB5101
REMOVING
13114R1
Remove the mounting bolt (1).

Release the opening control linkage (2).
51-2
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51

Door opening handle - exterior, front door
PRB5102
REMOVING
First remove the trim (see section 72) and the antitamper shield. Then remove the handle mounting
bolt.
12980S
12981R
Disconnect the control linkage for locking the

door and opening it from the outside.
51-3
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51

Front door lock
51
PRB5104
REMOVING
After removing the trim (see section 72), remove:
12983R
the interior slide rail (A).
Disconnect the control linkage for locking the

door and opening it from the outside.
12982R
Remove the fittings securing the lock (B).

-
the anti-tamper shield (1) from the lock,

Disconnect the electric harness, depending on the
version.
51-4
http://vnx.su

Front door window riser
51
PRB5105
REMOVING
First remove the trim. Then move the window into

the fully open position and remove the fittings securing the mechanism.
12984S
Take out the mechanism.
12983R2
Disconnect the mechanism from the window.

Disconnect the wiring harness, depending on the
version.
51-5
http://vnx.su

Door barrels
PRB5106
REMOVING
12974R
First remove the exterior door handle. Then open

out the clips and take out the barrel.
51-6
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51

Interior handle for opening the sliding door
PRB5103
REMOVING
Remove the mounting bolt.

Unclip the opening control cable.
13102R
51-7
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51

Exterior handle for sliding door
PRB5103
REMOVING
First remove the trim (see section 72) and then unclip:
- the linkage for the door locking warning light
(1),
13159R
the opening control cable (2).
Remove the mounting bolts (3).
51-8
http://vnx.su
51
51
Locking warning light and sliding door lock
13158R
First remove the trim. Then perform the following operations:

REMOVING THE WARNING LIGHT
Release the mounting clips (1), linkage (2) and control cable (3).
REMOVING THE LOCK
Remove the mounting bolts.

Disconnect the wiring harness, depending on the version.
Disconnect the control cables.
51-9
http://vnx.su

51
REMOVE THE MOUNTING FITTINGS FOR THE

UPPER RUNNER
REMOVING THE SLIDING DOOR
12979R

RUNNER IN MID-HEIGHT POSITION
12978R
Take out the rear stop.
12977R
Remove the interior trim.

13105R
Remove the shaft.
51-10
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51
12976R
13106R
Remove the lower trim, depending on the version.

LOWER RUNNER
12975R
51-11
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51
12333-3R1
Opening clearances:
A = 4.5 mm
B = 4 mm
C = 4 mm
D = 6 mm
51-12
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51
13156R
2 Adjust the upper bracket to balance the clearance (A).
13157R
1 Adjust the height of the lower bracket so that

clearances B and D are obtained.
13155S
3 Adjust the mid-height bracket to obtain clearances A and C.
51-13
http://vnx.su

Exterior handle for rear door
PRB5201
REMOVING
First remove trim (see section 72) and then take

out:
13070R1
- mounting bolt (1),

- handle.
52-1
http://vnx.su
52

Rear screen wiper motor
PRB5205
REMOVING
First remove the trim and the screen wiper arm.
Swing-out doors
Tailgate
13070R
13071R
Then remove mounting bolts (B).

Disconnect wiring harness (A).
52-2
http://vnx.su
52

Rear door lock
52
PRB5206
13113R
REMOVING
Unclip control cables for top and bottom latches.
First remove trim and screen wiper assembly.
13104R
Then remove mounting bolts.
52-3
http://vnx.su

Rear door latches
PRB5202
REMOVING
First remove trim for lock (see section 72) and then
unclip cables (see section 52).
13256R
Remove mounting bolts and pull latch - cable

assembly.
52-4
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52

Exterior handle for tailgate
PRB5203
REMOVING
First take off trim.
13071-1R
Then remove mounting fittings (1).

Unclip control linkage (2).
52-5
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52

Hinged rear roof flap cross member
52
PRB5204
REMOVING
13247R
Remove blanking cover and securing nut (A).

Release linkage (B) from its location.
Remove mounting fittings for cross member (C).
52-6
http://vnx.su
WINDOWS
Windscreen
54
PRB5401
Remove the windscreen wipers.
REMOVING
Tool Ele. 1294-01 must be used to avoid damaging

the splines and to make it easier to remove the
wiper arms.
Use masking tape to protect the bodywork
around the windscreen aperture.
REFITTING
Use a metal brush to clean the shaft splines.

Refit the arms and nuts.
Torque tighten to 18 N.m.
96826R
54-1
http://vnx.su
WINDOWS
Windscreen
54
Remove:
- the lower embellisher strip (4),
- the positioning spacers (5),
- the lower seal (can be reused),
- the exterior embellisher surround (cannot be
reused) for the traditional "wire" cutting
operation.
The exterior embellisher does not have to be
removed when the "EASY CUT" tool is used (see
Technical Note 414A).
REFITTING
Fit the exterior embellisher surround in its correct

position before bonding the windscreen.
13254R
Refer to Technical Note 371A for information on

how to prepare and bond the windscreen.
Unclip the side cover (1).
Do not forget to affix the adhesive labels if the

vehicle is equipped with an air bag.
Remove the seal (2) and bolt (3).
All these labels are available under Part No.

77 01 205 442.
Take off the cowl vent grille.

Disconnect the screen washer pipe.
13069-1R
54-2
http://vnx.su
WINDOWS
Front door window
54
PRB5402
REMOVING
First remove the trim and then the interior

weather strip.
12983R1
Move window to fully open position.

Remove mountings for window riser mechanism.
Separate window and mechanism.
Take out the window.
54-3
http://vnx.su
WINDOWS
Tilting or fixed windows in sliding door
54
TILTING WINDOW
FIXED WINDOW
PRB5403
REMOVING
FIXED WINDOW
Unclip exterior embellisher surround (1).

Release interior seal (2).
TILTING WINDOW

Unclip embellisher (4).
Cut through bead of adhesive mastic.
REFITTING
Seat or clip the exterior embellisher surround in

position before bonding the window or the
frame/window assembly.
See Technical Note 371A for information on
preparation and bonding.
54-4
http://vnx.su
WINDOWS
Fixed or moving side window
54
PRB5404
REMOVING
FIXED WINDOW

Release inside seal (2).
MOVING WINDOW
Unclip exterior embellisher (3).

Unclip embellisher (4).
Cut through bead of adhesive mastic.
REFITTING
Seat or clip the exterior embellisher surround in

position before bonding the window or the
frame/window assembly.
NOTE: Metal/glass primer (green bottle) must be
applied to the frame when a frame is replaced.
54-5
http://vnx.su
WINDOWS
Window in rear door and window in tailgate
54
PRB5405
When the screen wiper arm has been removed,

disconnect the wiring harness for the rear screen
heater.
REMOVING
Remove:
- window (window in rear door),
- exterior embellisher surround for tailgate
window (bonded window).
13256S
54-6
http://vnx.su
WINDOWS
Moving window/latch
54
PRB5406
REMOVING WINDOW
13333R
13332R
Separate the window and the lip.
Unclip embellisher.
Remove screws (A) holding window in position.
54-7
http://vnx.su
WINDOWS
Moving window/latch
REMOVING THE LATCH
13253R
Remove cover.
13252R
Unclip latch.
54-8
http://vnx.su
54
EXTERIOR PROTECTION
55
PRB5501
REMOVING
REFITTING
13115R
13245R
Use a flat screwdriver to press point (A).
Fit the clip on the retaining lug (B).
Unclip protection strip.

NOTE: So that the instructions are clearer, the
protection strip is shown from above.
55-1
http://vnx.su
EXTERIOR PROTECTION
13246R
Fit the clip in position.

Position the protection strip and clip it in place.
PRB5502
For the version with the hinged rear roof flap,

section (C) of the protection strip will need to be
cut according to the dimension shown below:
C = 610 mm
55-2
http://vnx.su
55
EXTERIOR PROTECTION
Bumpers
55
FRONT
PRB5503

REAR
PRB5504
55-3
http://vnx.su
EXTERIOR PROTECTION
Side protection strips
55
PRB5505
For the front door, slide strips towards rear of

vehicle and for the side door and the side panel
slide strips towards front of vehicle.
REMOVING THE PROTECTION STRIPS
13258S
13259S
Remove bolt (A) on inner surface.

Remove clips.
55-4
http://vnx.su
EXTERIOR PROTECTION
55
PRB5506
REMOVING
13112S
13111S
Remove clips.
Remove bolt or bolts (A) on inner surface.
55-5
http://vnx.su
EXTERIOR PROTECTION
REFITTING
Position clips on protective panel and secure clips

on assembly.
13255S
55-6
http://vnx.su
55
Exterior rear view mirror
56
PRB5601
REMOVING
13108R
- mounting nuts.
13109S
Disconnect electric wiring harness, depending on

version.
Remove:
- inner cover,
56-1
http://vnx.su
Rear view mirror
PRB5602
REMOVING
13107S
Use tool Car. 1363 to remove the mirror.
56-2
http://vnx.su
56
Rear screen washer jet
PRB5605
REMOVING
13110R
First remove the third stop light and then

disconnect the pipe at the union.
56-3
http://vnx.su
56
Number plate light
PRB5604
REMOVING
13111-1R
Unclip the part of the unit which is on the outside

of the vehicle.
Disconnect wiring harness.
Remove mounting bolts.
56-4
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56

Dashboard
57
PRB5702
REMOVING
Remove the two bolts behind the steering wheel.
Disconnect the connectors (air bag, horn).
Remove steering wheel (with air bag).
Remove:
- the air bag,
- the steering wheel bolt (when refitting, use a
new bolt with adhesive applied and tightened
to a torque of 4.5 daN.m),
- the steering wheel (with the wheels in the
straight ahead position).
Removing steering wheel (without air bag).

Remove:
- the centre boss,
- the steering wheel bolt (when refitting, use a
new bolt with adhesive applied and tightened
to a torque of 4.5 daN.m),
- the steering wheel (with the wheels in
straight ahead position).
12973S
57-1
http://vnx.su

Dashboard
12971R
57
12969-1R
Remove :
- the half cowling (three bolts),
- the instrument panel (four screws).
12968S
12970-1R
- the instrument panel binnacle (six screws) and

the dashboard cowling (two screws),
57-2
http://vnx.su

Dashboard
12967-1R
57
12966R
Remove:
- lower protector (four screws).
Special instructions for vehicles with air bags

Before removing the assembly, it is essential to
mark the position of the rotating switch under the
steering wheel :
- Make sure the wheels are in the straight ahead
position when the assembly is removed so that
the length of the the ribbon can be positioned
in the centre,
- By immobilising the rotating switch rotor, using
adhesive tape .
Undo the screw and then give the screwdriver a
sharp tap to release the cone.
12971-1R
- lower section of dashboard (four screws, two

clips).
57-3
http://vnx.su

Dashboard
12965-1R
57
12963R
Remove fuse holder (five screws).
- the ashtray and its bracket (two screws).
Unclip diagnostic socket.
Disconnect connectors.
12965-1R1
12963R1
Remove :
- fittings securing steering column (two nuts,
two bolts),
Remove :
- heating control panel (two screws).
57-4
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Dashboard
57
CONSOLE
12964R
Take out speaker grilles.
PRB5701
Remove fittings securing dashboard.

Unclip gear lever gaiter.
Pull dashboard gently.
Remove the four mounting bolts.
Detach clips holding wiring harness.
Disconnect connectors.
Disconnect:
- connectors for headlight height adjustment
and hazard warning lights,
- remaining connectors (e.g. decoder).
Remove dashboard.
57-5
http://vnx.su
UPPER INTERIOR ACCESSORIES

Upper storage compartment in cab
PRB5801
REMOVING
13249R1
Remove fasteners securing storage compartment

(1) and sun visors.
Remove unit (A).
Take unit (B) off its bracket (C).
58-1
http://vnx.su
58

Front seat belts
59
PRB5903
TIGHTENING TORQUES (in N.m)
Seat belt mounting bolts

Pretensioner bolts
59-1
http://vnx.su
37
25

Rear seat belts
59
PRB5904
TIGHTENING TORQUES (in N.m)
Seat belt mounting bolts
59-2
http://vnx.su
37
Heating and Ventilation

HEATING
AIR CONDITIONING
D7F - E7J - F8Q ENGINES
CANCELS AND REPLACES:

Section n 6 of M.R. 325 Part Number: 77 11 194 262 of JULY 1997,
Technical Note n 2871A Part Number: 77 11 197 147 of DECEMBER 1997.
77 11 198 230
FEBRUARY 1998
Edition Anglaise

are constructed".
Renault.
Renault 1998
http://vnx.su
EXPLODED VIEW
PRO60.5
http://vnx.su
Heating and
Ventilation
Contents
Pages
61 HEATING
Control panel
Control cables
Particle filter
Fan assembly (GMV)
Radiator
Air distribution unit
61-1
61-2
61-3
61-4
61-5
61-6
62 AIR CONDITIONING
General
Fault finding - Interpretation
of XR25 bargraphs
Fault finding charts
Fault finding - Associated checks
Wiring diagram
Evaporator
Air blower unit
Compressor
Condenser
Pressure relief valve
Dehydration canister
Connecting pipes
Electrical control
Computer
http://vnx.su
62-1
62-3
62-4
62-6
62-18
62-19
62-43
62-44
62-48
62-50
62-51
62-54
62-55
62-56
62-57
62-60
62-61
HEATING
Control panel
61
Disconnect :
- control panel connector,
- the control cables for the rotator arms.
REMOVAL

Remove:
- the ashtray,
- the mounting screws.
92224S
REFITTING
Refitting is carried out in reverse order to removal.

Check the adjustment of the air distribution and
air mixing controls (refer to the section on
"Control cables").
12963R
- the two screws securing the control panel to

the dashboard.
12963R1
61-1
http://vnx.su
HEATING
Control cables
61
REMOVAL
REFITTING
The control cables can be removed without removing the dashboard.
Route the cable through the control panel location.
Remove :
- the ashtray,
- the control unit.
Push back the flap control to prevent the cable

from coming out of its location.
Fit securing clips (E) and (M).
In the bottom right-hand side of the passenger

compartment
Remove the securing clip (E) (depending on which
cable is to be replaced) :
- from the hot/cold air flap control cable,
or
- from the air distribution cable.
92224R1
Fit the complete control panel without screwing it

in place.
On the bottom right-hand side
Fit the cable on to the mark.
Place the air distribution control on position
, place the heater control on the maximum cold position (blue mark) and check that the
flaps are at their end stop.
98815R
61-2
http://vnx.su
HEATING
Particle filter
REPLACEMENT
Refer to the Warranty and Servicing book for the vehicle.
REMOVAL
Open the bonnet.

Remove :
- the air intake grille by freeing off the access flap clips,
- the water drainage channel,
- the nut (A) securing the particle filter to the bracket.
PRO61.1
REFITTING

Check to make sure that the water drainage channel is correctly fitted in place.
61-3
http://vnx.su
61
HEATING
Fan assembly (GMV)
61
REMOVAL

Remove :
- the windscreen wiper arms using tool
El. 1294-01,
- the upper seal for the plenum chamber as well
as the external air intake grille.
Disconnect the feed connector.
Remove the fan assembly mounting bolts.
PRO61.2
Take out the fan assembly through the right-hand

side of the plenum chamber.
REFITTING

Check the condition of the seal.
61-4
http://vnx.su
HEATING
Radiator
61
Fit a deflector and blow out the remaining liquid

using compressed air.
REMOVAL
The radiator is removed after first removing the

air blower unit, the dashboard and the air distribution unit.
Remove the heater pipe flange bolt on the bulkhead.
Engine compartment end
Passenger compartment end
Fit a hose clamp and disconnect the quick-release

clamps from the heater hoses.
Unclip the four securing clips (E) and take out the
radiator.
13084S
98816R
Other type of quick-release hose clamps.

REFITTING

Fit two mounting bolts (F) onto the body of the
unit if the clips have broken.
13085S
61-5
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HEATING
61
Using adhesive tape, immobilise the rotor for the

air bag switch.
REMOVAL

Remove :
- the steering wheel bolt,
- the steering wheel after first placing the wheels
in a straight line.
ATTENTION: Follow the recommendations contained in section 88 relating to the AIR BAG system.
Remove :
- the steering wheel half-shell cowlings,
12969-1R
Remove :
- the ashtray,
- the two screws securing the heater control panel,
- the fuse holder plate securing screws (five
screws),
- the dashboard mounting nuts.
12971R
- the visor and the instrument panel,

- the switch stalk block assembly.
12965-1R
Unclip the wiring from the dashboard.

Remove the dashboard.
61-6
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HEATING
61
Fit a deflector and blow out the remaining liquid

using compressed air.
Engine compartment end

Fit a hose clamp and disconnect the quick-release
clamps from the heater hoses.
Remove :
- the flange bolt from the heater pipes,
- the windscreen wiper arms using tool
El. 1294-01,
- the upper seal for the plenum chamber as well
as the external air intake grille,
- the blown air unit,
- the air distribution unit mounting bolt.
13084S
Other type of quick-release clamps.
13069R3
13085S
61-7
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HEATING
61
In the passenger compartment
REFITTING
Remove :
- the air distribution unit,
- the heater unit radiator.
Check :
- that the wiring is correctly routed behind the
dashboard,
- that the air ducts are correctly secured to prevent noises developing.
Change the steering wheel bolt (pre-bonded bolt,
tightening torque : 4.5 daN.m).
IMPORTANT : Before reconnecting the AIR BAG
cushion it is necessary to apply the air bag system
operational check procedure :
Check that the AIR BAG warning light on the

instrument panel is illuminated when the ignition is switched on.
Connect an inert ignition unit to the AIR BAG
cushion connector and check that the warning
light extinguishes.
Switch off the ignition, connect the AIR BAG
cushion in place of the inert ignition unit and
secure the cushion on to the steering wheel.
PRO61.3
Switch on the ignition, check that the air bag

warning light illuminates for three seconds
when the ignition is switched on and then extinguishes and remains extinguished.
If the warning light does not operate as indicated
above, please consult section 88 of the workshop
repair manual.
61-8
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AIR CONDITIONING
General
62
91096-3R1
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AIR CONDITIONING
General
A
B
C
D
E
F
Passenger compartment
Engine compartment
Exterior air
To air mixing unit
Scuttle panel grille
Exterior or recirculated air
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Compressor with variable capacity

Condenser
Pressure sensor
High pressure valve
Evaporator
Low pressure valve
Heating/ventilation fan
Cooling fan
Engine radiator
High pressure fluid
Low pressure vapour
High pressure vapour
Consumables:
-
Compressor oil
Coolant
R134a: 650 g 35
Compressor
SANDEN SP 10: 135 cm3 15
SANDEN SD 7V 16
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KANGOO
ALL TYPES
AIR CONDITIONING
62
ESTABLISHING XR25 / HEATING-VENTILATION CONTROL UNIT DIALOGUE
ISO selector on S8
Enter D17
n.61
PRECAUTION :
When carrying out checks using a multimeter, avoid using a contact tip on the connectors the size of which
could damage the clips and result in poor contact.
ERASING THE MEMORY:
After repairing the air conditioning system, enter G0** on the XR25 keypad to erase the fault stored.
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62
PRESENTATION OF XR25 FICHE N 61
FI21761
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REPRESENTATION OF BARGRAPHS
REPRESENTATION OF FAULTS (always on a coloured background)
If illuminated, this indicates a fault on the component in question, the associated text defines
the fault.
REPRESENTATION OF STATUS (always on a white background)

Illuminates when dialogue is established with the component computer, if it remains
extinguished:
- there is an equipment, computer or line fault.
Engine stopped, ignition on, no operator action
The status bargraphs on the fiche are represented as they should appear with the engine stopped, ignition
on and no operator action.
- If on the fiche, the bargraph is represented
the XR25 should display
either
or
Engine running
Extinguished when the function or condition described on the fiche is no longer carried out.
Illuminated when the function or condition described on the fiche is carried out.
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AIR CONDITIONING
Left-hand bargraph 1 illuminated
62
Fiche n 61
COMPUTER FAULT
NOTES
None.
Change the air conditioning control unit.
AFTER
REPAIR
Enter G0** on the XR25.

