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Documentos de Profesional
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3470A
XB07
Basic manual: Workshop Repair Manual 337
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
RENAULT 2001
Contents
Page Page
16 STARTING - CHARGING
Starter motor 16-1
Alternator 16-3
Page
Exhaust
Exhaust system 19-4
Catalytic converter 19-5
Engine mounting
Suspended engine mounting 19-7
VALUES AND 107
SETTINGS
07
WITHOUT AIR
CONDITIONING
Accessories belt
REMOVAL REFITTING
Put the car on a two-post lift. After refitting the accessories belt make sure to turn
the engine over twice fully to position the belt correctly.
Disconnect the battery.
Remove:
The belt tension is set using tool Mot. 1638 to tighten
the front right wheel,
the nut (1), (when the two tensioner mounting bolts
the front right wheel arch,
have been unscrewed).
the engine undertray,
the accessories belt by unscrewing the tension wheel
support bolts,
the grille.
07-1
VALUES AND SETTINGS
07
WITHOUT AIR
CONDITIONING
Accessories belt
A crankshaft
B power steering pump
C alternator
T tensioner
point for checking belt tension
07-2
VALUES AND SETTINGS
07
WITH AIR
CONDITIONING
Accessories belt
Remove:
the front right wheel,
the front right wheel arch,
the engine undertray,
the accessories belt by swivelling the automatic
tension wheel to the right using a 16 mm wrench.
REFITTING
07-3
VALUES AND SETTINGS
Tightening the cylinder head 07
CYLINDER HEAD TIGHTENING PROCEDURE
07-4
210
ENGINE AND PERIPHERALS
Sump 10
SPECIAL TOOLING REQUIRED
10-1
ENGINE AND PERIPHERALS
Sump 10
the tie-rods between the sub-frame and body (3),
10-2
ENGINE AND PERIPHERALS
Sump 10
Remove the sub-frame mounting bolts, inserting the Mot. 1233-01 threaded rods as
you go.
Lower the sub-frame gradually using the Mot. 1233-01 threaded rods until dimensions
X1 = 11 cm are achieved.
Remove:
oil level sensor,
the oil level gauge guide on the sump,
the sump.
10-3
ENGINE AND PERIPHERALS
Sump 10
Apply RHODORSEAL 5661 at (A) (on either side of Refit the sump with a new seal by pretightening the
bearing No. 1), and at (B) on the crankshaft closure bolts to a torque of 0.8 daN.m, then tighten them (in a
panel. spiral) to a torque of 1.4 daN.m.
10-4
ENGINE AND PERIPHERALS
Oil pressure 10
SPECIAL TOOLING REQUIRED
USE
C+E+F
10-5
ENGINE AND PERIPHERALS
Identification 10
10-6
ENGINE AND PERIPHERALS
Engine and gearbox assembly 10
SPECIAL TOOLING REQUIRED
Drain:
TIGHTENING TORQUES (in daNm and/or ) the refrigerant circuit (if fitted) using filling equipment,
the gearbox and the engine (if necessary),
Sub-frame front mounting bolts 6.2
the cooling circuit through the bottom hose of the
Sub-frame rear mounting bolts 10.5 radiator.
Mounting bolt for front right suspended
mounting cover to engine 3.7
Remove:
Mounting nut for rubber engine the front wheels as well as the right and left mud
mounting pad on front left-hand side flaps,
member support 6.2 the right and left brake calipers (as well as the ABS
sensors, if fitted) and secure them to the suspension
Shock absorber base bolts 18 springs,
Steering shaft yoke mounting bolts 2.1 the right and left base of the shock absorber
mountings,
Wheel bolts 9 the front fog light connectors,
the radiator grille,
Brake caliper mounting bolts 4
the front bumper,
the engine cover,
the air intake sleeve,
REMOVAL the upper cooling radiator mountings then attach the
radiator to the engine.
Put the car on a two-post lift.
10-7
ENGINE AND PERIPHERALS
Engine and gearbox assembly 10
the computer from its support at (A), Remove:
the battery tray (B). the clutch cable,
connector (A) from the accelerator pedal position
potentiometer.
10-8
ENGINE AND PERIPHERALS
Engine and gearbox assembly 10
Remove the power assisted steering reservoir from its Remove:
support. the earth strap on the gearbox,
the nut and the eccentric bolt of the steering shaft
Remove: yoke, after pushing back the guard.
brake servo vacuum pipe,
the expansion bottle,
the connections between the passenger SPECIAL NOTES FOR VEHICLES FITTED WITH A
compartment wiring loom and the fuse box. DRIVER'S AIR BAG
WARNING:
In order to eliminate any risk of damaging the
steering wheel rotary switch, observe the
recommendations below:
Before the steering column and the steering
rack are disconnected, the steering wheel
MUST be immobilised with the wheels straight
for the duration of the operation using a
steering wheel locking tool.
If there is any doubt regarding the correct
alignment of the rotary switch the steering
wheel must be removed so that the alignment
procedure described in section 88 Air bag can
be applied.
Remove:
the exhaust bracket then the centre tube,
10-9
ENGINE AND PERIPHERALS
Engine and gearbox assembly 10
the gearbox control, Fit tool Mot. 1453 with the retaining straps.
the tie-rods (4).
10-10
ENGINE AND PERIPHERALS
Engine and gearbox assembly 10
Fit tool Mot. 1159 between the sub-frame and the Lower the lift until the tool touches the ground.
cylinder block.
Remove the sub-frame mounting bolts and take out
Fit a wooden block between the multifunction support the engine and transmission assembly by lifting the
and the sub-frame. body.
REFITTING
10-11
111FRONT
ENGINE TOP AND
Timing belt 11
SPECIAL TOOLING REQUIRED
REMOVAL
11-1
ENGINE TOP AND FRONT
Timing belt 11
Remove:
the right-hand suspended
mounting support and cover,
the upper timing cover by
unclipping the two tabs (1),
11-2
ENGINE TOP AND FRONT
Timing belt 11
Remove:
the cylinder head suspended
mounting support,
11-3
ENGINE TOP AND FRONT
Timing belt 11
Positioning the belt at the timing point. Turn the engine clockwise (timing side) until the
crankshaft comes to rest on the TDC pin Mot. 1489.
Position the hole (4) in the camshaft pulley almost
opposite the hole (5) in the cylinder head.
11-4
ENGINE TOP AND FRONT
Timing belt 11
Remove the crankshaft accessories
pulley by blocking the flywheel using
a screwdriver.
11-5
ENGINE TOP AND FRONT
Timing belt 11
REFITTING
IMPORTANT: it is essential to
degrease the end of the
crankshaft, the bore of the
crankshaft sprocket and the
bearing faces of the accessories
pulley to prevent any slip
between the timing and the
crankshaft which would risk
destroying the engine.
Check that:
the mark on the high pressure
pump pulley (9) is opposite the
bolt head (10),
the crankshaft is resting on the
Top Dead Centre pin Mot. 1489
(the crankshaft groove (11) must
be facing upwards).
11-6
ENGINE TOP AND FRONT
Timing belt 11
Fit the timing belt by aligning the belt markings with Tighten the tension wheel bolt to a torque of
those of the camshaft and the high pressure pump. 2.5 daNm.
Remove the Top Dead Centre pin Mot. 1489 and the
camshaft pulley timing pin Mot. 1430
11-7
ENGINE TOP AND FRONT
Timing belt 11
Check that the pin Mot. 1430 is properly engaged in Loosen the tension wheel bolt by a maximum of one
the camshaft pulley and cylinder head holes. turn while holding it using a 6 mm, Allen key, then
gradually bring the movable index (1) (by turning the
key clockwise) to the centre of the timing window (2)
and tighten the nut to a torque of 2.5 daNm.
Remove the Top Dead Centre pin Mot. 1489 and the
camshaft pulley timing pin Mot. 1430
11-8
ENGINE TOP AND FRONT
Timing belt 11
Refit:
the cylinder head mounting,
tightening the bolts to a torque of
2.1 daNm,
11-9
ENGINE TOP AND FRONT
Timing belt 11
the lower timing cover by
positioning the tab (1) into the
hole (2) on the inner timing cover,
11-10
ENGINE TOP AND FRONT
Timing belt 11
the upper timing cover,
11-11
ENGINE TOP AND FRONT
Timing belt 11
the right-hand suspended mounting support and
cover, tightening the bolts to a torque of 6.2 daNm,
11-12
ENGINE TOP AND111FRONT
Cylinder head gasket 11
SPECIAL TOOLING REQUIRED
11-13
ENGINE TOP AND FRONT
Cylinder head gasket 11
Remove the connectors from the sensors:
air intake temperature before turbocharger,
air intake temperature after turbocharger,
turbocharging pressure,
EGR valve control
the air filter unit.
Disconnect:
the fuel temperature sensor (1),
the connector from the low pressure flow adjuster (2).
11-14
ENGINE TOP AND FRONT
Cylinder head gasket 11
Disconnect:
the injector connectors (A),
the pre-heater plug connectors (B),
11-15
ENGINE TOP AND FRONT
Cylinder head gasket 11
the support from the wiring and the diesel fuel return the two struts (A),
pipe (1), the oxidation catalyser (B),
the oil fuel return pipe (C),
11-16
ENGINE TOP AND FRONT
Cylinder head gasket 11
NOTE: when removing and refitting the high the brake assistance pipe from the vacuum pump,
pressure pipes, a precise procedure must be the air filter support bracket (A),
followed to ensure the system operates correctly.
Refer to the method in section 13 "High pressure
pipes".
Remove:
the four high pressure pipes between the rail and the
injectors,
the fuel supply pipe from the rail,
the diesel pressure sensor connector from the rail in
(1),
fit plugs to maintain cleanness,
11-17
ENGINE TOP AND FRONT
Cylinder head gasket 11
CLEANING CHECKING THE GASKET FACE
It is very important not to scratch the gasket faces Check for mating surface bow using a ruler and a set
of any aluminium component. of shims.
Apply the product to the part to be cleaned, wait Test the cylinder head to detect possible cracks using
approximately 10 minutes, then remove it using a the cylinder head test tools (a container and a kit for
wooden spatula. the particular cylinder head, plug, sealing plate,
blanking plate). The approval number of the cylinder
head test container is 664000
Wear gloves whilst carrying out this operation.
Protect the oil outlet duct in order to prevent any Lubricate the threads and under the heads of the
foreign bodies from entering the oilways in the cylinder mounting bolts.
head.
Tighten the cylinder head using a wrench (see section
Failure to take this advice could lead to the 07 "Tightening the cylinder head").
blocking of the oilways, resulting in a rapid
deterioration of the camshaft. Refit using the same procedure as for removal in
reverse.
The cylinder head tightening studs must be replaced
each time they are removed and should not be oiled Refit the timing belt (see method described in section
before being fitted. 11 "Timing belt ").
11-18
ENGINE TOP AND FRONT
Cylinder head gasket 11
ADJUSTMENT OF VALVE ROCKERS (IF NECESSARY)
Follow the same method for the other cylinders, in the order shown by the table.
Exhaust valve to be fully opened Inlet valve to be adjusted Exhaust valve to be adjusted
11-19
112
FUEL MIXTURE
Air intake 12
AIR INTAKE CIRCUIT DIAGRAM
12-1
FUEL MIXTURE
Air filter 12
REPLACING THE FILTER ELEMENT
Remove the four mounting bolts (2) from the air filter
unit.
Open the cover (3) of the air filter unit then remove the
filter element.
12-2
FUEL MIXTURE
Inlet manifold 12
TIGHTENING TORQUES (in daN.m)
REMOVAL
Remove:
the EGR tube,
the two mounting bolts (2) from the EGR unit,
the EGR unit,
the eight mounting nuts (3) from the manifold then
remove it.