Check that the system operates correctly.
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Right-hand bargraph 1 extinguished
Fiche n 61
XR25 / CONTROL UNIT COMMUNICATION
NOTES
None.
Before establishing communication between the XR25 and the control unit, check that you have switched
on the ignition.
Ensure that the XR25 is not the cause of the fault by trying to communicate with a computer on another
vehicle.
Check that the ISO interface is in position S8 and that you are using the latest version of the XR25 cassette
and the correct access code (D 17).
Check that the control unit connectors are engaged correctly.
Check that the air conditioning control unit is supplied correctly:
- earth on track 4 of the red 15-way connector
-+ after ignition on track 1 of the blue 30-way connector
-+ after ignition on track 6 of the red 15-way connector
-+ fuse board on track 5 of the red 15-way connector
Check that the diagnostic socket is supplied correctly:
track K
track L
track 6
track 3
of the air conditioning control unit

blue 30-way connector
If there is still no dialogue between the XR25 and the control unit, change the air conditioning control
unit.
AFTER
REPAIR
You may begin the fault finding procedure.

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Fiche n 61
COOLANT SENSOR
XR 25 assistance:
NOTES
*02
: 2 def = low level

1 def = high level
None.
Low level
Check that the coolant sensor connector is correctly engaged.

Engage the connector correctly if necessary.
Check the continuity and insulation from earth of the electrical wiring between tracks A, B and C of the
sensor and tracks 9, 10 and 11 of the air conditioning control unit 30-way connector (sensor supplied with
5 V).
Connect the XR25 and enter # 16. Measure the coolant pressure. The low pressure should be less than or
equal to 2 bars.
Is it correct?
YES
Change the coolant pressure sensor.
NO
Top up the coolant.
AFTER
REPAIR

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CONT
High level
Check that the coolant sensor connector is correctly engaged.

Engage the connector correctly if necessary.
Check the condition of the electrical wiring between tracks A, B and C of the sensor and tracks 9, 10 and
11 of the air conditioning control unit 30-way connector (sensor supplied with 5 V).
Connect the XR25 and enter # 16. Measure the coolant pressure. The high pressure should be less than or
equal to 28 bars.
Is it correct?
YES
Change the coolant pressure sensor.
NO
Top up the coolant.
AFTER
REPAIR

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Fiche n 61
COMPRESSOR CONTROL
XR25 assistance :
NOTES
C.O.
C.C.1
open circuit
short circuit to 12 volts
Before any removal, enter G0** on the XR25 and reinitialise the system.
Enter G21* on the XR25 to control the compressor.

Does the compressor cut in?
YES
Using the XR25, check the pressure of the circuit (# 16).

At an ambient temperature of approximately 20 C, a pressure of between 2 and
28 bars should be measured.
Is the pressure between these values?
YES
Change the clutch.
NO
Top up the coolant circuit.

Repair the circuit if necessary.
If left-hand bargraph 4 remains permanently illuminated, change
the clutch.
If left-hand bargraph 4 still remains permanently illuminated,
change the compressor.
NO
AFTER
REPAIR
Refer to Left-hand bargraph 4 illuminated, CONT 1.

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CONT 1
Check that 12 volts is present on track 1 of the clutch connector.

Is 12 volts present?
YES
Check the condition of the compressor earth.

Is the compressor earth in good condition?
YES
Check the continuity and absence of short circuits of the electrical

wiring between the clutch and the compressor.
If the electrical wiring is faulty, repair it.
If the electrical wiring is in good condition, change the compressor.
NO
NO
Repair the compressor earth.
Check the continuity and absence of short circuits of the electrical wiring
between track 1 of the clutch and tracks 2 and 17 of the air conditioning control
unit 30-way connector.
Repair the electrical wiring if necessary.
For petrol vehicles:
Use the XR25 fiche which corresponds to the vehicle.
With the engine running, operate the AC then check on the XR25 fiche whether
the "Compression authorised or prohibited" status bargraph is illuminated.
Is the bargraph illuminated?
AFTER
REPAIR
YES
Check and repair the electrical wiring.
NO
Refer to Left-hand bargraph 4 illuminated, cont 2.

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CONT 2
For petrol vehicles:

Use the XR25 injection fiche which corresponds to the vehicle.
With the engine running, operate the AC then check on the XR25 fiche whether the " AC authorisation"
status bargraph is illuminated.
Is the bargraph illuminated?
YES
There is a problem at the injection end.

Refer to the injection fault finding procedure which corresponds to the vehicle.
NO
Check the continuity and absence of short circuits of the electrical wiring.
Check that 12 volts is present on tracks 2 and 17 of the air conditioning control
unit 30-way connector.
Is 12 volts present?
YES
There is a problem at the injection end.

Refer to the injection fault finding procedure which corresponds to
the vehicle.
NO
Check whether the evaporator temperature sensor is in place.

Check its resistance: disconnect the evaporator temperature sensor
and measure the resistance at its terminals. The resistance measured
should be between 90 ohms and 13.7 kohms.
If the evaporator temperature sensor is in good condition, change
the air conditioning control unit.
If the evaporator temperature sensor is not in good condition,
change it.
AFTER
REPAIR

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Right-hand bargraph 4 illuminated
62
Fiche n 61
AIR RECIRCULATION MOTOR
NOTES
This fault only appears on the XR25 if air recirculation is selected.
Check the condition of the air recirculation flap control motor.

On the motor connector, measure the resistance between the two tracks.
Change the recirculation motor if necessary.
Check the condition of the electrical wiring between tracks:
control
panel
A2
air conditioning control unit

red 15-way connector
Check the continuity and insulation from earth and from 12 volts of the electrical wiring between tracks:
air recirculation
motor connector
B2
B3
air conditioning control unit

blue 30-way connector
27
26

If the fault persists, change the air conditioning control unit.
AFTER
REPAIR

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Fiche n 61
FAN ASSEMBLY (2) CONTROL

XR25 assistance :
NOTES
C.O.
C.C.1
open circuit
Check that the air conditioning has been selected.

Check that right-hand bargraph 6 is extinguished, if it is not, deal with right-hand
bargraph 6 first.
If left-hand bargraph 6 remains illuminated, you can begin the fault finding
procedure.
Check the condition of the earth of fan assembly (2) (the relay is controlled by 0 volt).
Repair the fan assembly earth if necessary.
Connect the XR25 and enter # 16. Check that the coolant pressure is approximately 20 bars.
If it is not, top up the coolant (operation of the cooling fan assembly is dependent on the coolant
pressure).
Check the condition of the wiring between the relay of fan assembly (2) and track 10 of the injection
computer.
Repair it if necessary.
Check the operating status of the relay by entering G23* on the XR25.
The fan assembly should be heard to knock.
Is the fan assembly heard to knock?
YES
Check the continuity and insulation from 12 volts of the electrical wiring
between track F2 and track 23 of the air conditioning control unit 30-way
connector.
NO
AFTER
REPAIR
Change the relay of fan assembly (2).

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Right-hand bargraph 6 illuminated
Fiche n 61
FAN ASSEMBLY (1) CONTROL

XR25 assistance:
NOTES
C.O.
C.C.1
open circuit
Check that the air conditioning has been selected.

If right-hand bargraph 6 remains illuminated, you can begin the fault finding
procedure.
Check that the air conditioning is operating.

Fan assembly (1) is controlled from the time the air conditioning is switched on.
Check the condition of the earth of fan assembly (1) (the relay is controlled by 0 volt).
Repair the fan assembly earth if necessary.
Connect the XR25 and enter #16. Check that the coolant pressure is approximately 10 bars.
If it is not, top up the coolant (operation of the cooling fan assembly is dependent on the coolant
pressure).
Check the operating status of the relay by entering G22* on the XR25.
The fan assembly should be heard to knock.
Is the fan assembly heard to knock?
YES
Check the continuity and insulation from 12 volts of the electrical wiring
between track M2 and track 22 of the air conditioning control unit 30-way
connector.
NO
AFTER
REPAIR
Change the relay of fan assembly (1).

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Incorrect illumination of left-hand bargraph 7
Fiche n 61
+ 12 accessories
NOTES
This bargraph is illuminated outside the starting phase.

If it is not illuminated, the compressor and the fan assemblies will not be
controlled.
Check the condition of the + fuse board fuse.

Check the condition of the electrical wiring between track A26 of the fuse box and track B1 of the air
conditioning control panel.
Repair the faulty wiring if necessary.
AFTER
REPAIR

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13
Fiche n 61
AIR CONDITIONING PROHIBITED BY INJECTION
NOTES
This bargraph should be extinguished when the engine is running.

If it is illuminated, you can begin the fault finding procedure.
First check that the air conditioning has been selected (selection on the control panel).
Check the continuity of the electrical wiring between track 5 of the injection computer and track 13 of
the air conditioning control unit 30-way connector (P.A. information).
Check the continuity of the electrical wiring between:
- track 51 of the injection computer and track 18 of the AC computer 30-way connector for D7F and E7J
engines,
- track 19 of the injection computer and track 18 of the AC computer 30-way connector for F8Q engines.
If the problem persists, check the injection fault finding procedure, as it is a problem related to the
injection.
AFTER
REPAIR

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Air distribution problem
CHART 1
Air flow problem
CHART 2
Heater performance poor
CHART 3
No heat
CHART 4
Too hot
CHART 5
Heating inadequate in the rear
CHART 6
Deicing/demisting performance poor
CHART 7
Ventilation performance poor
CHART 8
PASSENGER COMPARTMENT FAN DOES NOT OPERATE
CHART 9
PASSENGER COMPARTMENT INCONVENIENCE
CHART 10
Controls stiff
RECIRCULATION FLAP DOES NOT OPERATE
CHART 11
AIR CONDITIONING PROBLEMS
No cold air
CHART 12
Too cold
CHART 13
Performance poor
CHART 14
COOLING FAN ASSEMBLY DOES NOT OPERATE
CHART 15
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CHART 1
62
AIR DISTRIBUTION PROBLEMS
Before carrying out any work, check that the customer uses the air conditioning
correctly.
Non regulated air conditioning.
NOTES
Place the passenger compartment

fan on full,
temperature control on
maximum heat or maximum cold,
and move the air distribution control.
Check that the air output
corresponds to the selection.
Is it correct?
yes
The air distribution is correct.

If necessary, explain how the system works to
the customer again.
yes
Check the adjustment of the air distribution

flap control cable.
no
Check visually or by touch, on the right-hand

side of the air distribution unit,
that moving the control
moves the sprockets
and the lever.
Do they move?
In the case of a ventilation problem,

check the ventilation ducts
and the vents.
no
If the fault persists,

remove the air distribution unit and
check the distribution flaps.
Repair or change the assembly.
Check the connection of the cable

to the air distribution unit
and the control panel
and check the condition of the cable and its
retainer. Is it correct?
no
Change the control cable

or repair the connection of the cable (clip)
or change the faulty part
(control panel or distribution unit).
yes
A
AFTER
REPAIR

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CHART 1
CONT
Check the condition of the kinematic

(sprockets, levers...) on the air distribution
unit and the control panel.
Is it correct?
no
Repair if possible,
otherwise change the distribution unit or the
control panel.
yes
Remove the air distribution unit and check

the distribution flaps.
Repair or change the unit.
AFTER
REPAIR

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CHART 2
62
AIR FLOW PROBLEM
correctly.
NOTES
Does the passenger compartment fan

operate?
no
See CHART 9.
no
Repair or clean or change

the particle filter.
no
yes
See CHART 1.
yes
Check the air intake circuit, scuttle panel
grille, particle filter, rain shield.
Are they correct?
yes
Check that the air extraction circuit
is not blocked.
Does the fault persist?
yes
Is it a passenger compartment
air distribution problem?
no
Remove the heater radiator.
It must be blocked, clean or change it
(only valid for vehicles which have been
driven without the particle filter).
AFTER
REPAIR

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CHART 3
62
HEATER PERFORMANCE POOR
correctly.
NOTES
Carry out a road test to observe the customer

complaints.
Is the test satisfactory?
yes
Advise the customer how to use the heating

system correctly
(eg. : Do not place the passenger
compartment fan on full when starting from
cold, turn it up gradually instead).
no
See CHART 1.
no
Readjust the control cable

(cable which controls the sprockets to the
right of the air distribution unit).
no
no
Visually check that
the action of the control moves
the mixing flap.
Does the flap move?
yes
Visually check
whether the flap travel is complete.
Is it complete?
yes
Check the cooling circuit
(correct filling and bleeding),
the condition of the circuit (pipes,
connections, conformity
of the circuit...).
yes
AFTER
REPAIR

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CHART 3
CONT
With the engine cold, remove the engine

coolant thermostat and check that it is not
jammed in the open position.
Is it correct?
no
Change the thermostat.
no
no
yes
Check that there is no unwanted intake of
cold air into the passenger compartment
(seals, grommets, cables ...).
Repair if necessary
yes
Check the air inlets (particle filter)
and outlets.
Partially blocked air inlets or outlets
reduce the flow of heated air
into the
passenger compartment.
yes
The heater radiator must be blocked. Remove
the radiator and clean or change it
(only valid for vehicles which have been
driven without the particle filter).
AFTER
REPAIR
Check that the components which were removed are connected correctly.
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CHART 4
62
NO HEAT
correctly.
NOTES
Is it an air flow problem?
yes
See CHART 2.
no
no
See CHART 1.
no
no
Check the level of coolant in the cooling
circuit.
NOTE: if the coolant level is too low, the circuit may become unprimed when driving at
low load and at idle.
yes
Visually check that moving the control
moves the mixing flap.
Does it move?
yes
Check the coolant circuit.
NOTE: fitting an oil, water or air cooler which
has not been approved by the research centre

and which is incorrectly connected may reduce or even stop the flow of coolant in the
heater radiator.
Repair the coolant circuit if necessary.
yes
Remove the heater radiator.
Clean or change it if necessary.
AFTER
REPAIR
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CHART 5
62
TOO HOT
correctly.
NOTES
Visually check that moving the control

moves the mixing flap.
Does it move?
no
See CHART 1.
no
Readjust the cable

(to the right of the air distribution unit).
yes
Check that the flap travel
is complete.
Is the travel complete?
yes
Check the operation
of the recirculation flap.
Is it jammed in the recirculation position?
yes
See CHART 11.
no
Check the operation
of the engine coolant thermostat.
Change the thermostat if necessary.
AFTER
REPAIR

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CHART 6
62
HEATING INADEQUATE IN THE REAR
None.
NOTES
Check that the air inlets at the rear of the

centre console are not blocked.
(floor carpet...).
Are they correct?
no
Free the air outlets.
yes
Remove the centre console and check
that the connection and sealing between the
air distribution unit and the heating duct to
the rear seats is correct.
AFTER
REPAIR
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CHART 7
62
DEICING/DEMISTING PERFORMANCE POOR
Check that the windows are clean on the inside.
NOTES
Check that the air extractors

are not blocked.
no
no
yes
See CHART 1.
yes
See CHART 2.
yes
See CHART 3.
yes
Ensure that there are no water leaks into the
passenger compartment which would
significantly increase the humidity level and
reduce the effectiveness of the demisting.
Locate the leak and repair it.
yes
Is it an air distribution problem?
no
no
Is it a heater performance problem?
no
Check that the recirculation flap is not
jammed in the recirculated air position
(see CHART 11).
AFTER
REPAIR
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CHART 8
62
VENTILATION PERFORMANCE POOR
None.
NOTES
yes
See CHART 2.
yes
See CHART 1.
yes
no
Is it an air distribution problem?
no
Check that the mixing flap
travel is complete.
Is is correct?
no
Readjust the cable.
AFTER
REPAIR
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CHART 9
62
PASSENGER COMPARTMENT FAN DOES NOT OPERATE
correctly.
NOTES
Check fuses +battery, +fuse board, +side

lights. Are the fuses in good condition?
no
Change the faulty fuse(s).
no
no
Change the control panel.
no
Repair the faulty

electrical wiring.
yes
Check the connections between the fuses
and the instrument panel connector.
yes
With the ignition on and the air conditioning
selected, position the ventilation at the
various speeds and check that 12 V
is present on the tracks of the
control panel connector:
- B5 in position 1,
- B4 in position 2,
- B2 in position 3,
- B3 in position 4.
Is 12 V present?
yes
Check the condition of the wiring between:
B2
A2
control
B3
A1
resistance
panel
B4
C4
unit
B5
C1
yes
A
AFTER
REPAIR
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CHART 9
CONT
A
Supply the fan with 0 and 12 V.
Does the fan operate?
no
Change the fan.
no
Repair the electrical wiring.
yes
Check the condition of the electrical wiring
between the the fan and tracks A1 and A2 of
the resistor unit connector at the fan end.
yes
Change the resistor unit.
AFTER
REPAIR
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CONTROLS STIFF
(passenger compartment inconvenience)
CHART 10
None.
NOTES
Check the travel of the control cable.