12-3
FUEL MIXTURE
Inlet manifold 12
REFITTING
Refit the manifold then tighten the nuts, making sure to maintain the torque and order of tightening.
Fit the EGR unit and its new tube with two new clamps.
Tighten the two EGR unit mounting bolts on the cylinder head.
12-4
FUEL MIXTURE
EGR unit 12
Disconnect:
TIGHTENING TORQUES (in daN.m) the EGR solenoid valve (4),
the downstream air temperature sensor (5),
EGR unit mounting bolts 2.1
the rubber tube (6) from the turbocharging pressure
Air inlet metallic tube mounting bolts 2.1 adjustment valve on the air duct.
Lifting ring mounting bolts (timing side) 2.1
Remove:
EGR solenoid valve heat shield mounting the air duct (7) between the EGR unit and the
bolts 1.2 turbocharger,
the lifting ring (8),
the mounting bolt from the air inlet metallic tube (9)
then pull it to remove it.
REMOVAL
Remove:
the engine cover,
the air filter unit, to do this:
Disconnect:
the air aspiration sleeve from the air filter unit,
the connector from the upstream air temperature
sensor (1).
12-5
FUEL MIXTURE
EGR unit 12
Remove the heat shield (10) from the EGR solenoid
valve.
Remove:
the EGR tube,
the two mounting bolts (12) from the EGR unit,
the EGR unit.
REFITTING
12-6
TURBOCHARGING
Turbocharger 12
Loosen the air aspiration pipe clamp on the air filter
TIGHTENING TORQUES (in daN.m) unit.
Exhaust pipe clamp 2.1
Remove the air filter unit (3).
Catalytic converter rear mounting bolts 2.1
Catalytic converter side strut mounting
bolts 2.5
Engine side strut mounting bolts 4.4
Nuts securing catalytic converter to the
turbocharger 2.6
Air inlet metallic tube mounting bolts 2.1
Lifting ring mounting bolts (timing side) 2.1
Turbo mounting nuts on the exhaust
manifold. 2.6
EGR solenoid valve heat shield mounting
bolts 1.2
Turbocharger oil supply pipe union bolts 2.3
Turbocharger oil supply pipe union on the
cylinder head 2.3
Turbocharger oil return pipe on the
turbocharger 1.2
Turbocharger studs on the manifold 0.9
Turbocharger outlet studs 0.9
REMOVAL
From above:
Remove:
the engine cover,
the air filter unit, to do this:
Disconnect:
the air aspiration sleeve from the air filter unit,
the connector from the upstream air temperature
sensor (1).
12-7
TURBOCHARGING
Turbocharger 12
Disconnect the connector from:
the downstream air temperature sensor (4),
the EGR solenoid valve (5),
the rubber tube (6) from the turbocharging pressure
adjustment valve on the air duct.
Remove:
the air duct (7) between the EGR unit and the
turbocharger,
the air duct (8) between the EGR unit and the
turbocharger,
From below:
Remove:
the side strut from the catalytic converter (12),
the rear mounting bolt from the catalytic converter
(13).
12-8
TURBOCHARGING
Turbocharger 12
IMPORTANT: before starting the engine, connect
the fault finding tool then inhibit the injection using
the VP005 "Injection inhibition" command located
in "Command modes/Set up".
Then activate the starter motor until the oil pressure
warning light extinguishes (persist for a few
seconds).
Stop the engine, cut off the ignition for about
15 seconds then restart the engine.
Run the engine at idle speed and check that there
are no leaks at the oil connections.
Special precautions
From above:
Remove:
the heat shield from the EGR solenoid valve,
the oil supply pipe (14) from the turbocharger,
the lower turbocharger mounting nut on the exhaust
manifold.
the two upper mounting nuts 15).
REFITTING
12-9
TURBOCHARGING
Pressure adjustment 12
TURBOCHARGING PRESSURE CONTROL VALVE Calibration pressure value
(WASTEGATE)
The turbocharging pressure limitation valve is Pressure value Rod movement (mm)
activated by a rod and is controlled by the (mbars)
turbocharging pressure applied to the LDA diaphragm.
First remove:
the lifting rings,
the mounting bolt from the air inlet metallic tube then
pull it to remove it.
Disconnect the pipe (1), then apply progressive Loosen the lock nut then loosen or tighten the
pressure to the wastegate using a manual pressure adjusting nut (B).
pump.
NOTE: It is essential to replace all the disconnected air
inlet plastic pipes.
12-10
113
DIESEL EQUIPMENT
Cleanliness 13
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE
DIRECT INJECTION SYSTEM
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
damage or destruction of the high pressure injection system and the engine,
seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
IMPORTANT: it is not possible to clean the engine using a high pressure washer because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection problems.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Part no. 77 01
206 804). Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and
cleaning is not sufficient to make them reusable). Unused plugs must be thrown away.
Ensure that you have the hermetically resealable plastic bags for storing removed parts. Stored parts will therefore
be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away.
Make sure that lint-free towelettes are available (part number 77 11 211 707). The use of a normal cloth or paper
for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. Each
lint-free cloth should only be used once.
13-1
DIESEL EQUIPMENT
Cleanliness 13
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles remain adhered.
When wearing leather protective gloves, cover these with latex gloves.
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Stores (part number 77 01 206 804). They must not, under any
circumstances, be reused.
Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries
contamination.
All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once
the plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
These items are likely to allow impurities to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
13-2
DIESEL EQUIPMENT
Cleanliness 13
FITTING INSTRUCTIONS FOR THE PLUGS KIT (part number 77 01 206 804)
13-3
DIESEL EQUIPMENT
Special features 13
The high pressure injection system is intended to deliver a specific quantity of diesel to the engine at a specific time.
DESCRIPTION
DELPHI and type "LVCR" flash EEPROM injection controlling 112 track computer.
The "common rail" direct high pressure injection system works sequentially (based on the operation of multipoint
injection for petrol engines).