Remove any constraints
on it:
- bending,
- cable clamped with plastic clips.
Change it if necessary.
no
no
Change the control panel or repair the

kinematic of the flap or change the air
distribution unit.
yes
Unclip the cable from the side
of the unit and check the stiffness of
movement of each component, control
button and flap control
on the air distribution unit.
Is it correct?
yes
Change the flap control cable.
AFTER
REPAIR
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CHART 11
62
RECIRCULATION FLAP DOES NOT OPERATE
correctly.
NOTES
First of all check the condition of fuses

+battery, + fuse board, +after ignition.
Change them if necessary.
Check the condition of the electrical wiring

between:
control
computer
panel
A2
3
15-way
connector
no
Repair the faulty wiring.
no
no
Repair the faulty

electrical wiring.
yes
With the ignition on and air recirculation
selected, check that 12 V is present on track
A2 of the control panel.
Is 12 V present?
yes
Check the insulation and continuity of the
electrical wiring between:
computer
26
B3
resistance
blue 30-way
unit
connector
27
B2
connector
yes
AFTER
REPAIR
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CHART 11
CONT
Check the electrical wiring between the

recirculation motor and the resistor unit.
Is it in good condition?
no
Repair the faulty

electrical wiring.
no
yes
Check that the recirculation flap control
sprockets are in good condition and that the
flap is not jammed.
yes
Change the recirculation motor.
AFTER
REPAIR
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No cold air
CHART 12

The passenger compartment fan operates.
NOTES
With the heating and ventilation selected,

check that there is a voltage
on track A1 of the control panel.
Is there a voltage?
no
no
Repair the wiring.
no
Repair the wiring.
no
Change the compressor.
yes
Check the connections between track A1 of
the control panel and track 2
of the air conditioning computer.
yes
Check the electrical wiring between:
air
2
1
conditioning
compressor
computer
17
1
Is the wiring on good condition?
yes
Using the XR25, enter G21*
(compressor clutch control).
Does the compressor cut in?
yes
Change the
air conditioning computer.
AFTER
REPAIR
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No cold air
CHART 12A

The passenger compartment fan operates.
NOTES
Check that left-hand bargraph 13 is

extinguished. This relates to the inhibiting of
heating/ventilation/air conditioning by the
injection or the automatic gearbox.
Is this bargraph extinguished?
yes
Refer to left-hand bargraph 13.
no
no
Repair the faulty

electrical wiring.
no
Using the XR25, measure the pressures of the
coolant circuit by entering #16 or use
pressure gauges.
The pressures should be:
- high pressure
< 28 bars,
- low pressure
> 2 bars.
Is this correct?
yes
Check the connections between:
air
9
A
fluid
conditioning
pressure
computer
10
B
sensor
yes
Change the pressure sensor.
AFTER
REPAIR
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Too cold
CHART 13
correctly.
NOTES
Is the fan assembly always operating?

(normal if high pressure 20 bars)
yes
Check the coolant circuit pressures using the

XR25 or pressure gauges.
The fan assembly operates if the high
pressure 20 bars and stops if the pressure
15 bars.
If the pressures are correct, change
the pressure sensor, otherwise, top up
the coolant circuit.
no
See CHART 11.
no
See CHART 1.
no
Readjust the cable.
no
Check that the recirculation flap does not
remain in the recirculated air position.
Operate the control button
and check that the flap moves.
Does it move?
yes
Check that the action of the
heater control
moves the flap.
Does it move?
yes
Visually check that
the flap travel is complete.
Is it correct?
yes
Change the fan assembly.
AFTER
REPAIR
c11010.0
62-36
http://vnx.su
AIR CONDITIONING
KANGOO
ALL TYPES
62

Performance poor
CHART 14
correctly.
NOTES
Check that the compressor operates, with the

air conditioning on, passenger compartment
ventilation on maximum in recirculation
mode, engine running at idle.
Does the compressor operate?
no
See CHART 14A.
no
no
See CHART 11.
no
yes
See CHART 2 or CHART 9.
yes
Check the tension of the compressor belt, the
clutch air gap and its condition.
Retension the belt or change
the compressor clutch.
yes
Ensure that the recirculation flap is in the
recirculation position in air conditioning
recirculation mode.
Is it in this position?
yes
Check that the flap travel is complete,
readjust the cable if necessary.
yes
no
A
AFTER
REPAIR
c11010.0
62-37
http://vnx.su
CONDITIONING
KANGOO
ALL TYPES
62
CHART 14
CONT
With the vehicle stationary, engine running

at idle, air conditioning on maximum,
measure the pressure of the coolant circuit.
If the pressure is > 28 bars, there is :
- too much fluid,
- or the operation of the fan assembly is abnormal,
- or the condenser is clogged,
- or the engine heats up too much.
Is the pressure < 28 bars ?
no
no
See CHART 15.
yes
Check the cleanness of the
condenser wiring harness.
Clean or change the condenser.
If the fault persists, check the operation of

the cooling fan assembly at high speed
(ventilation and air conditioning
on maximum).
It should be:
- operating if high pressure
20 bars
- stopped if high pressure
15 bars
Is the operation of the fan assembly normal?
yes
AFTER
REPAIR
c11010.0
62-38
http://vnx.su
AIR CONDITIONING
KANGOO
ALL TYPES
62

Performance poor
CHART 14A
correctly.
NOTES
With the air conditioning and ventilation on

maximum and the engine running at idle,
check that the compressor operates.
yes
See CHART 14.
no
Check the wiring between

the heating and ventilation computer
and the compressor clutch.
no
Connect the XR25 and enter G21*
(direct compressor control).
yes
change the compressor.
Check the pressure of the coolant circuit.
The compressor should cut in for:
- low pressure
2 bars,
- high pressure
28 bars.
Is this correct?
no
no
Repair the faulty

electrical wiring.
yes
Check the electrical wiring:
air
9
1
pressure
conditioning
10
4
sensor
computer
11
3
connector
and between the connector and the sensor.
yes
AFTER
REPAIR
c11010.0
62-39
http://vnx.su
AIR CONDITIONING
KANGOO
ALL TYPES
62

Performance poor
CHART 14B
correctly.
NOTES
Check the operation of the fan assembly.

Connect the XR25 and enter G22* and G23*
(direct fan assembly control).
Does the fan assembly operate
at low and high speed?
no
Check the electrical wiring

between tracks 22 and 23 of the heating and
ventilation computer and the fan assembly.
yes

change the fan assembly.
Check the pressure of the coolant circuit.

The fan assembly should be:
- operating for a pressure
10 bars,
- stopped for a pressure
20 bars.
Is this correct?
no
Top up the coolant.
no
yes
air
9
1
pressure
conditioning
10
4
sensor
computer
11
5
connector
and between the connector and the sensor.
Is the electrical wiring in good condition?
yes
AFTER
REPAIR
c11010.0
62-40
http://vnx.su
AIR CONDITIONING
KANGOO
ALL TYPES
62
COOLING FAN DOES NOT OPERATE
CHART 15

The compressor operates.
NOTES
Check the condition of the fuses.

Change them if necessary.
Check the continuity and insulation from 12

volts of the electrical wiring
between:
air
22
F2
low speed
conditioning
relay
computer
23
M2
high speed
relay
no
Repair the faulty

electrical wiring.
no
Change the faulty relay(s).
no
Repair.
yes
Check that 12 volts is present on track 5 of the
low speed and high speed relays.
Is this correct?
yes
Check that the fan assembly is correctly
supplied with 12 volts and 0 volt.
Is this correct?
yes
AFTER
REPAIR
c11010.0
62-41
http://vnx.su
AIR CONDITIONING
KANGOO
ALL TYPES
62
CHART 15
CONT
With the air conditioning selected and

ventilation on maximum, check the pressure
of the coolant circuit using the XR25 by
entering #16.
- The fan cuts in at low speed for a pressure
10 bars,
- The fan cuts in at high speed for a pressure
20 bars.
Are the pressure values correct?
no
no
Repair the faulty

electrical wiring.
yes
heating and
9
1
interventilation
10
4
mediate
computer
11
3
connector
and between:
inter1
A
pressure
mediate
4
C
sensor
connector
3
B
yes
change the fan.
AFTER
REPAIR
c11010.0
62-42
http://vnx.su
KANGOO
ALL TYPES
AIR CONDITIONING
Fault finding - Associated checks
62
COMMAND MODE G--*
To use this function, enter G on the XR25 keypad, then the number of the command selected followed by
an asterisk.
G21* : compressor clutch control
G22* : fan low speed control
G23* : fan high speed control
G24* : recirculation motor control
G13* : end of fault finding
COMMAND MODE #
# 08 : fan assembly speed

# 15 : engine speed
# 16 : pressure of coolant in the circuit
c11010.0
62-43
http://vnx.su
D7F ENGINE
AIR CONDITIONING
Wiring diagram
62
PRO13781
62-44
http://vnx.su
F8Q ENGINE
AIR CONDITIONING
Wiring diagram
62
PRO13948
62-45
http://vnx.su
E7J ENGINE
AIR CONDITIONING
Wiring diagram
62
PRO14441
62-46
http://vnx.su
AIR CONDITIONING
Wiring diagram
D7F/F8Q and E7J

ENGINES
120
Injection computer
171
Air conditioning clutch
206
Air control pressure switch
225
Diagnostic socket
234
Fan assembly relay
236
Fuel pump relay
248
Fan assembly thermal switch
260
Fuse box
319
Air conditioning control panel
320
Base fan assembly/Air conditioning
419
Air conditioning control unit
466
Shunt box
597
Engine fuse box
700
Cooling fan relay (low speed)
R67 Front of engine/Engine

NB : Evaporator sensor (depending on assembly)
62-47
http://vnx.su
62
AIR CONDITIONING
Evaporator
Remove:
- the windscreen wiper arms,
- the air inlet grille,
- the six plenum chamber closure panel (2) retaining bolts (A) and remove the plenum chamber,
- the evaporator protector in the plenum chamber.
Pressure relief valve to evaporator bolt

Connecting pipes to pressure relief valve
retaining nut
Pressure relief valve connecting pipe to
dehydration canister retaining bolt
Condenser connecting pipe to
dehydration canister retaining bolt
Compressor connecting pipe to condenser
retaining bolt
Connecting pipes to compressor
retaining bolt
Compressor retaining bolt
Circuit pressure sensor
62
0.6
0.8
0.8
Disconnect the electrical connectors (4) and the

earth leads (5).
1.2
0.8
Remove the intermediate sleeve (6) between the

evaporator housing and the heater fan assembly.
2.1
2.1
0.8
REMOVAL

Drain the R134a coolant circuit using the filling
equipment.
Disconnect the R134a connecting pipes (bolt 1) to
the pressure relief valve.
Install the plugs on the pipes and the pressure relief valve.
13826R
13831R
62-48
http://vnx.su
AIR CONDITIONING
Evaporator
Move aside the dashboard by removing:
- the six steering column mounting bolts,
- the four dashboard side retaining nuts and the
two bolts behind the ashtray assembly.
NOTE: take care to protect the sections of the
dashboard which are susceptible to damage using

cloths.
Remove the two evaporator housing mountings
behind the dashboard on the passenger side.
Remove the evaporator housing.
Carefully remove the evaporator from its housing.
REFITTING
Check that the harness tubes are not in contact

(risk of noise).
Proceed in the reverse order to removal.
Tighten the retaining nut (connecting pipes to
pressure relief valve) to 0.8 daN.m (pay attention
to the condition of the seals).
NOTE: when refitting the dashboard, check:
- that the electrical wiring is positioned correctly,

- that the air flow pipes are positioned correctly
(glove box for example).
Create a vacuum, then fill the R134a coolant circuit using the filling equipment.
IMPORTANT
When an evaporator is changed, add 30 ml of

P.A.G. SP 10 oil to the circuit.
Use the same oil for refitting the seals taking care
to position them correctly.
62-49
http://vnx.su
62
AIR CONDITIONING
Air blower unit
REMOVAL
An air blower unit can only be changed following

removal of the evaporator (refer to the
"Evaporator" section).
Remove the two heater fan assembly mounting
bolts.
Remove the heater fan assembly.
REFITTING
Refitting does not present any special points.

After refitting the heater fan assembly and the
evaporator, create a vacuum and then fill the
R134a coolant circuit using the filling equipment.
IMPORTANT
Ensure that all of the seals are positioned correctly. Lubricate them with P.A.G. SP 10 oil.
62-50
http://vnx.su
62
D7F ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL
REFITTING
Drain the R134a coolant circuit.
If it is changed, the compressor is supplied filled

with oil.

Position the compressor the correct way round
(filler plug facing upwards).
Remove:
- the compressor drive belt,
- the two connecting pipes (A),
- the retaining strut bolt (B),
- the three compressor retaining bolts (C).
Tighten the three bolts (C) (Tightening torque:

2.1 daN.m).
Fit the strut retaining bolts (B).
Remove the compressor.

NOTE: it is essential to place plugs on the pipes
Refit the two R134a coolant pipes (A) on the

compressor (Tightening torque: 2.1 daN.m).
and on the compressor to prevent the entry of humidity into the circuit.
Fit the drive belt and tension it.

NOTE: when refitting the connecting pipes on the
compressor, it is essential to fit all the bolts, then

bring them into contact before torque tightening
them. The aim is to ensure that the pipe is positioned correctly so that it is not damaged at the cut
off (1).
Check the condition of the seals and lubricate
them with P.A.G. SP 10 oil.
IMPORTANT
When changing the compressor, it is essential to

top up the oil.
13829R1
62-51
http://vnx.su
F8Q ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL
REFITTING
Place the vehicle on a lift.

with oil.


Remove the front bumper.
Tighten the three bolts (C) (Tightening torque:

2.1 daN.m).
From above, remove:

- the two connecting pipes (A),
- the connecting pipe retaining lug (B).

compressor (Tightening torque: 2.1 daN.m) as well
as bracket (B).
From underneath the vehicle, remove the three

compressor retaining bolts and remove the
compressor.
Fit the drive belt and tension it.

NOTE: it is essential to fit plugs on the pipes and
on the compressor to prevent humidity from entering the circuit.

off (1).
IMPORTANT

top up the oil.
13947R
62-52
http://vnx.su
E7J ENGINE
AIR CONDITIONING
Compressor
62
REMOVAL
REFITTING
Place the vehicle on a lift.

with oil.


Remove:
- the engine undertray,
- the bumper.
Tighten the retaining bolts (C) (Tightening torque: 2.1 daN.m).

compressor (Tightening torque: 2.1 daN.m).
From above, remove:

- the accessories drive belt,
- the two R134a connecting pipes (A).
Fit the drive belts and tension them.
From underneath the vehicle, remove:

- the compressor retaining bolts and remove the
the compressor.

off (1).
NOTE: it is essential to fit plugs on the pipes and
on the compressor to prevent humidity from entering the circuit.

IMPORTANT

top up the oil.
14229R
62-53
http://vnx.su
AIR CONDITIONING
Condenser
62
Move the radiator-condenser assembly as far back

as possible towards the engine.
REMOVAL
It is not necessary to use a lift.

Remove the four condenser to radiator retaining

bolts (6).
Carefully remove the condenser.
Remove:
- the plastic air deflector on the upper crossmember,
- the seal (1),
- the upper crossmember (2),
- the retaining bolt (3),
- the two R134a coolant pipes (4) (fit plugs to
prevent the entry of humidity),
- the two radiator upper retaining bolts.
13828R
REFITTING
13830R
Check the condition of the seals.

Create a vacuum, then fill the circuit with R134a
using the filling equipment.
IMPORTANT
When changing the condenser, add 30 ml of

P.A.G. SP 10 oil to the circuit.
NOTE: tightening torque of bolts (6) : 0.8 daN.m.
62-54
http://vnx.su
AIR CONDITIONING
REPLACEMENT

equipment.
Remove:
- the connecting pipes retaining nut (A),
- the two pressure relief valve to evaporator retaining bolts (B).
13826R1
On refitting, ensure that the pipe seals are in

good condition.
Bolt tightening torques:
- bolt (A) : 0.8 daN.m,
- bolt (B) : 0.6 daN.m.
62-55
http://vnx.su
62
AIR CONDITIONING
REMOVAL
REFITTING

equipment.
62
Check that the seals are in good condition and lubricate them with P.A.G. SP 10 oil.
Remove:
- the two radiator upper mounting bolts,
- the two mounting bolts which secure the pipes
to the dehydration canister.
Move back the radiator-condenser assembly

slightly.
When changing the dehydration canister, add 15

ml of P.A.G. SP 10 oil to the circuit.
Through the bumper, remove the two dehydration canister to condenser retaining bolts (1).
NOTE: tightening torque of bolt (2) : 1.2 daN.m
13828R1
Remove the dehydration canister from underneath the vehicle.

Fit plugs on each hole to prevent any entry of humidity into the components.
62-56
http://vnx.su
AIR CONDITIONING
Connecting pipes
62

equipment.
LOW PRESSURE PIPE
REFITTING
REMOVAL
Remove the mounting bolt on the pressure relief

valve.

Fit plugs to the pressure relief valve and the pipe.
When changing a pipe, add 10 ml of SP 10 oil or

when a pipe bursts (rapid leak), add 100 ml.
Remove the mounting bolt on the compressor.

Fit plugs to the compressor and the pipe.
Unscrew the pipe retaining lug.
NOTE:
- Pipes to compressor
retaining bolt:
- Pipes to pressure relief valve
retaining nut:
- Pipes to condenser
retaining bolt:
Remove the low pressure pipe.
PRO62.4
62-57
http://vnx.su
2.1 daN.m
0.8 daN.m
0.8 daN.m
AIR CONDITIONING
Connecting pipes
62

equipment.
COMPRESSOR-CONDENSER HIGH PRESSURE PIPE
REFITTING
REMOVAL
Remove the mounting bolt on the compressor.
NOTE:
When refitting this connecting pipe to the

compressor, it is essential to fit all the bolts and
then bring them into contact before torque tightening them. The aim is to ensure that the pipe is
positioned correctly so that it is not damaged at
the cut off (1).
Fit plugs to the compressor and the pipe.

Remove the mounting bolt on the condenser.
Remove the pipe.
Fit plugs to the condenser and the pipe.

them using P.A.G. SP 10 oil.
PRO62.5
NOTE: the front bumper must be removed on the
version fitted with the E7J engine, in order to remove the cut off (1) retaining bolt.
62-58
http://vnx.su
AIR CONDITIONING
Connecting pipes
62

equipment.
DEHYDRATION CANISTER-PRESSURE RELIEF

VALVE HIGH PRESSURE PIPE
REFITTING

REMOVAL

them using P.A.G. SP 10 oil.
Detach the pipe from its mountings.

Disconnect the pressure sensor connector.

Remove the mounting bolt on the pressure relief

valve.
Fit plugs to the pressure relief valve and the pipe.

NOTE:
- Pipe to dehydration canister

retaining bolt:
- Pipe to pressure relief valve
retaining nut:
Remove the mounting bolt on the dehydration canister.

Fit plugs to the dehydration canister and the pipe.
Remove the pipe.
PRO62.6
62-59
http://vnx.su
0.8 daN.m
0.8 daN.m
AIR CONDITIONING
Electrical control
62
PRESSURE SENSOR
EVAPORATOR SENSOR (depending on assem-
bly)
The pressure sensor (1) is located next to the
condenser on the pressure relief valvedehydration canister high pressure pipe.
REMOVAL

Remove:
- the windscreen wiper arms,
- the air inlet grille,
- the evaporator protector in the plenum chamber.
Disconnect the evaporator sensor connector and
the air recirculation motor connector.
Free the wiring from its fasteners.
Remove the evaporator sensor.
REFITTING

Ensure that the sensor is correctly positioned on
its seat on the evaporator.
13827R
0.28 FAN ASSEMBLY SPEED RESISTOR (2)
All work on the pressure sensor can be carried out

without draining the coolant circuit. It is secured
to a "SKRADER" valve.
This is secured to the engine cooling fan support.

Tightening torque: 0.8 daN.m.
This pressure sensor is fitted with seal. Check that
it is in good condition on refitting and lubricate it
using P.A.G. SP 10 oil.
RECIRCULATION MOTOR
It is only possible to gain access to the recirculation motor following removal of the air blower
unit (refer to the relevant section) and therefore
the evaporator assembly.
62-60
http://vnx.su
AIR CONDITIONING
Computer
62
13825R
15-way connector (A)

Track
Description
Not used
AC operating information
Recirculation on/off
AC computer earth
+ 12 V accessories (fan assembly fuse)
+ 12 V after ignition (brake fuse)
Not used
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Not used
14
Not used
15
Not used
62-61
http://vnx.su
AIR CONDITIONING
Computer
30-way connector (B)
Track
Description
Compressor control
L diagnostic information
Fan assembly voltage information
Not used
K diagnostic information
Not used
TDC information
Coolant pressure sensor
10
Coolant pressure sensor
11
Coolant pressure sensor signal
12
Evaporator sensor (depending on

assembly)
13
Power absorbed information (when the

compressor cuts in)
14
Not used
15
Not used
16
17
Compressor control
18
AC cut off information
19
Not used
20
AC fast idle information
21
Not used
22
Fan assembly low speed control
23
Fan assembly high speed control
24
Not used
25
Not used
26
AC recirculation motor
27
AC recirculation motor
28
Not used
29
Evaporator sensor (depending on

assembly)
30
Not used
62-62
http://vnx.su
62
Sealing and Soundproofing
BODY SEALING
77 11 194 289
JULY 1997
Edition Anglaise

are constructed".
RENAULT.
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB6000
http://vnx.su
Sealing and
Soundproofing
Contents
Pages
64 BODY SEALING
Seals for side opening elements
Luggage compartment seal
Interior finishing seal for sliding
door and side opening
http://vnx.su
64-1
64-2
64-3
BODY SEALING
Seals for side opening elements
PRB6402
For reasons of standardisation, the Parts

Department only supplies front door seals.
Cut a length of 189 mm 15 from the seal to
adapt it to the length required for a sliding door.
64-1
http://vnx.su
64
BODY SEALING
Luggage compartment seal
PRB6403
For reasons of standardisation, the Parts

Department only supplies luggage compartment
seals for hinged rear roof flaps.
Cut off the following length:
940 mm
+ 20
-0
to adapt the seal to suit the body version with

swing-out doors or a tailgate.
64-2
http://vnx.su
64
BODY SEALING
Interior finishing seal for sliding door and side opening
PRB6401
For reasons of standardisation, the Parts Department only

supplies seals for the left-hand side opening.
The following lengths will need to be cut from the seals:
- 1401 mm 2.5 to adapt the seal for a sliding door,
- 1590 mm 2.5 to adapt the seal for a right-hand side
opening.
64-3
http://vnx.su
64
Trim and upholstery

INTERIOR BODY LININGS
REAR PARCEL SHELVES
FRONT SEAT FRAMES AND RUNNERS
REAR SEAT FRAMES AND RUNNERS
FRONT SEAT TRIM
REAR SEAT TRIM
SEAT ACCESSORIES

77 11 194 298
JULY 1997

RENAULT.

are constructed".
Edition Anglaise
Renault 1997
http://vnx.su
EXPLODED VIEW
PRB7000
http://vnx.su
Trim and
upholstery
Contents
Pages
FRONT SEAT FRAMES AND
75 RUNNERS
71 INTERIOR BODY LININGS

Door sill lining
B-pillar lining
Side trim panels
Upper central trim assembly
Head lining
Carpet
Pages
71-1
71-1
71-2
71-3
71-5
71-7
Complete front seat and runners
75-1
REAR SEAT FRAMES AND
76 RUNNERS
Complete rear bench
72 SIDE OPENING ELEMENTS TRIM

Front door trim
Side door trim
76-1
72-1
72-2
77 FRONT SEAT TRIM
73
Seatback trim
Folding seatback trim
Seat squab trim

TRIM
Lining for rear door or tailgate
77-1
77-3
77-4
73-1
78 REAR SEAT TRIM

1/3 - 2/3 seatback trim
1/3 - 2/3 seat squab trim
78-1
78-4
74 REAR PARCEL SHELF

Rear side shelves
74-1
79 SEAT ACCESSORIES
Locking cable - 3rd seat belt
retractor
http://vnx.su
79-1

Door sill lining
PRB7101
REMOVING
Unclip the lining.
B-pillar lining
PRB7102
REMOVING
Unclip the lining.
71-1
http://vnx.su
71

Side trim panels
PRB7103
REMOVING
13100S
Remove the parcel shelves (depending on

version).
Unclip the trim panel.
71-2
http://vnx.su
71

71
PRB7104
REMOVING
13072R1
Remove the mountings.
13073S
Disconnect the wiring harness.
Unclip the outer section.
Unclip the trim assembly.
71-3
http://vnx.su

Depending on the version, the following parts
will need to be removed:
- the modular partition and/or the upper storage
compartment in the cab,
13248R
- the upper nuts and the lower bolts,
13249R
- the mounting bolts (A) for the upper storage

compartment,
- the partition mounting studs (B).
71-4
http://vnx.su
71

Head lining
71
PRB7105
REMOVING
PRB7104
Remove the central trim assembly.

Carefully release the head lining (affixed with
adhesive).
Use a tool (such as a mastic knife) to cut through
the beads of adhesive.
PRB7106
Remove the upper storage compartment and/or

the pivoting modular partition, depending on the
version.
71-5
http://vnx.su

Head lining
71
REFITTING
13250S
First protect the seats and then apply adhesive to the section(s) of
head lining as shown below:
- 6 beads, 4 mm dia.
- 2 beads, 4 mm dia.
At least two persons are required to carry out this operation.
NOTE: For bonding the headlining use a single-pot PU adhesive
(windscreen adhesive type).
71-6
http://vnx.su

Carpet
71
PRB7107
Remove the centre console to fit the carpet at the front and take out the seats to fit it at the back.
Unclip the retaining pins.
71-7
http://vnx.su
SIDE OPENING ELEMENTS TRIM

Front door trim
72
Unclip the trim and separate the trim from the

adhesive as it is removed.
When the trim has been removed or replaced,
apply preformed sealing mastic (Part No. 77 01
423 330) when the trim is refitted.
PRB7201
REMOVING
13114R
Remove:
- the window winder handle,
- the pull handle for closing the door,
- the inside opening handle,
- the door storage compartment.
72-1
http://vnx.su
SIDE OPENING ELEMENTS TRIM

Side door trim
PRB7202
REMOVING
13102R
Remove the handle.

Unclip the trim.
Unclip the opening handle.
72-2
http://vnx.su
72
NON-SIDE OPENING ELEMENTS TRIM

Lining for rear door or tailgate
PRB7301
REMOVING
13103R
Remove the handle.

Unclip the lining.
73-1
http://vnx.su
73
REAR PARCEL SHELF

Rear side shelves
PRB7401

Disconnect the speaker connector.
74-1
http://vnx.su
74
FRONT SEAT FRAMES AND RUNNERS

Complete front seat and runners
75
PRB7501
Runners
REMOVING
13178
13160R
Put the vehicle on a lift.
Please see the air bag manual for information on

the precautions which need to be taken when removing runner covers on vehicles equipped with
pretensioners.
Remove the mountings under the body.

Disconnect the electric wiring harness.
75-1
http://vnx.su
REAR SEAT FRAMES AND RUNNERS

Complete rear bench seat
PRB7601
REMOVING
13251R
Tilt the lever.

Release the seat.
76-1
http://vnx.su
76
FRONT SEAT TRIM

Seatback trim
77
PRB7701
REMOVING
13178-1
94121S
the button for tilting the seatback.
Remove :
- the seat,
- the head restraint and the upper parts of the
head restraint guide,
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FRONT SEAT TRIM

Seatback trim
13177
77
13175
Undo the tensioning elastic (A).
Refit the trim and cut the "pigs snout" clips.
13176
Unclip the rear edge of the trim (B).
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FRONT SEAT TRIM

Folding seatback trim
77
REMOVING
13173
13174
Unclip the trim at (A), (B) and (C).

Remove :
- the seat,
- the head restraint and the upper parts of the
head restraint guide.
Unclip :
- the stops,
- the rear section of the seatback using tool
Car. 1363.
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FRONT SEAT TRIM

Seat squab trim
77
PRB7702
Folding seat squab
REMOVING
13176-1
13172
Remove the seat.
Unclip the trim edges.
Unclip the rear edge of the seatback trim (B) and

the seat squab trim (C).
Cut the "pigs snout" clips (D).
Release the front section of the trim (E).
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REAR SEAT TRIM

78
PRB7801
REMOVING
13170
13171
Remove seatback mountings and spacers.

Separate the two seats (A).
Remove the mounting for the third belt (B).
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REAR SEAT TRIM

13169
78
13167
Unclip :
- the cover for the third belt and the seatback,
and the upper parts of the head restraint
guide.
Undo the zip fastener.

Refit the trim and cut the "pigs snout" clips.
1/3 section of seatback
13168
13166
- Unclip the two sections of the cover.
Remove the seatback mountings and the upper

parts of the head restraint guide.
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REAR SEAT TRIM

13165
Undo the zip and cut the "pigs snout" clips .
13164
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78
REAR SEAT TRIM

1/3 - 2/3 seat squab trim
78
PRB7802
1/3 seat squab
REMOVING
13162
13163
Remove the seat belt mounting point (A).
Unclip the rear edge of the trim.
Unclip the rear edge of the trim.
Cut the "pigs snout" clips.
Cut the "pigs snout" clip.
Unclip the trim.
Unclip the other parts of the trim.
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SEAT ACCESSORIES
Locking cable - 3rd seat belt retractor
13161
After the trim has been removed :

Unclip the sleeve stops (A),
Remove :
- the cable,
- the retractor mounting bolt (B).
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79
Electrical equipment
BATTERY - HEADLIGHTS
REAR AND INTERIOR LIGHTING
IMMOBILISER
INSTRUMENT PANEL
CONTROLS - SIGNALS
WIPERS
ELECTRICAL ASSISTANCE EQUIPMENT
WIRING

77 11 194 271
JULY 1997
Edition Anglaise

Renault.

Renault 1997
http://vnx.su
EXPLODED VIEW
PRO80.1
http://vnx.su
Electrical
Equipment
Contents
Page
BATTERIE -PROJECTEURS
HEADLIGHTS
80 BATTERY
Page
84 CONTROLS - SIGNALS
Battery
Special notes
80-1
Headlights
Lens units and indicators
Remote adjustment
80-3
80-4
Windscreen wiper stalk

Lights stalk
Stalk mounting
Rotary switch under steering
wheel
Ignition switch
84-1
84-2
84-3
84-4
84-6
85 WIPERS
ECLAIRAGE
AND INTERIOR
ARRIERE LIGHTS
81 REAR
Courtesy light
Fuses
82
81-1
81-2
87
IMMOBILISER
Coded key immobiliser system
82-1
83 INSTRUMENT PANEL
Dashboard
Instrument panel
Fuel level sensor
Oil level sensor
Front windscreen wiper

Rear screen wiper
Electric washer pump
85-1
85-3
85-4
Relay plate
87-1
88 WIRING
83-1
83-6
83-10
83-12
83-13
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Heated rear screen

Remote control for door locking
Airbags and seat belt pretensioners
88-1
88-3
88-8
BATTERY
Special notes
To remove the battery, slacken mounting (A).
80
It is vital :
to ensure that there is no sulphation on the
terminals,
to clean and grease the terminals if necessary,
to check that the nuts are correctly tightened
on the terminals. Incorrect contact could cause
starting faults or charging faults which could
cause sparks, making the battery liable to
explode,
to check the electrolyte level.
Batteries with sets of removable plugs:

remove the cover by hand or by using a tool
(stiff spatula),
check that the electrolyte level in all the cells is
well above the level of the separators,
12422R
if necessary, use demineralised water to top up

the level.
A - CHECKING
Check and ensure that:
Note: certain types of battery have translucent

bodies which allow the level of the electrolyte to
be seen.
the battery tray and cover are not cracked or

split,
the top of the battery is clean,
Never add electrolyte or other products to the

battery.
the terminals are in good condition.
80-1
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BATTERY
Special notes
80
B - PRECAUTIONS
2)
It should be remembered that a battery:
When a battery is charging (either in a vehicle or

elsewhere), oxygen and hydrogen are produced.
Gas production is at a maximum when the battery
is completely charged and the quantity of gas
produced is proportional to the intensity of the
charging current.
contains sulphuric acid, which is a dangerous

product,
produces oxygen and hydrogen during
charging. The mixture of these two gases
forms a detonating gas , hence the risk of an
explosion.
1)
DANGER = RISK OF EXPLOSION
The oxygen and the hydrogen join together in the

open air, on the surface of the plates and form a
highly explosive mixture.
The smallest of sparks, a cigarette or a recently
extinguished match are sufficient to cause an
explosion. The explosion is so strong that the
battery can shatter and the acid is dispersed into
the surrounding atmosphere. People nearby are
at risk (shattered casing parts, acid splashes). The
acid splashes are harmful to the eyes, face and
hands. They also attack clothing.
DANGER = ACID
The sulphuric acid solution is a highly aggressive,

toxic and corrosive product. It attacks skin,
clothing, concrete and corrodes most metals.
It is also very important, when handling a battery,
to take the following precautions:
to protect your eyes with goggles,
to wear anti-acid gloves and clothing.
Safeguarding against the danger of explosion,

which can be caused by a poorly handled battery,
must be taken very seriously. Avoid all risks of
sparks.
If acid splashes on to your clothing, rinse all the

contaminated areas thoroughly in water. If your
eyes are affected, consult a doctor.
Check that the "consumers" are switched off,

before disconnecting or reconnecting a
battery.
When a battery is being charged in a room,
switch off the charger before connecting or
disconnecting the battery.
Do not put any metallic items onto the battery
so as not to cause a short circuit across the
terminals.
Never place a naked flame, a welding torch,
hot air gun, a cigarette or a lighted match near
to a battery.
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HEADLIGHTS
Lens units and indicators
NOTE : The lens unit and indicators cannot be separated.
80
ADJUSTMENT
Ensure that the vehicle is unladen, then adjust the

height using bolt (G) and the direction using bolt
(F).
REMOVAL - REFITTING
Disconnect:
- the battery,
- the connectors for the bulbs in the lens unit
and the indicator and for the remote
adjustment unit.
Remove the upper bolt (A).
Remove:
- the two bolts (D) from the bumper and the
three mounting bolts for the mudguard to allow the bumper to be partially removed,
- mounting bolt (C) and bolt (B) to remove the
lens unit.
13057R
13055R
The headlight is refitted in the reverse manner to

removal.
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HEADLIGHTS
Remote adjustment
REMOVING - REFITTING OF THE CONTROL
80
REMOVING - REFITTING THE RECEIVER
Disconnect the remote adjustment receiver

connector.
13056S
Remove the coin tray or the switch mounting depending on version and, passing your hand inside
the dashboard, unclip the control and push it outwards.
13057R1
Turn the receiver an eighth of a turn towards the

centre of the vehicle to release the lens unit.
CONNECTION
Then release the ball joint of the receiver and the

lens unit parabola to remove the receiver.
Refer to the Technical Note "Wiring diagrams".
SPECIAL NOTES FOR REFITTING
Remove the bulb connector protective cover at

the rear of the lens unit.
Keep the parabola towards the rear of the lens
unit by pulling on the base of the bulb and click
the ball joint into position.
Now refit the receiver to the lens unit by turning it
an eighth of a turn.
Reconnect the connector and refit the protective
bulb cover at the rear of the lens unit.
Set the remote adjustment control to "0" and adjust the headlight:
- bolt (G) for height adjustment,
- bolt (F) for direction adjustment.
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REAR AND INTERIOR LIGHTS

Courtesy light
81
REMOVING - REFITTING THE COURTESY LIGHT
REMOVING - REFITTING THE MOUNTING (D)
Remove the light diffuser using a screwdriver to

lever it out at the two points (A).
After removing the bulb, remove bolt (C) and unclip the mounting (D).
NOTE : The map reading light diffuser (depending

on equipment) is removed in the same way.
13074R

13073R
When refitting the mounting (D), check that the

switch (E) is positioned to the right (see above) so
the contacts are not damaged on refitting.
Remove the two courtesy light console mounting

bolts (B).
13072R
Release the assembly towards the front and disconnect the connector.
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Fuses
FUSE BOX (passenger compartment)
This unit is located in the passenger compartment on the drivers side.
Allocation of fuses (depending on equipment level).
Symbol
Rating
Description
10
Instrument panel / Electric rear view mirrors/ Radio / Car phone
15
Courtesy light / Immobiliser
30
Consumer cut-out
30
Towing connection
30
Heated rear screen
20
Central door locking / Immobiliser
15
Front fog lights
15
Rear screen wash - wipe/ Reversing lights / Heated rear screen / Immobiliser
/ Lights on reminder buzzer
15
Front wash - wipe
15
Stop lights/ Instrument panel/ Airbag / Pretensioners
10
Anti-lock braking system (ABS)
25
Left hand electric window
25
Right hand electric window
20
Heated seats
15
Air conditioning
15
Radio / Cigar lighter / Car phone
25
Heating
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81

Fuses
81
Allocation of fuses (depending on equipment level). (cont)
Symbol
Rating
Description
10
Left hand main beam headlight/ Instrument panel
10
Right hand main beam headlight
10
Left hand dipped headlight
10
Right hand dipped headlight
7.5
Left hand side light/ Instrument panel / Controls lighting / Radio / Heating Control Panel
7.5
Right hand side light/ Controls lighting
7.5
Rear fog light
15
Horn
10
Flasher unit
10
Heated rear view mirrors
NOTE : To determine the exact position of the fuses, refer to the vehicle fuse box label or the Technical Note
"Wiring Diagrams".
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Fuses
81
FUSE BOX (engine compartment)
12840S
Rating
D7F
F8Q
E7J
30A
Injection (238-279)
Injection (236)
30A
Fan assembly
(234)
Fan assembly
(234)
Injection (238)
Injection (120)
15A
5A
15A
Engine functions
(238-250-450-927)
15A
Fan assembly / ignition