This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and
produces high engine torque at low engine speeds thanks to a pre-injection procedure.
The high pressure pump generates the high pressure sent to the injector rail. The flow actuator on the pump
controls the quantity of diesel engine fuel supplied according to the demand determined by the computer. The rail
supplies each injector through a steel pipe.
13-4
DIESEL EQUIPMENT
Special features 13
The computer:
determines the value of injection pressure necessary for the engine to operate well and then controls the pressure
regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure sensor
located on the rail,
determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should
be started,
controls each injector electrically and individually after determining these two values.
The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump). It supplies
the rail whose pressure is controlled for charge by the flow actuator and for discharge by the injector valves. Falls
in pressure can be compensated for in this way. The flow actuator allows the high pressure pump to provide just
the amount of diesel fuel necessary to maintain the pressure in the rail. Thanks to this element, heat generation is
minimised and engine output improved.
In order to discharge the rail using the injector valves, the valves are controlled by short electrical impulses:
short enough not to open the injector, (through the return circuit from the injectors),
long enough to open the valves and discharge the rail.
The injection computer controls the fan assemblies and the coolant temperature warning light on the instrument
panel (GCTE function).
13-5
DIESEL EQUIPMENT
Special features 13
IMPORTANT
The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out any
work, check that the injector rail is not under pressure and that the fuel temperature is not too high.
You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the diesel
temperature sensor and the venturi can be replaced.
For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is
running.
It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination problems. If the pressure sensor fails, the pressure sensor, the rail and the five high
pressure pipes must be replaced.
It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being
replaced, the pulley must be replaced.
It is forbidden to repair the wiring connecting the accelerometer and the engine speed sensor. If the wiring
should fail, it has to be replaced with new wiring.
Never start the engine without the battery being connected correctly.
Disconnect the injection system computer when carrying out any welding work on the vehicle.
13-6
DIESEL EQUIPMENT
Special features 13
There is a 16 character code on the injectors called C2I (individual injector correction). This code is specific
to each injector, and takes into account differences in manufacture and specifies the flow injected by each
of them.
When an injector is replaced, it is necessary to program the code of the new one into the computer.
When a computer is reprogrammed or replaced, it is necessary to program the codes of the four injectors.
13-7
DIESEL EQUIPMENT
Special features 13
All the high pressure pipe removed must be Rail/injector pipes
systematically replaced along with the clips.
Undo the rail,
TIGHTENING THE HIGH PRESSURE PIPES Grease the threads of the high pressure pipe nuts,
Insert the high pressure pipe olive into the taper of
NOTE: fit the pump/rail pipe before the rail/injector the high pressure injector inlet,
pipes. Insert the high pressure pipe olive into the taper of
the high pressure rail outlet.
Pump/rail pipe Move the nut into position by hand, on the injector
side then the rail side,
Undo the rail, Tighten the rail,
Grease the threads of the high pressure pipe nuts, Ensure that the new clip, supplied with the new high
Insert the high pressure pipe olive into the taper of pressure pipe, is fitted,
the high pressure pump outlet, Tighten the nuts of the high pressure pipes on the
Insert the high pressure pipe olive into the taper of injector side first and then on the fuel rail side.
the high pressure rail inlet.
Move the nut into position by hand, on the rail side NOTE: before fitting a new high pressure pipe,
then the pump side, move back the nuts on the pipe then lightly
Tighten the rail, lubricate the nut threads with the oil from the
Tighten the high pressure pipe nuts on the rail side sachet (1) provided in the new parts kit.
then on the pump side.
13-8
DIESEL EQUIPMENT
Special features 13
CHECKING SEALING AFTER REPAIR
Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
Once the coolant temperature is above 50C and provided there are no faults present, carry out a road test, taking
the engine speed up to 4000 rpm at least once to check that there are no leaks.
Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
13-9
DIESEL EQUIPMENT
Special features 13
REPLACING OR REPROGRAMMING THE COMPUTER
The system can be reprogrammed at the diagnostic socket using the RENAULT NXR and CLIP fault finding
tools.
Before a computer is reprogrammed or replaced in after-sales, the following must be stored in the fault
finding tool: the C2I parameters (individual injector correction) and the configurations by command SC005.
If command SC005 has been taken into account, reprogram or replace the computer then run command SC008 to
restore the C2I and the different configurations then run a static / autoconfiguration test with command SC003 to
reposition the control of the fan assembly 2.
If the save command in the fault finding tool did not work, a static / autoconfiguration test should be run using
command SC003 to reconfigure the different elements such as the power-assisted steering pump assembly, the
climate control system and the thermoplungers and to re-enter the C2I codes manually (refer to injector
replacement).
NOTE: C2I (individual injector correction) is a factory calibration carried out on each injector to adjust the
flow of each one precisely, taking into account differences in manufacture.
The correction values are written on a label affixed to each injector then entered in the computer which can then
control each injector by taking account of their differences in manufacture.
The system can be programmed at the diagnostic socket using the RENAULT NXR and CLIP fault finding
tools.
The C2I parameters must be replaced after replacing an injector. To do this, reprogram the C2I code into the
computer using the following commands:
Entering the four C2Is, when replacing the computer, enter command SC004.
Entering an individual C2I, when replacing one or more injectors, enter command:
injector cylinder 1: command VP021 cylinder on the flywheel side
injector cylinder 2: command VP022
injector cylinder 3: command VP023
injector cylinder 4: command VP024
The technician uses the appropriate command to reprogram the new C2I for the replaced injector and erase the
old C2I.