(234-778)
Injection / ignition
(236-250-663-664)
70A
Preheating unit
50A
Engine functions
(234-450-700)
60A
Dashboard (209-713)
Dashboard (209-713)
Dashboard (209-713)
60A
Dashboard (104-209)
Dashboard (104-209)
Dashboard (104-209)
10
60A
Electric windows / AC fan
Electric windows
Electric windows / AC fan
11
60A
ABS
ABS
ABS
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IMMOBILISER
82
GENERAL
NOTES
The immobiliser is controlled by a key recognition

system (known as coded key immobiliser system).
This system may be fitted to petrol or diesel vehicles.
An independently operating coded chip without a

battery is integrated into each head of the vehicle
keys.
Petrol vehicles: the immobiliser function is carried

out by the injection computer.
Diesel vehicles: the immobiliser function is carried
out by the coded solenoid valve (on the injection
pump).
When the ignition is switched on, an antenna ring

around the ignition switch interrogates and captures the code from the head of the key and transmits it to the decoder unit.
If the vehicle is fitted with a remote control for

door locking, a single decoder unit carries out
both functions (immobiliser and remote control).
The remote control has no effect on the immobiliser system (see section 88).
If the decoder unit recognises the code, the vehicle will be permitted to be started.
The immobiliser is activated a few seconds after
the key is withdrawn from the ignition and this is
shown by the flashing of the red immobiliser warning light on the instrument panel.
On these vehicles, the identification number of

the key heads contains eight alphanumeric characters, beginning with the letter E or A.
If there is a fault in the key recognition system, a

security code may be entered using the XR25 only.
This code may be communicated to the repair
agent (on his request) by the local assistance network (depending on country, for example: Delta
Assistance on 0800.05.15.15 for France, NVSR for
the UK by fax only).
IMPORTANT: The repair agent must inform the
customer that the immobiliser system will reset itself automatically 10 minutes after switching the
ignition off.
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IMMOBILISER
82
DESCRIPTION
Opening a key head
With this system the engine immobiliser is activated 10 seconds after switching off the ignition
(shown by the flashing of the red engine immobiliser warning light).
Place the key head on a table with the metal insert facing downwards.
Use a small screwdriver as a lever as shown below,
ensuring that the end of the screwdriver is placed
on the lower section (E) of the key head. This allows the upper section to slide off the lower section.
The system comprises:

two key heads fitted with either:
- a single coded chip for controlling the immobiliser (A),
13078R
- a coded chip (A) for controlling the immobiliser and the electronic unit for the remote control (B) allowing the opening
elements to be locked or unlocked (depending on equipment).
13077R
13076R
NOTE : To remove the metal insert, move the retaining tab aside before removing it. When refitting, check the insert is correctly clipped into position.
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IMMOBILISER
An antenna ring (C) around the ignition
switch, with an electronic unit which transmits
the key code to the decoder unit (D).
82
A decoder unit (D) in the dashboard on the left

hand side.
12967R1
13067R
This has the following functions:

- decoding of the key signal from the antenna
ring,
- management of the engine immobiliser
system by the sending of a code to the injection
computer (petrol) or coded solenoid valve
(diesel) to authorise the vehicle to be started
- operation of the red immobiliser warning light,
- locking and unlocking of the opening elements
(depending on version),
- timed illumination of the courtesy light (vehicle
fitted with a door locking remote control).
NOTE : This antenna ring is not coded.
Removal - Refitting
Remove the half cowlings from under the steering
wheel, release the antenna ring from the ignition
switch and disconnect its connector.
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IMMOBILISER
82
A red immobiliser warning light on the instrument panel used to :

- indicate activation of the engine immobiliser
system,
- signal a fault in the system for vehicles with a
coded solenoid valve (diesel) or nonrecognition of the key,
- signal entry into the door locking remote
control resynchronisation mode (depending
on equipment).
Removal - Refitting
The dashboard must be partially removed to remove the decoder unit.
Remove:
- the steering wheel with the wheels straight,
- the half cowlings under the steering wheel,
- the knee protector under the steering column,
- the lights and wiper controls,
- the instrument panel surround,
- the instrument panel,
- the ashtray, its mounting and the two dashboard mounting bolts on the heating unit,
- the trim at the bottom of the dashboard on the
drivers side,
- the two speaker grilles on the dashboard,
- the dashboard mountings.
An injection warning light (petrol vehicle)

which indicates a fault in the:
- injection,
- engine immobiliser system when the engine
is running (flashes during deceleration and
at idle speed).
13065R1
Move the dashboard as far back as possible, disconnect the decoder unit and remove the two
mounting bolts (B) using a small ratchet fitted
with a Torx 20 socket.
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IMMOBILISER
-
OPERATION
When the immobiliser system is activated (approximately 10 seconds after cutting + after ignition feed), the red immobiliser warning light
flashes (slow flashing; 1 flash / second).
After switching the ignition on, the antenna ring
analyses the code from the key and transmits it to
the decoder unit.
If the code is not recognised by the decoder unit,
the injection warning light (petrol) illuminates for
a few seconds and extinguishes while the red immobiliser warning light flashes (rapid flashing).
If the code is recognised by the decoder unit, it
sends a code to the injection computer (petrol) or
coded solenoid valve (diesel) via the coded line
and extinguishes the red immobiliser warning
light (after approximately 3 seconds).
At this precise moment, one of several situations
may arise:
- The injection computer (petrol) or coded solenoid valve (diesel) has no reference code in its
memory :
the code sent to it is stored in its memory.
82
The injection computer (petrol) or the coded

solenoid valve (diesel) has a reference code in
its memory:
the code sent to it is compared with the code
in its memory,
if the two codes match, the computer unlocks the injection system (petrol) or coded
solenoid valve (diesel) and the engine may
be started.
When the ignition is switched on, the injection warning light (petrol) and the immobiliser warning light illuminate for 3 seconds then
extinguish, showing that the system is operating correctly.
if the two codes do not match, the system remains locked to prevent the engine from
being started.
When the ignition is switched on, the injection warning light flashes (petrol) and the red
engine immobiliser warning light illuminates
permanently then extinguishes or the red immobiliser warning light remains illuminated
permanently (diesel) indicating that the coded solenoid valve has not recognised the
code.The vehicle may not be started.
NOTE : to ensure the system operates correctly, no

objects (eg. : keyrings) should be allowed to come
between the key and the antenna ring.
IMPORTANT: when the vehicle battery has a low
charge, the drop in voltage caused by operating
the starter may set the immobiliser. If the voltage
is too low, the engine cannot be started, even by
pushing the vehicle.
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IMMOBILISER
82
REPLACING A KEY HEAD
REPLACING THE DECODER UNIT ALONE
The coded chip in the key head or the remote

control (depending on equipment) is faulty :
- order a replacement key head using the number in the faulty key head (eight alphanumeric
characters beginning with the letter E or A). If
the key head is from a remote control type key,
carry out a resynchronisation operation.
IMPORTANT: The resynchronisation procedure
differs depending on if the decoder unit has
been replaced or not (see specific or simple resynchronisation procedure in section 88).
A new decoder unit is not coded. Once fitted to

the vehicle, the codes of both keys must be programmed so that it is operational (see programming procedure).
NOTE : if the decoder unit alone is replaced, no
operation is carried out on the injection computer
or coded solenoid valve. It retains the same engine immobiliser code.
IMPORTANT: when a decoder unit has been programmed with the key code, the code cannot be
erased and no other code may be memorised in its
place.
- if the customer requires the fault to be repaired

immediately (2nd key unavailable) a complete
kit may be fitted to the vehicle (decoder unit
plus two key heads) (see replacing a complete
kit).
SPECIAL NOTES
The key has been lost:

- order a replacement key head using the number in the key head of the 2nd key (eight alphanumeric characters beginning with the letter E
or A) or on the label (normally attached to the
keys when the vehicle is delivered).
In this case, remember to order the metal
number insert for the new key head. If the key
head is from a remote control type key, carry
out a resynchronisation operation.
IMPORTANT: The resynchronisation procedure
differs depending on if the decoder unit has
been replaced or not (see specific or simple resynchronisation procedure in section 88).
Diesel vehicles
On these vehicles, the decoder unit is identical to
the decoder unit of a petrol immobiliser system.
When replacing it the new "diesel" part must be
configured by means of the XR25 test kit.
This configuration will enable the decoder unit to
check that the coded solenoid valve is operating
correctly (indicated by the immobiliser warning
light) (see diesel configuration).
Vehicles fitted with a remote control

After replacing the decoder unit carry out a resynchronisation operation (see simple resynchronisation procedure, section 88).
IMPORTANT: Do not touch the key head chip

when taking note of the number in the key head.
Any key which has been touched must be replaced.
NOTE: if the key head number cannot be located
(both keys lost together with the label), the
complete kit must be replaced (decoder unit, plus
2 transponder keys, plus injection computer or coded solenoid valve electronic unit).
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IMMOBILISER
82
5. Check the immobiliser system operates correctly with both keys.
PROGRAMMING PROCEDURE
The procedure is carried out using one key.

Ignition off, the red immobiliser warning light
should flash 10 seconds after switching the
ignition off (slow flashing). Bargraph 10 LH
should be illuminated. The vehicle should not
start when other keys are used.
The XR25 must be used for this procedure to lock

the key programming.
1. Ignition off, connect the XR25 to the vehicle

and set the selector to S8.
NOTE : to simulate prevention from starting,

before switching the ignition on, wait for the
red warning light to flash slowly.
D
5
6
Enter code
(fiche n 56),
bargraphs 19 RH and 19 LH must be illuminated (programming not carried out). If both of
these bargraphs are not illuminated, replace
the decoder unit (this unit has already been
used).
G
0
4
*
Enter
on
the XR25, ignition still off (bargraph 9 LH illuminates).
Switch the ignition on, the red immobiliser
warning light should flash more quickly and
the vehicle should be impossible to start.
2. With one of the keys switch the ignition on

for approximately 2 seconds (without starting
the engine). Bargraph 18 LH illuminates and
bargraph 19 LH extinguishes.
The red immobiliser warning light flashes.
6. The procedure is complete. After switching

the ignition off and on again (for more than 2
seconds), check that the vehicle can be started
with both keys.
3. Switch the ignition off and start command

G60* to lock the programming. The red immobiliser warning light should flash (slow flashing). Bargraphs 19 RH and 18 LH should be
extinguished.
Diesel configuration
On diesel vehicles the decoder unit must be configured in "diesel" using the XR25.
4. Switch the ignition on for a few seconds (without starting the engine) to send the code to
the injection computer or the coded solenoid
valve.
1. Ignition off, XR25 connected (ISO selector on

S8).
D
5
6
Enter code
(fiche n 56),
bargraph 1 RH must be illuminated.
2. Enter programming mode

G
Bargraph 3 RH must illuminate.

The configuration is complete.
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IMMOBILISER
Connect the XR25, setting the ISO selector to

S8.
5.
REPLACING A KIT
(decoder unit plus two key heads)
If a kit is replaced it will be necessary to:

- programme the codes of the 2 new keys in the
new decoder unit (supplied uncoded).
- erase the old code in the injection computer or
coded solenoid valve using the security procedure (the code number for the old kit should be
requested from the local assistance network,
example Delta Assistance for France, NVSR for
the UK by fax only)
Enter code
With one of the keys switch the ignition on

for approximately 2 seconds (without starting the engine). Bargraph 18 LH illuminates
and bargraph 19 LH extinguishes.
The red immobiliser warning light flashes rapidly.
7.
Switch the ignition off and start command

G60* to lock the programming.
- the red immobiliser warning light should
flash (slow flashing)
- bargraphs 19 RH and 18 LH should be extinguished.
8.
Switch the ignition on for a few seconds,

check that the red immobiliser warning light
is illuminated permanently (diesel) or that
the injection warning light is flashing (petrol).
Fit the metal inserts from the old keys into

the new key heads.
9.
Switch the ignition on for more than 10

consecutive seconds.
Note the number of one of the old keys to

obtain the security code number.
10.
Switch the ignition off and wait for the red

immobiliser warning light to flash slowly.
NOTE : if the security code is entered when the

decoder unit has the same code as the injection
computer, or coded solenoid valve, it will not be
decoded.
3.
6.
The code in the injection computer or coded solenoid valve cannot be erased with the security code
(using the number for the old kit) unless the decoder unit fitted to the vehicle has been programmed with a different code (which is the case in the
following procedure).
2.
Bargraphs 19 RH and 19 LH must be illuminated (programming not carried out).
IMPORTANT : to erase the old code (memorised in

the injection computer or coded solenoid valve
electronic unit), the procedure described below
must be followed in the correct order.
1.
82
Remove the decoder unit with the ignition

off.
Enter command
with the ignition still off (bargraph 9 LH illuminates).

4.
Fit the new decoder unit, ignition off.

Switch the ignition on, the red immobiliser
warning light flashes more rapidly.
Follow the procedure for entering the security code (see procedure for entering the security code), using the code number corresponding to the old kit. This erases the old code
memorised in the injection computer or the
coded solenoid valve.
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IMMOBILISER
NOTE: On petrol vehicles use the XR25 to check
that the injection computer has been correctly decoded (in injection fault finding).
11. Switch the ignition off and on again for a few

seconds without starting the engine to programme the immobiliser code for the new kit
in the injection computer or coded solenoid
valve. The red warning light should illuminate
for 3 seconds then extinguish.
Connect the XR25 to the diagnostic socket , position the ISO selector and enter the injection code :
bargraph 2 RH side (immobiliser) should be illuminated.
After entering
82
For diesel :
Ignition off, configure the decoder unit to
"diesel" (see diesel configuration using command
)
G
2
2
*
2
*
Bargraph 3 RH should illuminate; the configuration is complete.
the message
should appear on the display on the XR25. The

erasure is complete.
NOTE
- petrol vehicles: Using the XR25, check the injection computer has been programmed with
the code. Bargraph 2 RH (immobiliser) should
be extinguished.
- If the display shows
After entering
there is a fault on the coded line. In this case,

repair the fault and start the procedure again.
the display should show

- If bargraph 2 RH side (immobiliser ) is extinguished,
and the display shows
The injection computer has been correctly coded.
(*22),
If the display shows
this shows that the injection computer code has

not been erased. In this case check the conformity of the security code and repeat the procedure.
the injection computer is still uncoded.
- diesel vehicles: When the ignition is switched

on, check the immobiliser warning light extinguishes after 3 seconds.
82-9
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IMMOBILISER
12.
Check the immobiliser system operates correctly with both keys.

Switch the ignition on and check that the red
warning light illuminates for 3 seconds then
extinguishes and that the vehicle can be started.
REPLACING THE INJECTION COMPUTER OR

CODED SOLENOID VALVE
The injection computer and coded solenoid valve

are supplied uncoded. The engine immobiliser
code must be programmed in when they are fitted.
NOTE : starting prevention can be checked

using the XR25:
It is sufficient to carry out the following operations:

- switch the ignition on, without starting the engine, using the vehicles coded key for a few
seconds,
- switch the ignition off, the immobiliser will be
activated approximately 10 seconds afterwards
(red immobiliser warning light flashes).
- Ignition off, wait for the warning light to

Enter
- Switch the ignition on and check the vehicle cannot be started and that the red warning light flashes (rapid flashing).
13.
82
NOTE : starting prevention can be checked

using the XR25:
The procedure is complete. After turning the

ignition off and on again (for more than 2 seconds), check the vehicle can be started and
erase all faults present in the decoder unit.
- Ignition off, wait for the warning light to

Enter
ignition still off (bargraph 9 LH illuminates).

Vehicles fitted with a remote control
- Switch the ignition on, the red immobiliser
warning light should flash more quickly and
the vehicle should be impossible to start.
After replacing the kit carry out a resynchronisation operation (see simple resynchronisation procedure, section 88).
NOTE : For removal - refitting information, refer

to the corresponding section (13 or 17).
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IMMOBILISER
82
Checking (on petrol vehicle only)
SPECIAL NOTES FOR TESTING AN INJECTION

COMPUTER OR A CODED SOLENOID VALVE (test
part)
If the test computer is to be returned to stock, it is

possible (before it is removed) to check using the
XR25 that the computer has not been coded during the test (example : incorrect operation).
IMPORTANT: if an uncoded injection computer or

solenoid valve is being tested from stock (test
part), the decoder unit MUST NOT be supplied during the operation.

Position the ISO selector and enter the injection
code: bargraph 2 RH (immobiliser) should be illuminated.
If the decoder unit is supplied, switching the ignition on causes a coded signal to be sent from the
decoder unit to the injection computer or coded
solenoid valve (and the code is then programmed).
After entering
To avoid memorising a code which could make

the injection computer or coded solenoid valve
electronic unit unusable after the test, the fuse
(+ before ignition feed) for the decoder unit
must be removed (fuse showing the door locking
symbol). This prevents the coded signal being sent
when the ignition is switched on (the computer or
the coded solenoid valve electronic unit remains
uncoded).
the message
should be displayed on the XR25.

This shows that the injection computer is not coded and may be returned to stock.
If bargraph 2 RH (immobiliser) is extinguished and
after entering
*
2
2
For petrol vehicles, the computer used for the test

MUST have the same Part Number as the original
computer on the vehicle (test computer may be
damaged).
the message
is displayed on the XR25, this shows that the

computer has been programmed with the immobiliser code (incorrect operation). In this case the
computer must be decoded before being returned
to stock.
The procedure for decoding consists of replacing
the decoder unit on the vehicle with another decoder unit with a different code (with its key
head) and entering the security code for the vehicle (security code number should be requested
from the local assistance network, example DELTA
Assistance for France, NVSR for the UK by fax only) using the number in the head of the key for the
vehicle.
Ignition off, fit in place of the original decoder
unit on the vehicle, a decoder unit coded with a
different number (the procedure will not work
with an uncoded decoder unit or one which has
the same code as the injection computer).
82-11
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IMMOBILISER
82
Switch the ignition on, the red engine immobiliser

warning light will flash (rapid flashing).
NOTE : this fault may be shown by the XR25 (in

injection fault finding).
Enter the vehicle security code (number corresponding to the original key number).
Connect the XR25 and enter the injection code.

The fault is shown by bargraph 2 RH side.
After entering the security code, the red warning

light will flash again.
The XR25 display should show
After entering
(in injection fault finding). This indicates that the

injection computer has been decoded.
the message
Switch the ignition off, remove the decoded

computer and return it to stock.
on the XR25 display indicates a fault on the coded

line.
Refit the computer and decoder unit to the vehicle.
Diesel vehicle
If a system fault is detected by the decoder unit

when the engine is running, the red immobiliser
warning light will illuminate permanently until
the ignition is switched off.
NOTE : When testing the injection using the XR25

on a vehicle without an immobiliser, bargraph 2
RH side will illuminate (*22 = 2 def = computer
not coded). This is normal.
IMPORTANT: In this case, after repair, the fault

memorised in the decoder unit must be erased by
entering command
SYSTEM FAULT, ENGINE RUNNING
Petrol vehicle
on the XR25 to allow the engine immobiliser system to operate again.
If a fault in the system is noted by the injection

computer when the engine is running, the injection warning light on the instrument panel will
flash during deceleration and at idle speed (engine speed less than 1500 rpm).
NOTE: this fault may be shown by the XR25 using

fault finding for the decoder unit (fiche no. 56).
Connect the XR25.

IMPORTANT: In this case, after repair, the fault
memorised in the injection computer and the decoder unit must be erased by entering command
Set the ISO selector to S8.
Enter code
on the XR25 or by disconnecting the battery (approximately 30 seconds) to allow the engine immobiliser system to operate again.
The fault may be shown by bargraph 6 RH or LH

side.
82-12
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IMMOBILISER
4. Enter mode
PROCEDURE FOR ENTERING THE SECURITY CODE
With this immobiliser system, the procedure for

entering the security code is managed by the decoder unit.
82
G
on the XR25 then the security code number

and validate using
The code is entered using the XR25 only.