13-10
DIESEL EQUIPMENT
Location of components 13
1 Camshaft sensor
2 Fuel filter
3 Injector
4 Air filter
5 Upstream air temperature sensor
6 Accelerometer.
7 Coolant temperature sensor
8 Spherical injector rail
9 Flow actuator
10 Diesel fuel temperature sensor
11 High pressure pump
12 Computer
13 Pre/postheating unit
14 Venturi
15 Rail pressure sensor
16 Priming bulb
17 Turbocharging pressure sensor
18 Accelerator pedal potentiometer
25 Impact sensor
13-11
DIESEL EQUIPMENT
Location of components 13
1 Camshaft sensor 3 Injector
8 Injector rail
15 Rail pressure sensor
9 Flow actuator
10 Diesel temperature sensor 5 Upstream air temperature sensor
11 High pressure pump 6 Accelerometer
14 Venturi 17 Turbocharger pressure sensor
13-12
DIESEL EQUIPMENT
Location of components 13
2 Fuel filter 7 Coolant temperature sensor
16 Priming bulb 19 Engine speed sensor
13-13
DIESEL EQUIPMENT
Location of components 13
22 Thermoplungers
23 Vehicle speed sensor
13-14
DIESEL EQUIPMENT
Accelerator pedal potentiometer 13
The accelerator pedal potentiometer (1) is attached by Potentiometer connector:
a bracket under the injection computer.
1 Track 2 potentiometer signal
2 Track 1 potentiometer signal
3 5 volt supply track 2
4 Track 1 earth
5 Track 2 earth
6 5 volt supply track 1
13-15
DIESEL EQUIPMENT
Specifications 13
Engine
Gear-
Vehicles Emission
boxes Bore Stroke Compression Catalytic
Type Suffix Capacity control
(mm) (mm) ratio converter
standard
IDLE SPEED Max. - no load Max. - under load Homologation Max. - legal
value
Pre/postheating unit NAGARES BED With pre-postheating function controlled by the computer
7-12
13-16
DIESEL EQUIPMENT
Specifications 13
DESCRIPTION MARQUE/TYPE SPECIAL NOTES
13-17
DIESEL EQUIPMENT
Diesel filter 13
IMPORTANT: before carrying out any work, wait
for the fuel temperature to drop.
REMOVAL - REFITTING
Fit the new diesel fuel filter (do not remove the plugs
until the last moment).
13-18
DIESEL INJECTION
High pressure pump 13
IMPORTANT: It is strictly forbidden to remove
any injection pump pulley marked number 070
575. If the pump is being replaced, the pulley
must be replaced.
13-19
DIESEL EQUIPMENT
High pressure pump 13
REMOVAL
It is strictly forbidden to remove any injection pump pulley marked number 070 575 (see diagram). If the pump is
being replaced, the pulley must be replaced.
The high pressure pump may be removed after having first removed the timing belt (see section 11 " Timing belt")
Remove:
the neck (1) located on the fuel rail,
the dipstick guide and plug the hole.
13-20
DIESEL EQUIPMENT
High pressure pump 13
Carefully disconnect:
the connectors from the flow actuator (3) and diesel temperature sensor (4),
the pre-heater plugs and the injectors (5),
the return pipe (8) connecting the injector with the pump.
13-21
DIESEL EQUIPMENT
High pressure pump 13
Remove the high pressure pipe (9) connecting the Refit the high pressure pipe, to do this:
pump to the rail. To do this:
remove the protective plugs,
undo the nut on the pump side then the nut on the rail insert the high pressure pipe olive into the taper of
side, the high pressure pump outlet,
move the nut along the tube keeping the olive in insert the high pressure pipe olive into the taper of
contact with the taper. the high pressure rail inlet.
Plug all the holes of the injection circuit. Finger tighten the nuts of the high pressure pipe
starting with the one located on the rail side.
Remove the three mounting bolts (10) from the
injection pump then remove it. Tighten the rail mounting nuts to a torque setting of
2.8 daNm).
REFITTING
13-22
DIESEL EQUIPMENT
Flow actuator 13
EQUIPMENT REQUIRED
Low torque wrench
Pipe socket for tightening the high pressure pipe
(for example, Facom Crowfoot 18-17 wrench).
13-23
DIESEL EQUIPMENT
Flow actuator 13
REMOVAL
REFITTING
Reconnect:
the diesel return pipe.
the electrical connectors.
13-24
DIESEL EQUIPMENT
Flow actuator 13
Refit in the reverse order to removal for the other
refitting operations.
13-25
DIESEL EQUIPMENT
Diesel fuel temperature sensor 13
EQUIPMENT REQUIRED
Low torque wrench
13-26
DIESEL EQUIPMENT
Diesel fuel temperature sensor 13
REMOVAL REFITTING
Remove the engine cover. Position the diesel fuel temperature sensor then
tighten to torque.
Disconnect the connector from the diesel temperature
sensor carefully (1). Reconnect:
the electrical connector.
Undo then remove the diesel temperature sensor. the battery.
13-27
DIESEL EQUIPMENT
Venturi 13
EQUIPMENT REQUIRED
Low torque wrench
13-28
DIESEL EQUIPMENT
Venturi 13
REMOVAL REFITTING
Remove the engine cover. Position the venturi then tighten it to torque.
13-29
DIESEL EQUIPMENT
Injector rail 13
SPECIAL TOOLING REQUIRED
13-30
DIESEL EQUIPMENT
Injector rail 13
REMOVAL
Carefully disconnect:
the connectors from the flow actuator(1),
the connectors from the diesel temperature sensor (2),
the injector connectors (3),
the heater plugs,
on the pump, the fuel supply (4) and return (5) pipes.
the return pipe (6) connecting the injectors with the pump.
Remove:
the neck (7) located on the fuel rail,
the dipstick guide and plug the hole.
13-31
DIESEL EQUIPMENT
Injector rail 13
Remove the clips connecting the high pressure pipes. Remove all the high pressure pipes (12).
13-32
DIESEL EQUIPMENT
Injector rail 13
REFITTING insert the high pressure pipe olive into the taper of
the high pressure injector inlet,
insert the high pressure pipe olive into the taper of
IMPORTANT: all the high pressure pipes
the high pressure rail outlet.
removed must be systematically replaced.
finger tighten the nuts of the high pressure pipe
starting with the one located on the injector side.
Fit a new high pressure rail on the studs.
Fit the remaining high pressure pipes as you did
Finger tighten the nuts. previously.
NOTE: fit the pump/rail pipe before the rail/injector Fit the clips supplied with the new pipes onto the high
pipes. pressure pipes:
insert the first half of the clip using adjustable pliers,
Fit the pump-rail high pressure pipe: Insert the second half of the clip using adjustable
pliers.
remove the protective plugs from the high pressure
pump outlet, the high pressure rail inlet and the pipe.
IMPORTANT: pay attention to the direction of
insert the high pressure pipe olive into the taper of
installation of the second clip. The tabs located
the high pressure pump outlet,
in the centre of the clip will only fit together in
insert the high pressure pipe olive into the taper of
one position.
the high pressure rail inlet.
finger tighten the nuts of the high pressure pipe
starting with the one located on the rail side.
13-33
DIESEL EQUIPMENT
Injector rail 13
Tighten the rail nuts to a torque of 2.8 daNm. Using the recommended tools, tighten the nuts on
the rail - injector high pressure pipes:
IMPORTANT: do not touch the pipes with the
tighten the nut on the injector side to a torque of
wrench when torque tightening.
3.8 daN.m.
tighten the nut on the rail side to a torque of
IMPORTANT: follow the order and tightening 3.8 daN.m.
torque of the high pressure pipes.
13-34
DIESEL EQUIPMENT
Pressure sensor 13
The pressure sensor (1) cannot be separated from the
fuel rail. If the pressure sensor fails, the pressure
sensor assembly - rail and high pressure pipes - must
be replaced (see fuel rail section).
13-35
DIESEL EQUIPMENT
Injectors 13
SPECIAL TOOLING REQUIRED
13-36
DIESEL EQUIPMENT
Injectors 13
REMOVAL
Remove:
the engine cover,
the neck (1) located on the high pressure rail,
the dipstick guide then plug the hole.
Disconnect:
the fuel return pipe (3),
the injector electrical connector.
Undo the nut on the injector side, then the nut located
on the rail side of the high pressure pipe.
13-37
DIESEL EQUIPMENT
Injectors 13
REFITTING
13-38
DIESEL EQUIPMENT
Injectors 13
Fit the high pressure pipe: Tighten the rail nuts to a torque of 2.8 daNm.
Fit a new clip supplied with the new pipes onto the
high pressure pipes: Using the recommended tools, tighten the following in
insert the first half of the clip using adjustable pliers, the order and to the torques shown:
Insert the second half of the clip using adjustable the nut on the injector side to a torque of 3.8 daN.m.
pliers. the nut on the rail side to a torque of 3.8 daN.m.
13-39
DIESEL EQUIPMENT
High pressure pipes 13
SPECIAL TOOLING REQUIRED
13-40
DIESEL EQUIPMENT
High pressure pipes 13
REMOVAL
Remove:
the engine cover,
the neck (1) located on the high pressure rail,
the dipstick guide then plug the hole.
13-41
DIESEL EQUIPMENT
High pressure pipes 13
Remove the high pressure pipes(s). Fit the remaining high pressure pipes as you did
previously.
Plug all the holes of the injection circuit.
REFITTING
IMPORTANT: all the high pressure pipes
removed must be systematically replaced.
NOTE: fit the pump/rail pipe before the rail/injector
pipes.
Before fitting the new high pressure pipes, lightly Fit a new clip supplied with the new pipes onto the
lubricate the nut threads with the oil from the sachet high pressure pipes:
provided in the new parts kit. insert the first half of the clip using adjustable pliers,
insert the second half of the clip using adjustable
Fit the pump-rail high pressure pipe: pliers.
13-42
DIESEL EQUIPMENT
High pressure pipes 13
Tighten the rail nuts to a torque of 2.8 daNm.. NOTE: tighten one pipe fully before moving on to
the next pipe.
13-43
DIESEL EQUIPMENT
Computer 13
NOTE: when replacing or reprogramming a computer, it is necessary to program the C21 parameters
(individual injector correction) and the other vehicle configurations using the RENAULT NXR and CLIP fault
finding tools.
There are two possible ways of doing this:
An automatic method which can be done if it is possible to read out the information contained in the old computer.
A manual method which is to be used if it is not possible to read out the information contained in the old computer.
Before a computer is reprogrammed or replaced in after-sales, the following must be stored in the fault
finding tool: the C2I parameters (individual injector correction) and the configurations by command SC005.
If command SC005 has been taken into account, reprogram or replace the computer then run command SC008 to
restore the C2I and other configurations then run a static / autoconfiguration test with command SC003 to
reposition the control of the fan assembly 2.
If the save command in the fault finding tool did not work, a static / autoconfiguration test should be run using
command SC003 to reconfigure the different elements such as the power-assisted steering pump assembly, the
climate control system and the thermoplungers and to re-enter the C2I codes manually (see section13 "Special
features, Replacing injectors").
13-44
DIESEL EQUIPMENT
Computer 13
REMOVAL REFITTING
Unclip the power steering reservoir and attach it to the Tighten the computer mounting nuts.
front bulkhead.
Clip the power steering reservoir back in.
Remove the mounting nuts from the computer (1) on
the battery tray. Reconnect the computer.
Tilt the computer slightly to the rear to free up the Connect the battery.
studs and pull it out upwards to free the positioning
tab. Turn the engine on and read the fault codes using the
fault finding tool.
13-45
DIESEL EQUIPMENT
Computer 13
COMPUTER ALLOCATION OF TRACKS
CONNECTOR A
H1 .... Not used
H2 Accelerator pedal potentiometer signal track 1
H3 --- Accelerator pedal potentiometer earth track 1
H 4 .... Not used
13-46
DIESEL EQUIPMENT
Computer 13
CONNECTOR B
M1 .... Not used
M2 .... Not used
M3 .... Not used
M4 Flow actuator control
F1 Accelerometer signal
F2 Engine speed sensor signal
F3 --- Engine speed sensor earth
F4 Control - injector N4
13-47
DIESEL EQUIPMENT
Computer 13
CONNECTOR C
A1 .... Not used
A2 .... Not used
A3 .... Not used
A4 .... Not used
13-48
DIESEL EQUIPMENT
Injection warning light 13
Vehicles that operate with the high pressure diesel system Delphi LVCR are fitted with three warning lights,
dependent on the level of seriousness of the fault detected, to inform the customer and determine the diagnostic.