- If the code is correct
The security code can only be entered if the engine immobiliser system is active. The red immobiliser warning light must flash when the ignition is
switched on (rapid flashing).
is displayed.
After determining the security code number (request from the local assistance network, example
DELTA Assistance for France, NVSR for the UK by
fax only) , carry out the following operations:
Bargraph 10 LH extinguishes.
The engine may be started.
The vehicle is protected once more :
approximately 10 minutes after switching
the ignition off (automatically),
after disconnecting the battery.
1. Ignition off, the red engine immobiliser warning light should flash (slow flashing).
2. Switch the ignition on, the injection warning

light (petrol vehicle) illuminates for approximately 3 seconds then extinguishes, while the
red immobiliser warning light should flash
more quickly.
- If the code is incorrect
is displayed.
3. Connect the XR25 to the vehicle and set the

ISO selector on S8.
Enter code
Bargraph 10 LH remains illuminated.

The engine may not be started.
The red immobiliser warning light and the injection warning light (depending on version)
flash.
Switch the ignition off, then repeat the procedure for entering the code.
Bargraph 10 LH should be illuminated (fault

finding fiche n 56).
IMPORTANT : you may make 3 attempts to enter

the code. If, after the third attempt, the code is invalid, you must wait for approximately 15 minutes before making another attempt.
When this period has expired, switch the ignition
off and on again and 3 more attempts may be
made.
NOTE : This procedure does not decode the injection computer or coded solenoid valve (depending on the type of engine)- it only authorises the
starting of the vehicle.
REMINDER : The ignition must be switched off
and on again between attempts to enter the
code.
82-13
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IMMOBILISER
DECODER UNIT CONNECTIONS (fullest version)
13063R
Track
Allocation
A1
Courtesy light timer*
A2
Antenna ring coded connection
A3
Diagnostic socket information (line K)
A4
Diagnostic socket information (line L)
A5
Red immobiliser warning light
A6
Coded information to injection computer

or coded solenoid valve
A7
+ after ignition
A8
Earth
A9
+ before ignition
B1
Infrared input*
B2
Door lock command*
B3
Not used
B4
Door switch*
B5
Door open command*
B6
Not used
B7
Not used
B8
Door open*
B9
Door lock*
* Vehicle with remote control
82-14
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82
IMMOBILISER
82
DIAGRAM (vehicle with remote control)
PRO12827
82-15
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IMMOBILISER
KEY
104
120
123
138
140
141
142
154
178
180
181
213
225
247
249
260
503
711
82
FAULT FINDING
Ignition switch
Injection computer
Door locking button
Rear right door locking motor
Drivers door locking motor
Passengers door locking motor
Luggage compartment door locking motor
Luggage compartment door switch
Rear right door switch
Drivers door switch
Passengers door switch
Courtesy light
Diagnostic socket
Injection warning light and red immobiliser
warning light on instrument panel
Remote control receiver
Passenger compartment fuse box
Decoder unit
If this immobiliser system is faulty, fault finding

may be carried out using the XR25.
CONNECTION
Use cassette no 17 and the corresponding fault

finding fiche no 56.
92656S2

Position the ISO selector on S8.
Enter the code for the immobiliser system D56.
NOTE : For information on the interpretation of
the bargraphs, the fault charts, checking conformity and additional tests, refer to the fault finding section.
82-16
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INSTRUMENT PANEL
Dashboard
83
PRB5702
Remove the two airbag cushion bolts behind the

steering wheel.
REMOVAL

Disconnect the connectors (airbag, horn).
Removing the steering wheel (with AIRBAG)
Remove:
- the airbag cushion,
- the steering wheel bolt (renew it on refitting,
pre-bonded bolt, tightening torque: 4.5
daN.m),
straight.
Removing the steering wheel (without AIRBAG)

Remove:
- the central cushion,
- the steering wheel bolt (renew it on refitting,
pre-bonded bolt, tightening torque: 4.5
daN.m),
straight.
12973S
83-1
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INSTRUMENT PANEL
Dashboard
Remove:
- the half cowlings (three bolts),
83
- the instrument panel (four bolts),
12969-1R
12971R

- the instrument panel visor (six bolts) and the
dashboard visor (two bolts),
12968S
12970-1R
83-2
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INSTRUMENT PANEL
Dashboard
83
Remove:
- the lower protector (four bolts),
Special notes for vehicles with airbag

Before removing the assembly, the position of the
rotary switch under the steering wheel must be
noted:
- by ensuring that the wheels are straight on removal so that the strip may be positioned in the
centre,
- by immobilising the rotary switch rotor using
adhesive tape.
Slacken the bolt then sharply tap the screwdriver
to release the cone.
12966R
- the lower section of the dashboard (four bolts,

two clips),
12967-1R
12971-1R
83-3
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INSTRUMENT PANEL
Dashboard
- the fuse boards (five bolts).
- the ashtray and its mounting (two bolts).
Unclip the diagnostic socket.
12965-1R
83
12963R
Remove:
- the steering column mountings (two bolts, two
nuts),
Remove:
- the heating control unit (two bolts),
12965-1R1
12963R1
83-4
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INSTRUMENT PANEL
Dashboard
- the loud speaker grilles,
83
REFITTING
When refitting, it is important to ensure the various wires are correctly routed and have sufficient space so that the dashboard can be correctly
centred.
Gently pull the dashboard.

Release the wiring retaining clips.
Disconnect:
- the headlight remote adjustment control
connector and hazard warning light connector,
- the remaining connectors (example : decoder
unit).
SPECIAL NOTES FOR REFITTING THE STEERING

WHEEL WITH AIRBAG
Remove the dashboard.
If there is any doubt that this switch is correctly

centred follow the method for centring described
in section 88 "drivers airbag".
Ensure the rotary switch under the steering wheel

is correctly positioned.
Renew the steering wheel bolt each time it is removed (pre-bonded bolt) for a steering wheel
with airbag.
Observe the correct tightening torque (4.5
daN.m).
IMPORTANT
follows:

ignition is on,
12964R

extinguished.
If the warning light does not operate exactly as

described above, refer to the fault finding section
and test the system using the XRBAG (El. 1288)
(see section 88).
83-5
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INSTRUMENT PANEL
Instrument panel
83
REMOVAL - REFITTING
REPAIR
The instrument panel MAY NOT be opened.
Remove:
- the two bolts (A) and remove the upper half
cowling,
- the four bolts (B) and the two bolts (C).
If it is faulty, it must be renewed.
NOTE : only the glass may be replaced.
Remove the dashboard visor.

Before reconnecting the instrument panel, check

the condition of the connectors and their wiring.
Ensure the connectors are correctly connected.
Check the information given by the instrument
panel is correct.
12971R1
Remove the four bolts (D) and remove the instrument panel.
12969R
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INSTRUMENT PANEL
Instrument panel
83
DESCRIPTION
electronic speedometer,
display : mileometer/trip recorder and clock
coolant temperature gauge,
fuel gauge,
warning light functions.
13054S
Trip mileometer reset button and clock reset (rotate).
NOTE :
Under normal operating conditions, the oil level is only measured if the ignition has been switched off for
over one minute; otherwise the old oil level value is re-displayed.
If a fault is detected, however, an oil level measurement is made each time the ignition is switched on to
check if the fault is persisting.
It is normal to find that the oil level is not always the same:
- parking on a slope,
- too short a wait after running the engine for a short moment (especially when the oil is cold), ...
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INSTRUMENT PANEL
Instrument panel
CONNECTION
(fullest
83
version)
13066S
Connector C (clear)
Track
Connector M (brown)
Allocation
Track
Allocation
Left hand indicator tell-tale
Fuel gauge earth
Dipped headlight tell-tale
Fuel gauge
Main beam headlight tell-tale
+ before ignition
Catalytic converter fault warning light
Not used
Preheating warning light
Not used
Airbag warning light
Electronic fault warning light
Opening element warning light
OBD warning light (Not used)
+ lighting
AT warning light
Coolant temperature gauge
Not used
10
Not used
10
+ after ignition
83-8
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INSTRUMENT PANEL
Instrument panel
Connector N (black)
Track
Allocation
Not used
Brake pad wear warning light
ABS warning light
Handbrake / brake info warning light

(NIVOCODE)
Immobiliser warning light
Not used
Not used
Speed signal
Oil level sensor
10
Oil level sensor earth
Connector G (grey)
Track
Allocation
Earth
Not used
Not used
Low fuel level warning light
Coolant temperature warning light
Oil pressure warning light
Battery charge warning light
Rear fog light tell-tale
Front fog lights tell-tale
10
Right hand indicator tell-tale
83-9
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83
INSTRUMENT PANEL
Fuel level sensor
83
Mot. 1264
Mot. 1264-01
Mot. 1265
Mot. 1265-01
Wrench for removing sender unit nut

Pliers for removing quick-release unions
Sender unit nut
Lift the rear bench seat (depending on

equipment).
IMPORTANT :
Remove the pump and sender unit steel cover.
During any operation on the fuel level sensor

you must observe the following precautions:
Disconnect the electrical connector (1).

Release the clips (2).
- Do not smoke.
Then disconnect the fuel supply pipe (3) (green

marking on the quick-release union) and the fuel
return pipe (4) (red marking on the quick-release
union) using the special pliers Mot. 1265 or Mot.
1265-01.
IMPORTANT: When the pipes are removed, fuel
may be splashed out due to the residual pressure
in the pipes. Take appropriate precautions.
- Keep all flames or incandescent objects away

from the working area.
REMOVAL OF THE PUMP - SENDER
ASSEMBLY
The pump and sender unit assembly may be

removed through the inspection cover under the
rear bench seat and the fuel tank does not have to
be removed.
97163R6
96420R2
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INSTRUMENT PANEL
Fuel level sensor
Disconnect the connector and the pipes on the
sender unit side.
83
Tighten the mounting nut on the fuel and sender

unit assembly to a torque of 3.5 daN.m using the
tool Mot. 1264-01, holding the sender unit to prevent it from rotating.
Remove the mounting nut (5) of the pump and

sender unit using tool Mot. 1264-01.
Slacken the nut, remove the tool, unscrew the nut
by hand and remove it.
Make sure that the connector is firmly locked and

that the quick-release unions are securely clipped
on (with 2 O-ring seals)
Remove the pump and sender unit assembly.
Reconnect the battery.
NOTE : If several hours may pass between

removing and refitting the pump and sender unit
assembly, refit the nut to the fuel tank to prevent
it from distorting.
CONNECTION
REFITTING OF THE PUMP AND SENDER UNIT

ASSEMBLY
Special notes
Check that the seal is in good condition and replace it if necessary.
97162S
Fit the seal on the fuel tank first before fitting the
assembly.
Refit the pump and sender unit assembly in the
fuel tank by aligning it so that the indexing arrow
(F) is positioned in line with the longitudinal axis
of the vehicle, pointing towards the rear of the
vehicle.
DI8307
Track
Allocation
A1
Earth
A2
Low fuel level warning light
B1
Sender unit information to instrument

panel
B2
Not used
C1
+ pump
C2
- pump
Checking
97163R7
Indication
Value between
terminals
A1 and B1 (in )
4/4
7 maximum
3/4
54.5 7
1/2
98 10
1/4
155 16
Low fuel
300 20
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INSTRUMENT PANEL
Oil level sensor
83
OPERATION
CHECKING
The sensor consists of a wire with a high

coefficient of resistance. When a current passes
through the wire it does not have the same
thermal conductivity when it is immersed in a
liquid as when it is in the open air.
The sensor resistance must be between 6 and 20

ohms.
After a fixed time a voltage difference is obtained

at the sensor terminals depending on the depth of
immersion of the wire. This voltage difference is
recorded by the electronic unit which manages
the level display function and also controls the
"low oil level" warning light display on the
central liquid crystal display.
The sensor is deemed to be in open circuit for a value higher than 22 ohms.
The sensor is deemed to be in short circuit for a value lower than 4 ohms.
LOCATION
Example : F engine
When the ignition is switched on, the central display shows the oil level in a series of "blocks" for
approximately 30 seconds, before returning to
displaying the trip mileometer and total mileometer functions (or "odometer" function).
NOTE : Turning the trip mileometer reset button
before the end of the timed period will display
the "odometer" function.
LOOKING FOR FAULTS
If a short circuit or an open circuit is detected

when the oil level is measured, the display will immediately show the trip mileometer / clock displays.
98898R1
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INSTRUMENT PANEL
83
F engine
OPERATION
A thermistor transmits a variation in resistance to

a receiver, depending on the coolant
temperature, and a threshold overshoot switch
illuminates the warning light on the instrument
panel when the temperature reaches 118C.
CHECKING
Connect an ohmmeter between track 1 (K and E

engines) or track 2 (F engine) on the sensor and
vehicle earth.
Correct value : 160 to 1 250 .
LOCATION
D engine
12535R1
E engine
11634R3
1 Warning light sensor

2 Gauge sensor
98711R4
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CONTROLS - SIGNALS
Windscreen wiper stalk
REMOVAL -
REFITTING
84
CONNECTION

Remove the two half cowlings under the steering
wheel.
Release the immobiliser antenna ring or the plastic surround from the ignition switch.
Remove the two mounting bolts (A) for the wiper
stalk.
Release the stalk from its mounting and disconnect the connector.
13061R
Track
12970R
NOTE : the steering wheel does not have to be removed.
Allocation
A1
Front timer
A2
Wiper high speed
A3
Wiper low speed
A4
Front washer pump
A5
Not used
A6
Intermittent slow speed
A7
+ after ignition, front wiper
B1
Rear washer pump
B2
Rear timer
B3
Not used
B4
+ after ignition, rear wiper
B5
Earth
B6
Not used
B7
Not used
84-1
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CONTROLS - SIGNALS
Lights stalk
REMOVAL -
REFITTING
84
CONNECTION

Remove the two half cowlings under the steering
wheel.
Remove the two mounting bolts (B) for the lights
stalk.
Release the stalk from its mounting and disconnect the connector.
13062R
Track
12970R1
NOTE : the steering wheel does not have to be removed.
Allocation
A1
Front fog lights
A2
Not used
A3
Rear fog light
A4
Horn
A5
Right hand indicators
A6
Central flasher unit
A7
Left hand indicators
B1
Side lights
B2
+ before ignition, side lights
B3
+ before ignition, dipped headlights
B4
Not used
B5
Dipped headlights
B6
+ before ignition, main beam headlights
B7
Main beam headlights
84-2
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CONTROLS - SIGNALS
Stalk mounting
84
REMOVAL - REFITTING
Special notes for refitting
Disconnect the battery and set the wheels

straight.
Fit the mounting with its components, connect

the various connectors and push the assembly
back against the steering column.
Remove the steering wheel and the two half cowlings (for vehicles with an airbag, refer to the removal of the rotary switch on the following page
or section 88 for special notes on removing the
steering wheel).
Continue refitting and do not lock bolt (C) until

the two half cowlings are refitted, so that the
stalks may be aligned with the dashboard and the
instrument panel.
This operation is made easier by a cut-out section
giving access to bolt (C) in the lower half cowling.
Special notes for vehicles with an airbag

Before removing the assembly, the position of the
rotary switch under the steering wheel must be
noted:
- by ensuring that the wheels are straight on removal so that the strip may be positioned in the
centre,
adhesive tape.
Slacken the bolt (C) then sharply tap the screwdriver to release the cone.
For vehicles with an airbag, observe the recommendations in the section " Special notes for
the rotary switch under the steering wheel" on
the following page or section 88 (drivers airbag).
12970R2
Move the stalk mounting assembly back slightly

and disconnect the connectors.
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CONTROLS - SIGNALS
Rotary switch under steering wheel
This makes the electrical connection between the
steering column and the steering wheel.
84
- the horn connector, if fitted,

straight,
- the half cowlings (3 bolts).
It consists of a strip of conductor tracks (airbag)

whose length is designed to guarantee 2.5
steering wheel turns (steering lock plus safety
margin) on each side.
Disconnect the connector for the rotary switch

and remove it after removing the three mounting
bolts (E).
REMOVAL - REFITTING
Before removing the rotary switch its position

must be noted:
- by ensuring that the wheels are straight on removal so that the track may be positioned in
the centre,
adhesive tape.
IMPORTANT: It is not permitted to operate the

pyrotechnical systems (airbags and pretensioners)
near a source of heat or flame as there is a risk of
triggering.
IMPORTANT : If the steering wheel is removed,

the airbag connector (D) MUST be disconnected.
The airbag has a connector which short circuits if
it is disconnected to prevent incorrect triggering.
If it is being replaced, the new part is supplied ready centred by an adhesive label which will tear off
as soon as the steering wheel is turned for the first
time (fit with the wheels straight).

Remove:
- the airbag cushion by the two torx T30 bolts
(tightening torque : 0.5 daN.m) located behind
the steering wheel and disconnect the connector (D),
12970R3
12973R
84-4
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CONTROLS - SIGNALS
Rotary switch under steering wheel
Ensure the wheels are still straight.
is still immobilised before refitting.
If there is any doubt follow the method for centring described in section 88 "drivers airbag".
Renew the steering wheel bolt each time it is removed (pre-bonded bolt).
Observe the correct tightening torque (4.5
daN.m).
IMPORTANT
follows:

ignition is on,
extinguished.
If the warning light does not operate exactly as
described above, refer to the fault finding section
and test the system using the XRBAG (El. 1288)
(see section 88).
IMPORTANT: if these instructions are not observed, the systems may not operate normally and
may be incorrectly triggered.
84-5
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84
CONTROLS - SIGNALS
Ignition switch
84
REMOVAL - REFITTING
Remove bolt (G) from the ignition switch.
Position the ignition key in position 3 and tilt retaining lugs (H) while releasing the switch.
Set the wheels straight.

Remove:
- the half cowlings,
- the radio or glovebox (depending on equipment),
- the immobiliser antenna ring or plastic surround from the ignition switch (depending on
equipment).
Disconnect the ignition switch connectors (F).
DI8404
13068R
84-6
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WIPERS
85
El. 1294-01
Wiper arm removing tool
REMOVAL OF THE WIPER MECHANISM WITH

MOTOR
Check that the motor is in the park position before refitting the wiper arms.
Make sure that the wiper motor is in the park

position.
Clean the splines on the wiper arm pins using a

metal brush.

Note the position of the wiper arms.
Refit the wiper arms, locating the blade on the

marks made on removal.
Open the bonnet.

Fit new nuts and torque tighten to 1.8 daN.m (
15 %) using a torque wrench.
Remove:
- the wiper arms using tool El. 1294-01,
- the scuttle panel grille seal,
- the scuttle panel grille after removing the two
side covers and the two bolts and disconnecting
the washer pipe.
13069R
Remove the three mechanism mounting bolts (A).

Disconnect the motor and release the assembly.
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WIPERS
85
REMOVING THE MOTOR ALONE
Make sure that the wiper motor is in the park position.
Refit the linkage to the motor on the mark made

during removal.

metal brush.
Open the bonnet.

Remove:
- the wiper arms using tool El. 1294-01,
the washer pipe.