These warning lights are used during the preheating phase and in case of an injection fault or engine overheating.
This warning light is used as an operating indicator light and as a system fault indicator light.
The orange preheating warning light comes on when the ignition is switched on, remains lit during the preheating
phase and then goes out (see section 13 Pre/post-heating control).
After the preheating phase and an automatic timed 3 second stop, a severity level 1 problem is indicated by
flashing. It indicates reduced level operation and a limited safety level. The driver should carry out repairs as soon
as possible.
This warning light is used as an operating indicator light and as a system fault indicator light.
When the ignition is switched on, the coolant temperature warning light lights up for 3 seconds then goes out.
13-49
DIESEL EQUIPMENT
Injection warning light 13
When there is a serious fault, the coolant temperature warning light lights up continuously and signals a fault
linked to the injection system or engine overheating.
In the event of an injection system fault, the engine is automatically switched off after 1 minute 30 seconds or
immediately.
In the event of engine overheating, it is the driver's choice to stop the car or continue driving.
This warning light, depicted by an engine, lights up for about 5 seconds when the engine is switched on then goes
out. It is never visible when the engine is running (not operational).
13-50
DIESEL INJECTION
Immobiliser function 13
This vehicle is fitted with an engine immobiliser system which is controlled by a key recognition system.
The injection computers are supplied without a code but they must all be programmed with one.
If a computer is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine
immobiliser function must be checked.
To do this, switch on the ignition for a few seconds without starting the engine, then switch it off. With the ignition off,
the engine immobiliser function comes into operation after approximately 10 seconds (the red engine immobiliser
warning light flashes).
WARNING:
These vehicles have a special injection computer which does not function unless it is coded.
Consequently, it is strongly recommended that you do not carry out tests using computers borrowed from the
warehouse or on another vehicle to prevent coding and uncoding problems which may leave the computer useless.
UNCODING PROCEDURE
If the injection computer has learnt a code and must be returned to the workshop it is imperative that you uncode it
before removing it. (See the repair manual or engine immobiliser Technical Note ).
13-51
DIESEL INJECTION
Idle speed adjustment 13
The computer takes over calculation of the idle speed to maintain the idle speed at the recommended level and
to compensate for any variation in the mechanical or electrical couple as regards:
the coolant temperature,
battery voltage,
the gear selected on the gearbox,
the electrical consumers (thermoplungers, climate control system, fan assembly etc.),
any faults found.
At the engine operating temperature, without high electrical consumer, the idle speed is 850 rpm.
If one or both tracks of the accelerator pedal potentiometer are faulty, the computer overrides the idle speed to
maintain it at 1100 rpm. This defect mode limits performance. The orange injection warning light lights up and
flashes.
If the potentiometer is blocked, is no longer being supplied, or is not transmitting an output signal, the
computer overrides the idle speed to maintain it at 1300 rpm. This mode limits performance. The orange injection
warning light lights up and flashes.
In both cases, when the brake pedal is depressed, the idle speed is stabilised at the recommended speed.
If the information from the accelerator pedal position potentiometer and the brake switch information does
not correspond, the speed is changed to 1100 rpm.
13-52
DIESEL INJECTION
Idle speed adjustment 13
IDLE SPEED ADJUSTMENT WHEN THERE IS AN INJECTOR C21 CODE FAULT
When there is an injector C21 code fault, the computer overrides the idle speed to maintain it at 1300 rpmn . This
mode limits performance. The orange injection warning light lights up and flashes.
The idling speed is modified according to the gear engaged in the gearbox:
in neutral, 1st and 2nd gear, the speed is (at the engine operating temperature) 850 rpm (graph A),
for the other gears, the speed is (at the engine operating temperature) 900 rpm (graph B).
13-53
DIESEL INJECTION
Injection/air conditioning management 13
INJECTION COMPUTER / AIR CONDITIONING COMPUTER CONNECTION
The injection computer and the air conditioning computer are connected by three wires:
the signal for output absorbed by the compressor passes through track E4 of connector C. It is possible to see
the output absorbed using the diagnostic tool. With air conditioning switched on, the reading should be between
250 and 5000 watts.
the compressor is activated or deactivated via track E2 of connector A.
track E3 of connector C, is not operational.
When the air conditioning switch is activated, the injection computer authorises the clutch compressor according to
the parameters and adopts a fast idling speed. In this case, the engine speed can reach 900 rpm depending on how
much power is absorbed by the compressor.
IMPORTANT: the value for the parameter "PR power absorbed by the AC compressor" (PR044) is never equal
to 0, whatever the status of the compressor. The minimum value read is approximately 250 watts.
During certain stages of operation, the injection computer stops the compressor from functioning.
The compressor is prevented from operating for 4 seconds after the engine has started.
The compressor is not engaged when the engine temperature is higher than 115 C or from 110 C at high speed,
4500 rpm for more than 3 seconds.
At idling speed and when driving, with the air conditioning activated, the speed of the fan assembly is determined
according to the refrigerant fluid pressure and the vehicle speed.
13-54
DIESEL INJECTION
Injection/air conditioning management 13
Recovery of performance
When pressure is applied to the accelerator pedal above 70 %, the compressor is disengaged for 5 seconds.
In order to help the vehicle move off, the air conditioning compressor is disengaged if the position of the accelerator
pedal is above 35 % and the idling speed less than 1250 rpm.
Anti-stall protection
The compressor is disengaged if the engine speed is lower than 750 rpm.
The compressor is disengaged when the speed reaches 4500 rpm for more than 3 seconds.