13069R1
Remove:
- the motor shaft nut (B) and release the linkage
after noting its position,
- the three motor mountings.
Release the motor after disconnecting it.
85-2
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WIPERS
Rear screen wiper
Tailgate version
REMOVING THE MOTOR
Make sure that the wiper motor is in the park position.

Remove:
- the wiper arm mounting nut,
- the wiper arm from its pin using special tool
El. 1294-01,
- the inner door handle on versions with swinging doors (1 bolt),
- the tailgate trim (clipped).
Disconnect connector (A) for the wiper motor.
Remove the three bolts (B) mounting the motor
and release it.
13071R

Version with swinging doors
Check that the motor is in the park position before refitting the wiper arm.
Clean the splines on the wiper arm pin using a metal brush.
Refit the wiper arm, locating the blade on the
Fit a new nut and torque tighten to 1.2 daN.m (
13070R
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WIPERS
Electric washer pump
This vehicle is fitted with a bidirectional electric
pump (E) which feeds fluid from the same reservoir to both the front and rear screen washers according to the electrical feed to the two track
connector (D).
REMOVAL - REFITTING
To reach the washer pump it is necessary to remove:

- the wiper arms using tool El. 1294-01 after noting their positions,
the front washer pipe.
Two cases may be considered:

Track
Feed
+ 12 Volts
Earth
85
The pipes are fed via the white end piece (1)
whilst the front windscreen washer is in operation.
Track
Feed
Earth
+ 12 Volts
The pipes are fed via the black end piece (2) whilst
the rear screen washer is in operation.
13069R2
When removing the washer pump (E), mark the

two pipes (1 and 2) before disconnecting them.

metal brush.
DI8503

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Relay plate
POSITION AND ALLOCATION
(Most complete plate)
12965R
The relays are located above the fuse board at the

bottom of the dashboard. To reach them, open
the fuse box cover.
1
2
3
4
5
6
7
Lights on reminder buzzer

Front wiper timer
Flasher unit
Rear wiper timer
Heated rear screen relay
After ignition relay (electric window feed)
Front fog lights relay
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87

Relay plate
LIGHTS ON REMINDER BUZZER
FRONT WIPER TIMER
8
4
87
L
1
5
2
95182R4
95182R2
CONNECTION
Track
CONNECTION
Allocation
Track
Allocation
+ after ignition feed
+ timer
Door switch
Earth
+ side lights
Wiper control
Wiper park
+ washer pump
NOTE : The track numbers are as for the component.
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Relay plate
FLASHER UNIT
87
REAR WIPER TIMER
R
+
8
4
C
1
5
2
95182R5
95182R2
CONNECTION
Track
CONNECTION
Allocation
Track
Allocation
+ indicators
+ timer
+ central control
Earth
Earth
+ rear wiper
Not used
Earth
+ washer pump
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Relay plate
HEATED REAR SCREEN RELAY
AFTER IGNITION RELAY

(electric window feed)
87
86
87a
87
87
85
86
87a
30
85
30
95182R6
95182R6
CONNECTION
Track
CONNECTION
Allocation
Track
Allocation
86
+ relay control
86
+ accessories feed
85
Earth
85
Earth
30
+ before ignition feed
30
87a
Not used
87a
Not used
87
Rear screen
87
+ after ignition feed via relay (electric

window feed)
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Relay plate
FRONT FOG LIGHTS RELAY
13058R
CONNECTION
Track
Allocation
85
+ relay control
86
Earth
30
87a
Not used
87
Front fog lights
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WIRING
Heated rear screen
The heated grid applied to the inner face of the
window may be accidentally cut, making the part
of the grid affected inefficient.
DETECTION
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BETWEEN LINES C AND A
Connect the - wire of the voltmeter to the - terminal of the rear screen.
The exact point of the disconnection may be determined by means of a voltmeter.
Place the + wire of the voltmeter on a filament

on the + terminal side of the rear screen (line C);
essentially a voltage equal to the battery voltage
must be obtained.
It is possible to repair such faults by applying the

heated rear screen varnish sold under Part
Number 77 01 421 135 (2 g pack).
Move the + wire towards line A (arrow); the voltage drops progressively.
If the voltage drops quickly, the filament must be
cut at this point (carry out this operation for each
filament).
DETERMINING THE EXACT POINT OF

DISCONNECTION WITH A VOLTMETER.

Switch on the heated rear screen feed.
DETECTION
BETWEEN LINES B AND A
Connect the + wire of the voltmeter to the +

feed terminal of the rear screen.
Place the - wire of the voltmeter on a filament on
the - terminal side of the rear screen (line B). A
voltage approximately equal to battery voltage
must be obtained.
Move the - wire towards line A (arrow): the voltage drops progressively.
DI8815
If the voltage drops quickly the filament is cut at

that point (carry out this operation for each filament).
REPAIR OF THE FILAMENT
Clean the section to be treated locally to remove

all dust or grease, preferably using alcohol or a
glass cleaner, and wipe with a clean, dry cloth.
To obtain a regular line during the repair, apply
scotch adhesive tape on either side of the section
to be repaired, leaving the conducting line free.
Before applying the varnish, shake the bottle to
prevent the deposit of silver particles on the bottom of the bottle.
DI8814
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Heated rear screen
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REPAIR
Using a small brush proceed to carry out the repair, applying a sufficiently thick coat. Where successive coats are applied allow drying time between each coat. Do not repeat the operation
more than three times.
However, if there is a run it will be possible to eliminate it using the point of a knife or razor blade
once the product is sufficiently hardened (after several hours).
The adhesive tape acting as a guide must not be
removed for one hour after application. The tape
must be torn off perpendicularly to the resistance
in the direction of the arrow. The varnish, applied
at an ambient temperature of 20oC, is completely
dry in three hours. At a lower temperature the
drying time should be slightly increased.
77324S
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. GENERAL
2.
These vehicles are equipped with an infrared or

radio frequency remote control with rolling code,
which prevents the code from being copied.
Switch the ignition off and enter command

mode G32*.
From this moment, the operator has 10 seconds to carry out the next operation.
When a transmitter is replaced it will therefore be

necessary to resynchronise it so that the transmitters are returned to phase with the decoder unit.
NOTE: The 10 seconds are shown by the illumination of the red immobiliser warning light
and bargraph 17 LH on the XR25 (code D56,
fiche n 56).
This remote control is only used for locking and

unlocking the opening elements (it has no effect
on the immobiliser).
3.
IMPORTANT: this system cannot operate with

three remote controls (the decoder unit can only
manage two different rolling codes).
Press the remote control twice (the doors lock

and unlock and the red warning light extinguishes).
NOTE :
- When replacing a key head, resynchronisation of the second remote control (if fitted)
is not always necessary.
Check that the second control operates,
otherwise resynchronise it.
THE TRANSMITTER (PLIP)
Replacing or adding a remote control with immobiliser function without replacing the decoder
unit.
- If both remote controls (if fitted) are desynchronised, two resynchronisation procedures will have to be carried out (one for
each remote control).
Order a spare key head using the number in the

head of one of the old keys or the label normally
attached to the keys when the vehicle is delivered
(eight alphanumeric characters).
IMPORTANT: To ensure that the infrared code

is correctly transmitted it is essential to direct
the transmitter correctly towards the receiver.
If the procedure fails it will be necessary to
restart from the beginning (infrared remote
control only).
If a key is being added or has been lost, remember

to order the insert with the key number.
Carry out the special resynchronisation procedure
using the XR25.
This procedure resets the remote control into sequence with the decoder unit (rolling code) and
should only be used if the decoder unit is not
being replaced (with immobiliser only).
1.
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4.
The procedure is complete - check that the

doors lock correctly.
Ignition off, connect the XR25 (ISO selector on

S8, code D56).
For vehicles fitted with an infra-red remote
control, enter command mode G04* (forced
protection mode) then switch the ignition on
again and enter the vehicles security code
(see procedure in section 82).
For vehicles fitted with a radio frequency remote control, go to point 2.
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WIRING
Replacing or adding a remote control without immobiliser function without replacing the decoder
unit.
3.
If a key is being added or has been lost, remember

to order the insert with the key number.
- If both remote controls (if fitted) are desynchronised, two resynchronisation procedures will have to be carried out (one for
each remote control).
Carry out the special resynchronisation procedure

using the XR25.
This procedure resets the remote control into sequence with the decoder unit (rolling code) and
should only be used if the decoder unit is not
being replaced (with immobiliser only).

control only).
Ignition off, connect the XR25 (ISO selector on

S8, code D56).
4.
2.

and unlock).
NOTE :
- When replacing a key head, resynchronisation of the second remote control (if fitted)
is not always necessary.
Check that the second control operates,
otherwise resynchronise it.
If the vehicle does not have an immobiliser, the remote control does not have a special number. A
key head without a number may therefore be ordered.
1.
88
Enter command mode G32* (the doors lock

and unlock).

Simple resynchronisation procedure

This procedure allows the remote controls to be
reset with the decoder unit (rolling code).
NOTE: The 10 seconds are shown by the illumination of bargraph 17 LH on the XR25 (code
D56, fiche n 56).
This procedure is used:

- when the remote control code no longer lies
within the reception range of the decoder unit
(over 1,000 consecutive presses on the remote
control, away from the vehicle).
- when replacing a decoder unit alone (new decoder unit),
- when replacing a remote control if the decoder
unit is new (replacing a kit).
REMINDER: when replacing or adding a remote
control with immobiliser function without replacing the decoder unit, refer to "Replacing or adding a remote control with or without immobiliser function without replacing the decoder unit"
(specific resynchronisation procedure).
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Ignition off:
1.
88
THE DECODER UNIT
Press and hold the central door locking button

for a few seconds until the doors lock and unlock.
The decoder unit is located in the left hand side of

the dashboard (A).
NOTE: The 10 seconds are shown by the illumination of the red immobiliser warning light
(if fitted) and bargraph 17 LH on the XR25
(code D56, fiche n 56).
2.

and unlock and the red warning light extinguishes, if fitted).
NOTE : If both remote controls (if fitted) are
desynchronised, two resynchronisation procedures will have to be carried out (one for each
remote control).
control only).
3.
12967R
Removal - Refitting

The dashboard must be partially removed to remove the decoder unit.

Remove:
- the steering wheel with the wheels straight,
- the half cowlings under the steering wheel,
- the knee protector under the steering column,
- the lights and wiper controls,
- the instrument panel surround,
- the instrument panel,
- the ashtray, its mounting and the two dashboard mounting bolts on the heating unit,
- the trim at the bottom of the dashboard on the
drivers side,
- the two speaker grilles on the dashboard,
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Move the dashboard as far back as possible, disconnect the decoder unit and remove the two
mounting bolts (B) using a small ratchet fitted
with a Torx 20 socket.
88
REMOTE CONTROL RECEIVER
This is located near to the courtesy light.

It receives the remote control code and transmits
it to the decoder unit. Its function is to amplify the
signal.
The remote control receiver is replaced independently of the transmitter and the decoder unit (it
is not coded).
Removal - Refitting
Remove:
- the light diffuser, lifting it with a small screwdriver at points (A),
13065R
Replacement
For vehicles fitted with an immobiliser, refer to
section 82 (programming procedure). The decoder
unit is common to the immobiliser.
For vehicles without an immobiliser, carry out a
resynchronisation operation.
NOTE : Fault finding for the remote control system may be carried out using the XR25 (fault finding fiche n 56).
13073R
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- the two courtesy light console mounting bolts
(B).
88
Remove the receiver and its printed circuit by separating tabs (F) (example: infrared receiver).
13072R
13075R
Release the assembly forwards and disconnect the

connector.
When refitting the mounting (D), check that the

switch (E) is positioned towards the right (see diagram) to avoid damaging the contacts on reclipping the assembly.
After removing the bulb, remove bolt (C) and unclip mounting (D).
13074R1
13074R2
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The airbag cushion which inflates from the

centre of the steering wheel to protect the
drivers head.
GENERAL
IMPORTANT : all work on the airbag and

pretensioner systems must be carried out by
qualified personnel who have received the proper
training.
There are 3 safety systems which supplement the

seat belt.
If a frontal impact is sufficiently strong, the electronic unit controlling these systems triggers:
The pretensioners which restrict the seat belts

for the front seats so that they are pressed
against the body.
96310-1S
The airbag module which inflates from the

dashboard to protect the front passengers
head.
MAB11197S
98124S
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FUNCTION AND OPERATION OF THE AIRBAGS AND PRETENSIONERS
1) Function
In the event of an accident, the airbag prevents the head striking the steering wheel or dashboard.
It also reduces the maximum acceleration of the head, by absorption.
2) Trigger threshold
Generally speaking, there are four different basic situations.
1) FRONTAL IMPACT AGAINST A
OBSTACLE
2) OFFSET IMPACT AGAINST A
The trigger speed depends on the obstacles

surface. The softer the surface, the higher the
speed.
In this case, the airbag trigger speed depends on

the angle of impact .
The greater the angle, the higher the vehicle
speed for triggering.
The pretensioner generally triggers at a lower

speed than the airbag.
DI8816
A
B
OBSTACLE
DI8817
Direction of travel
Centre of gravity
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3) FRONTAL IMPACT AGAINST A FLEXIBLE

OBSTACLE
4) OFFSET IMPACT AGAINST A FLEXIBLE

OBSTACLE
The airbag trigger speed depends in this case on

the degree of flexibility of the bodywork of the
vehicle hit.
Here the airbag trigger speed depends on the angle of impact and the flexibility of the vehicle hit
in the direction of travel.
The more flexible the other vehicle, the higher the

trigger speed (for vehicles of equal flexibility and
100 % contact, the speed is higher than 40 km/h)
(relative speed).
The vehicle speed for airbag triggering is greater

when the angle of impact is greater and the
flexibility of the vehicle hit is high.
DI8818
A
B
C
DI8819
Direction of travel
Centre of gravity
Immobilised vehicle
5) SUMMARY AND CONCLUSION
- The airbag only reacts to deceleration in the direction of driving. A side impact or the vehicle rolling over
cannot trigger the airbag.
- The vehicles projectile energy is transformed into deformation energy of the front part of the vehicle.
Deceleration is greater when the deformation of the vehicle hit is less, meaning that the airbag will trigger
much earlier.
- The minimum speed at which the airbag is triggered is greater when the angle of impact is large (see
above).
- If, in a frontal impact, there is no deformation at the front pillars, or engine - gearbox - sub-frame impact,
the fact that the airbag was not triggered cannot be considered as a fault since the trigger speed may not
have been reached.
- The pretensioners always trigger at a lower speed than the airbag.
- Experience has shown that the impact speeds given by customers are often not correct. Their reactions are
generally reduced by shock: there is almost always confusion between the cruising speed before the impact and the actual speed of the impact which is thankfully much lower in most cases.
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Various vehicle configurations are possible:
SPECIAL TOOLING
Vehicle fitted with:
PRESENTATION
88
- pretensioners only,
XR25
- pretensioners and drivers airbag,

- pretensioners and drivers airbag and passengers airbag.
NOTE :
A vehicle fitted with a drivers airbag will be

identified by a label in the bottom corner of
the windscreen on the drivers side, and by the
word "Airbag" in the centre of the steering
wheel.
If a passenger airbag is fitted, a second label is
located in the lower corner of the windscreen
on the passenger side and the word "Airbag" is
located on the dashboard on the same side.
Each time the windscreen is replaced, remember
to fit the labels showing that the vehicle is fitted
with airbags.
92656S
The new 30-track computers are provided with

the K and L lines for fault finding with the XR25
(except for vehicles with pretensioners only).
These labels are available in a kit Part Number :

77 01 205 442.
This enables computer faults or faulty lines to be

detected in the system (see section on fault finding).
NOTE: before each operation an auxiliary function enables the ignition lines to be de-activated
to prevent the risk of triggering the pyrotechnic
gas generators.
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XRBAG TEST UNIT (El. 1288)
88
XRBAG 30-TRACK ADAPTER
96833G
This unit is a tool specifically designed for testing

and fault finding on airbag devices and seat belt
pretensioners.
It enables electrical measurements to be carried
out on the different lines in the systems.
(See "fault finding" section).
PRD99498
This bornier is connected instead of the computer,

fitted with a single 30-track connector.
It enables all the ignition lines to be checked by
means of the XRBAG, the supply voltage of the
computer to be measured, and the airbag warning light on the instrument panel to be illuminated.
IMPORTANT: It is not permitted to carry out measurements on these systems with an ohmmeter or
any other electrical measuring instrument: there
is a risk of triggering due to the operating current
of the instrument.
Terminals also enable the continuity checks to be

carried out on the diagnostic lines, the warning
light lines and the feed to the computer (see section on fault finding).
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DUMMY AIRBAG IGNITION MODULE
DESTRUCTION UNIT
A dummy airbag ignition module housed in a

small red box is supplied in the case containing
the XRBAG test kit.
To avoid all possible risks of an accident the

pyrotechnic gas generators in the airbags and seat
belt pretensioners must be triggered before the
vehicle or the individual part is scrapped.
It has the same electrical characteristics as a real

ignition module and its purpose is to replace the
airbag cushion when it is being checked for faults.
It is ESSENTIAL to use the tool Ele. 1287 for this

purpose.
Contact your After Sales Head Office for further

information.
96832R
Refer to the section entitled "Destruction

procedure".
IMPORTANT: Do not trigger pretensioners which

must be returned under warranty for a stalk problem. This makes analysis by the supplier impossible.
Return the part in the packaging of the new part.
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When refitting the computer, it MUST be mounted on the vehicle before its connectors are reconnected.
COMPUTER
Several types of unit may be found:

- one computer for pretensioners only.
The arrow on the computer must point towards

the front of the vehicle.
- one computer for pretensioners and airbag(s).

Vehicle fitted with airbag(s)
Depending on function, these computers have:
- an electromagnetic safety sensor,
- a decelerometer for the airbags
- an ignition circuit for the different pyrotechnic systems,
- a power reserve,
- a diagnostic and detected fault storage circuit
(except pretensioner only),
- a control circuit for the warning light on the
instrument panel (except pretensioner only),
- a K - L communication interface via the diagnostic socket (except pretensioner only).
Lock the computer using the XR25 and command

G80* (ISO selector on S8 code D49).
When this function is active, all the trigger lines
are inhibited, the airbag warning light on the instrument panel and bargraph 14 LH on the XR25 illuminate (new computers are supplied in this
condition).
When refitting the computer:
- Mount it on the vehicle (the arrow on the
computer must point towards the front of the
vehicle).
- Connect the 30 track computer connector and
carry out a check using the XR25.
IMPORTANT
Before removing the computer:
If everything is correct, unlock the computer using

command G81*.
Vehicle with pretensioners only (no air-bag) :

- Switch off the ignition.
- Remove the feed fuse (see fuse allocation) and
wait for 5 minutes for the reserve capacity to
discharge.
- Disconnect the computer connector to avoid
any risk of triggering.
- Ensure no-one is in the passenger compartment
during the complete operation on the computer.
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LOCATION OF THE COMPUTER
88
COMPUTER WITH AIRBAG(S)
It is located on the tunnel in the central console.
98716S
13059S
IMPORTANT :
The computer must be replaced after the pretensioners and airbags have been triggered.
Certain components will lose their nominal characteristics after the trigger energy has passed
through them.
COMPUTER WITHOUT AIRBAG
When replacing an airbag(s) computer, the

computer must be unlocked using the XR25 before it is used (see "Fault finding" section " : interpretation of bargraph 14 LH side).
IMPORTANT :When refitting the computer, it

MUST be mounted on the vehicle before its
connectors are reconnected. The arrow on the
computer must point towards the front of the
vehicle (tightening torque : 0.4 daN.m).
NOTE: The 30 track connector for the computer
short circuits the various trigger lines as soon as it
is disconnected. Shunts located opposite each pretensioner line or airbag line prevent the incorrect
triggering of these systems (by aerial effect for
example).
98715S
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WIRING
IMPORTANT :
CONNECTION
When carrying out an operation under the vehicle (exhaust, bodywork, etc.), do not use a
hammer or transmit impacts to the floor without having removed the pretensioner fuse
and waited 5 minutes for the reserve capacity
to discharge (see section "Fuse allocation", in
the "Wiring diagram" technical note) or for vehicles with the airbag function, wait for 2 seconds for the unit to discharge automatically.
2 track connector
(located under the front seats)
88
Pretensioner triggering.
NOTE: The pretensioner trigger line connectors
short circuit (tab holder side) when they are disconnected, which prevents incorrect triggering of
the systems (aerial effect for example).
When fitting an electrical accessory in After

Sales, (speaker, alarm unit or any equipment
which may create a magnetic field), it must not
be located near the airbag and pretensioner
computer.
30 track connecter (fullest version)
Track
NOTE : The computer and ignition modules are
normally fed from the vehicle battery.
A reserve capacity is however included in the
computer in case the battery is disconnected at
the start of the impact.
Allocation
+ Drivers pretensioner
- Drivers pretensioner
+ Passengers pretensioner
- Passengers pretensioner
+ After ignition
+ Passengers airbag (line 1)
- Passengers airbag (line 1)
Warning light
Earth
10
+ Drivers airbag
11
- Drivers airbag
12
Diagnostic line "K"
13
+ Passenger airbag (line 2)
14
- Passenger airbag (line 2)
15
Diagnostic line "L"
16
17
Shunt
18
19
Shunt
20
Not used
21
22
Shunt
23
Not used
24
Not used
25
26
Shunt
27
Not used
28
29
Shunt
30
Not used
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These systems are not triggered in the case of:

- a lateral impact,
- a rear impact.
OPERATIONS ON THE TRIGGER LINES
If a fault is noted on one of these lines, the

component must be renewed and not repaired.
When it is triggered the pyrotechnic gas

generator produces an explosion combined with
light smoke.
This safety equipment cannot be subjected to any

conventional wiring or connector repair operations.
NOTE : With pretensioners only,the computer has

a single sensor (electromechanical).
The airbag trigger wiring is integrated into the

passenger compartment wiring loom . To make
replacement easier, cut the two ends of the faulty
wiring and run the new wiring along the same
routing, alongside the passenger compartment
wiring loom.
IMPORTANT : When fitting the new wiring, ensure it is not in danger of being cut or rubbed and
that the original wiring cleanliness is respected.
IMPORTANT : the systems MUST be checked by

means of the XRBAG , following:
- an accident which has not given rise to
triggering,
- theft or attempted theft of the vehicle,
- before the sale of a used vehicle.
NOTE : The trigger lines are supplied by the Parts

Department in a kit containing both airbag and
pretensioner wiring.
WARNING LIGHT ON THE DASHBOARD
OPERATION WITH AIRBAG(S) AND PRETENSIONER

EQUIPMENT
This warning light controls the pretensioners and

airbags, except for vehicles fitted with pretensioners only.
When the ignition is switched on, the

warning light illuminates for a few
seconds then extinguishes.
It should illuminate for a few seconds when the

ignition is switched on, then extinguish (and
remain extinguished). If it does not illuminate
when the ignition is switched on, or illuminates
when the vehicle is being driven, there is a fault in
the system (see fault finding section).
This computer is then on standby and notes decelerations of the vehicle using the signal measured
by the integral decelerometer.
When a frontal impact of sufficient strength occurs it triggers the simultaneous ignition of the
pyrotechnic generators of the two seat belt pretensioners after receiving confirmation of detection of an impact by the electromechanical safety
sensor.
Under the action of the gases generated by the
system, a piston is displaced in its cylinder,
carrying with it a cable connected to the
corresponding central catch, thus enabling the
seat belt to be retracted (see pretensioner
section).
If the frontal impact is greater than this, the decelerometer triggers the ignition of the pyrotechnic
gas generators which inflate the driver and passenger airbags once the impact has been validated by the electromechanical safety sensor.
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SEAT BELT PRETENSIONERS
When it is triggered the system is able to retract

the seat belt catch by up to 70 mm (maximum)
DESCRIPTION
They are mounted on the side of the front seats.
DI8802
The components of the pretensioner cannot be separated.
96438S
A pretensioner includes:
- a special seat belt catch (A),
- a pyrotechnic gas generator and ignition
module (B).
DI8801R
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SEAT BELTS
REFITTING
When the pretensioners are triggered the front

seat belt or belts must be systematically replaced
if they were attached during the pretensioning (if
there is any doubt about wearing the belt it must
be replaced). The physical stresses exerted on the
catch are transmitted to the inertia reel and may
damage its mechanism.
Ensure that the wiring is correctly routed and the

wiring mounting points are correct under the
seat.
IMPORTANT :
For vehicles with pretensioners only (without

fault finding on the XR25) :
Before reconnecting the pretensioners (connector under the seat), check the condition of the
equipment using the XRBAG (El. 1288) on the
two pretensioners (see fault finding section),
On the pretensioners side, ensure the connector (C) is properly connected (clipped fully
home).
REMOVAL
IMPORTANT: The pyrotechnic systems (pretensioners) must not be handled near a heat source or
flame; there is a risk of triggering.
For vehicles with pretensioners and airbag :

Test using the XR25 after reconnecting the
connectors. Unlock the computer using
command G81* if everything is correct.
On the pretensioners side, ensure the connector (C) is properly connected (clipped fully
home).
NOTE: For vehicles with airbag(s), the computer

may be locked using the XR25 and command
G80* (ISO selector on S8 code D49) during the
operation.

condition).
REMINDER: if the pretensioners have been triggered their computer MUST be replaced.
After the operation, carry out a check using the

XR25. If everything is correct, unlock the computer using command G81*.
Remove:
- the pretensioner connector under the front
seat,
- the pretensioner assembly, after removing its
protective trim.
IMPORTANT : before scrapping a non-triggered

pretensioner it MUST be destroyed in accordance
with the method for destruction (except for parts
returned under warranty) (see section
"Destruction procedure").
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Warning light
on the instrument panel
shows the correct operation of the drivers airbag,
the passengers airbag and the pretensioners (depending on equipment).
DRIVERS AIRBAG
DESCRIPTION
It is located in the steering wheel cushion.

NOTE : this system is operational after the ignition
has been turned on. A vehicle fitted with a drivers
airbag will be identified by a label in the bottom
corner of the windscreen on the drivers side, and
by the word "Airbag" in the centre of the steering
wheel.
It comprises:
- an inflatable cushion,
- a pyrotechnic gas generator and ignition
module.
These components cannot be separated.
Each time the windscreen is replaced, remember

to fit the labels showing that the vehicle is fitted
with airbags.These labels are available in a kit Part
Number : 77 01 205 442.
REMINDER : The computer must be replaced after
the airbag has been triggered. Certain components will lose their nominal characteristics after
the trigger energy has passed through them.
96310-1S
NOTE : when the airbag inflates, the steering

wheel cover is torn.
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Remove:
- the airbag cushion by its two Torx bolts (tightening torque: 0.5 daN.m) located behind the
steering wheel and disconnect connector (D),
STEERING WHEEL AIRBAG AND ROTARY SWITCH

REMOVAL
IMPORTANT: The pyrotechnic systems (airbag
and pretensioners) must not be handled near a
heat source or flame; there is a risk of triggering.
IMPORTANT : If the steering wheel is removed,

the airbag connector MUST be disconnected (D) .
The airbag connector short circuits when it is disconnected to prevent incorrect triggering.
NOTE: For these vehicles, the computer may be

locked using the XR25 and command G80* (ISO
selector on S8 code D49) during the operation.

condition).
12973R

- the steering wheel after straightening the
wheels.

XR25. If everything is correct, unlock the computer using command G81*.

airbag cushion it MUST be destroyed in accordance with the method for destruction (see section "Destruction procedure": destruction of part
removed from the vehicle).
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SPECIAL NOTES FOR THE ROTARY SWITCH
UNDERNEATH THE STEERING WHEEL
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REFITTING
Ensure the wheels are still straight.

This makes the electrical connection between the
steering column and the steering wheel.

is still immobilised before refitting.
It consists of a strip of conductor tracks (airbag)

whose length is designed to guarantee 2.5 steering wheel turns (steering lock plus safety margin)
on each side.
If this is not the case, follow the centring method

described below:
- rotate the upper section of the rotary switch
anti-clockwise. The approach to the extreme
position, shown below, is indicated by a certain stiffness (do not force).
REMOVAL
Before removing the rotary switch its position

must be noted:
by ensuring that the wheels are straight on removal so that the track may be positioned in
the centre,
by immobilising the rotary switch rotor using
adhesive tape.
PRD99529
- then lightly rotate the upper section of the part

clockwise and check that the rotary switch is actually in the position shown below.
12970R4
If it is being replaced, the new part is supplied ready centred by an adhesive label which will tear off
as soon as the steering wheel is turned for the first
time (fit with the wheels straight).
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SPECIAL CASES
Where work is being done involving removal of

the steering, engine, transmission, etc., requiring
uncoupling of the rack and steering column:
the steering wheel must be immobilised using a
"steering wheel locking" tool.
IMPORTANT : to avoid destroying the rotary
switch under the steering wheel it is IMPORTANT
to maintain the fixed position of the steering
wheel throughout the operation.
If there is any doubt about its correct centring the

steering wheel must be removed so that the centring method described above can be applied.
REMINDER: in this case, only qualified personnel
who have received the correct training must work
on the airbag.
PRD99530
- again rotate the part in the clockwise direction

by making two complete turns, and after this
operation make sure that the rotary switch is
actually in the position previously described.
IMPORTANT :
Refit the steering wheel and replace the prebonded bolt, ensuring its correct tightening torque (4.5 daN.m).
Carry out a check using the XR25 to ensure that

there is no fault in the system.
When everything has been refitted:
Unlock the computer with command G81* .
Reconnect the airbag cushion and secure it to the

steering wheel, tightening torque (0.5 daNm).
Check that the airbag warning light illuminates

for 3 seconds after the ignition is switched on
then extinguishes and remains extinguished.

above, refer to the "Fault finding" section and
check the system using the XRBAG (El. 1288) or
XR25.
IMPORTANT:
If these procedures are not correctly observed the
systems may not operate correctly or may be
accidentally triggered.
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PASSENGER AIRBAG MODULE

DESCRIPTION:
It is located in the dashboard, opposite the front

seat passenger.
It comprises:
- an inflatable cushion,
- two pyrotechnic gas generators and ignition
modules.
LOCATION
98124S
NOTE : When it is triggered, the airbag opens the

plastic cover of the passenger airbag module.
Warning light
on the instrument panel
shows the correct operation of the airbags and
the pretensioners.
NOTE : this system is operational after the ignition
has been turned on. A vehicle fitted with a passengers airbag will be identified by a label in the
bottom corner of the windscreen on the passengers side, and by the word "Airbag" on the dashboard on the same side. Two additional labels on
the front window and the side of the dashboard
indicate that a child seat cannot be fitted to the
front seat. The passenger must not set his feet on
the dashboard or stick or pin objects to the dashboard (refer to the Drivers Handbook).
13060S
The components of the airbag module cannot be

separated.
Each time the windscreen (or passenger door window) is replaced, remember to fit the labels showing that the vehicle is fitted with airbags.These
labels are available in a kit Part Number : 77 01
205 442.
REMINDER : The computer must be replaced after
the airbag has been triggered. Certain components will lose their nominal characteristics after
the trigger energy has passed through them.
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Accessibility of passenger airbag ignition modules for fault finding
88
REMOVAL
The dashboard must be removed to remove the

passenger airbag module (see "Removing refitting the dashboard", section 83).
The dashboard must be removed to reach the passenger airbag ignition modules.
IMPORTANT : The ignition module must be
checked using the XRBAG as indicated in the
"Fault finding" section.
Then remove the airbag module (four nuts).
REPLACING THE PASSENGER AIRBAG MODULE
IMPORTANT: The pyrotechnic systems (airbag

and pretensioners) must not be handled near a
heat source or flame; there is a risk of triggering.
NOTE: For these vehicles, the computer may be

locked using the XR25 and command G80* (ISO
selector on S8 code D49) during the operation.

condition).
13064S
IMPORTANT : When the passenger airbag module

is triggered, the damage to its mountings means
that the dashboard must be renewed.

XR25.
If everything is correct, unlock the computer using
command G81*.

airbag it MUST be destroyed in accordance with
the method for destruction of the drivers airbag
(see section "Destruction procedure": destruction
of part removed from the vehicle).
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REFITTING
IMPORTANT : The following safety advice MUST
be followed when refitting or replacing a passenger airbag module. If these instructions are not
followed the system may not operate normally
and could even cause a risk for the vehicle occupants.
IMPORTANT :
Refitting is the reverse of removal. The tightening

torque of the 4 module mounting bolts
(0.6 daN.m) MUST be observed.
Renew the "System tamperproof " label with a
blue After Sales label sold in kit Part Number
77 01 205 356 for all types.
Remember to remove all foreign bodies (bolts,
clips) when fitting the airbag.
PRD99498
IMPORTANT :
If the measurements are correct:

Disconnect the dummy ignition module.
Connect the wiring to the passenger airbag
ignition module (by offering up the dashboard)
and connect the white 2 track measuring
connector of the XRBAG once more to wiring
(C) of the adapter, and the measurement
should be between 1.8 and 4.6 .
Before reconnecting the passenger airbag module

and refitting the dashboard, the system wiring
must be checked.
Fit a dummy ignition module (El. 1288) to the
passenger airbag module connector.
Connect the 30 track adapter of the XRBAG to the
orange 30 track connector on the computer
wiring.
If the measurements are correct:

Refit the dashboard.
Use the XR25 to check no faults are present in
the system.
Unlock the computer using command G81*.
Check that the airbag warning light illuminates
for 3 seconds when the ignition is switched on
then extinguishes and remains extinguished.
After supplying power to the XRBAG (battery),

connect the white 2 track measuring connector to
wiring (C) of the adapter, and the measurement
should be between 1.8 and 4.6 .

above, or the values measured are incorrect, refer
to the "Fault finding" section.
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DESTRUCTION PROCEDURE
Destruction of the part fitted to the vehicle
In order to avoid any risk of an accident, the pyrotechnic gas generators must be triggered before
the vehicle is scrapped or the part is scrapped.
Move the vehicle outside the workshop.

Connect the destruction tool to the connector (1)
under the front seat using the appropriate lead.
Tool El. 1287 must be used for this.

Unroll the wiring of the tool so you are
sufficiently far away from the vehicle
(approximately 10 metres) when the device is
triggered.
Connect the two feed wires on the tool to a
battery.
After checking that there is no-one nearby, carry
out the destruction of the pretensioner by pressing the two buttons on the tool at the same time.
96832R
PRETENSIONERS
IMPORTANT: Do not trigger pretensioners which
must be returned under warranty for a stalk problem. This makes analysis by the supplier impossible.
Return the part in the packaging of the new part.
96438R
Carry out the same operation for the 2nd pretensioner.

NOTE : if the pretensioner cannot be triggered
(ignition module faulty), return the part in the
packaging from the new component to ITG
(Service 0428).
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Cover the assembly with a stack of 4 old tyres.
Destruction of the part removed from the vehicle

Proceed in the same manner as for the airbag
(removed part).
DRIVERS AIRBAG

Carry out the operation outside of the workshop.
After connecting the appropriate wiring, set the
airbag cushion on 2 blocks of wood to avoid
damaging the connector against the ground.
96835S
Unroll the wiring of the tool so you are

sufficiently far away from the vehicle
(approximately 10 metres) when the device is
triggered and connect it to the airbag cushion
wiring.
Connect the two feed wires on the tool to a
battery.
96834S
After checking that there is no-one nearby, carry

out the destruction of the airbag by pressing the
two buttons on the tool at the same time.
NOTE : if the airbag cannot be triggered (ignition
module faulty), return the part in the packaging
from the new component to ITG (Service 0428).
PASSENGER AIRBAG

Proceed in the same manner as for the drivers
airbag (removed part).
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General

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

All copyrights reserved by Renault.

The methods may be modified as a result of changes introduced by the

07 VALUES AND SETTINGS

All dimensions are expressed in millimetres (mm) unless otherwise indicated.

Tightening torques given without a tolerance must be accurate to within:

Manual gearbox type

200 CPOV 3250

LOCATION OF VEHICLE IDENTIFICATION PLATE

1 Type mines of the vehicle and chassis number

Technical specifications of the vehicle

Safety symbol (special precautions to be taken when carrying out operations).

SPECIAL TOOLING REQUIRED

Cha. 280 -02

Adaptable cross piece for trolley jack

If a trolley jack is used, appropriate axle

When putting the vehicle on axle stands, they

It is forbidden to lift the vehicle by supporting its

TROLLEY JACK AT THE SIDE

Use cross piece Cha. 280-02.

These must be positioned level with the tool kit

Various cases have to be considered:

2 - REMOVING - REFITTING THE ENGINE AND

As a general rule, never use a 2 post lift whenever

In this particular case, the vehicle body must be

If this is not possible, place the lifting pads

"MOBIL CVJ" 825 Black star

HARDENER KIT (RHODORSEAL 5661)

AUTO joint blue

LUBRICANT CLEANING AGENTS

Engine drain plug spanner

DRAINING : plug (1)

FILLING: plug (2)

DRAINING: plug (1)

For topping up or filling, use ELF RENAULTMATIC

D7F - E7J - F8Q ENGINES

VALUES AND SETTINGS

VALUES AND SETTINGS

+10 C +20 C +30 C

* Check with dipstick

VALUES AND SETTINGS

0 C +10 C +20 C +30 C

+10 C +20 C +30 C

* Check with dipstick

VALUES AND SETTINGS

All countries: TRANSELF TRX 75 W 80 W

Brake fluids must be approved by the Technical

ELF RENAULT MATIC D2

MOBIL ATF 220

VALUES AND SETTINGS

SPECIAL TOOLING REQUIRED

Tool for checking belt tension

Calibrating the device

- switch on the device (button E) with the presser

The reaction from the belt is measured using a

VALUES AND SETTINGS

Checking the calibration

1 Knurled button (presser)

_ Never refit a belt which has been removed, replace it.

VALUES AND SETTINGS

Never refit a belt which has been removed.

VALUES AND SETTINGS