NOTE: the time between the compressor being disengaged twice is always greater than 10 seconds.
13-55
DIESEL INJECTION
Pre/postheating control 13
The pre/postheating function is controlled by the preheating unit.
1) Ignition on "preheating" During this phase the plugs are supplied continuously
according to coolant temperature.
a) Variable preheating
The time period for the warning light to light up and
the feed to heater plugs depends on the coolant
temperature and the battery voltage.
X. Time in seconds
Y. Temperature in C
b) Fixed preheating
After the warning light goes out the plugs remain
supplied for a fixed period of 5 seconds.
13-56
DIESEL EQUIPMENT
Pre-heater plugs 13
The resistance of a heater plug is 0.6 .
REMOVAL
REFITTING
13-57
DIESEL INJECTION
Coolant temperature management (GCTE) 13
The fan unit is controlled by the injection computer.
at slow speed if the coolant temperature exceeds 99C or if there is a coolant temperature sensor fault, and is
switched off when the temperature falls below 96C.
at high speed if the coolant temperature exceeds 102 C or if there is a low speed fault, and is switched off when
the temperature falls below 99C.
The fan assembly low and high speeds are controlled when the air conditioning function is selected on the
instrument panel.
If the low speed setting is faulty, the high speed setting operates under low speed conditions.
The temperature warning light remains lit if the coolant temperature exceeds 114 C. It goes out when the
temperature falls below 111 C.
13-58
DIESEL INJECTION
Thermoplungers 13
The three or four thermoplungers are located on a Control strategy
water unit (1), attached to the gearbox by a retaining
bracket. When the thermoplungers are operating the idle speed
is brought to 900 rpm.
The system is designed to reheat the coolant intended
for the passenger compartment heating system. Thermoplungers cannot operate in the case of:
preheating,
The thermoplungers are supplied with 12 volts by two post-heating,
or three relays. engine speed below 700 rpm.
When there are two relays: one relay controls one If the conditions mentioned above apply, the
thermoplunger and the other controls two thermoplungers are controlled according to a mapping
thermoplungers. This enables control of one, two or related to the air and coolant temperature.
three thermal plungers.
0.6 0.05 at 20 C
13-59
DIESEL EQUIPMENT
Thermoplungers 13
3 OR 4 RELAY THERMOPLUNGER CONTROL PROGRAM
If not then
If not then
If not then
If not then
13-60
114
ANTI-POLLUTION
Oil vapour rebreathing 14
CIRCUIT DIAGRAM
A. When there is a low charge, the vacuum in the air
intake duct is below the spring set point. The oil
vapours are extensively rebreathed by the
vacuum in the air intake duct.
CHECKING
14-1
ANTI-POLLUTION
Exhaust gas recirculation (EGR) 14
CIRCUIT DIAGRAM
1 Engine
2 Air filter unit
3 Air distributor
4 Exhaust manifold
5 EGR unit with solenoid valve
6 Turbocharger
7 Injection computer
A Air inlet
B Exhaust gas outlet
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.
14-2
ANTI-POLLUTION
Exhaust gas recirculation (EGR) 14
OPERATING PRINCIPLE In this case, the fault finding tool can read an RCO
value of the position of the EGR valve equal to 16 %.
The valve is controlled by an RCO (Opening Cyclic
Ratio) signal sent by the injection computer. The RCO EGR function is disabled if:
signal modulates the opening of the valve and the battery voltage is less than 9 volts,
consequently the quantity of exhaust gas directed engine speed is below 500 rpm.
back to the inlet manifold. the mapping (engine speed/load) exceeds a given
threshold,
The computer continuously carries out a test to detect the air conditioning compressor is activated.
the position of the EGR valve.
The EGR solenoid valve is not supplied after the
NOTE: the position of the EGR valve is determined by engine starts for 2 seconds.
the calculation of the amount of air taken in by the
engine. If there is a fault in:
the EGR valve,
OPERATING CONDITIONS the turbocharging pressure sensor,
the supply to the EGR solenoid valve is cut.
The parameters which determine the activation of the
EGR solenoid valve are as follows:
coolant temperature,
air temperature,
atmospheric pressure,
accelerator pedal position,
injected diesel flow,
the engine speed.
1 Solenoid feed
2 Position potentiometer feed
3 Not used
4 Position potentiometer earth
5 Solenoid earth control
6 Position potentiometer signal
14-3
716
STARTING - CHARGING
Starter 16
REMOVAL Disconnect the two electrical connectors from the
starter motor.
Put the car on a two-post lift.
Remove the two mountings from the starter motor (B).
Disconnect the battery.
Remove:
the engine undertray,
the front right driveshaft,
the air filter unit,
the oxidation catalyser mountings,
the two mounting struts of the oxidation catalyser,
the front right wheel,
the driveshaft (on the right side only),
the oxidation catalyser,
REFITTING
16-1
STARTING - CHARGING
Starter 16
Type Engine Starter
16-2
STARTING - CHARGING
Alternator 16
IDENTIFICATION:
CHECKING
800 - 64
1000 57 -
2000 94 81
3000 105 -
4000 82 118
6000 - 123
16-3
STARTING - CHARGING
Alternator 16
REMOVAL
Remove:
the front right wheel,
the front right wheel arch,
the accessories belt (see section 07 "Accessories belt tension"),
the alternator mounting bolts.
NOTE: the lower bolt cannot be completely released, you have to swivel the alternator towards the front to
remove it.
REFITTING
Refer to section 07 "Accessories belt tension" for the belt tensioning procedure.
NOTE: the inner tooth (on the engine side) of the air conditioning compressor and crankshaft pulleys must
remain free.
16-4
819
COOLING SYSTEM
Radiator 19
SPECIAL TOOLING REQUIRED
Disconnect the battery. Fill and bleed the cooling circuit (see section 19
"Filling - bleeding").
Remove the engine undertray.
Remove:
the air intake sleeve,
the connectors of the fan unit,
the fan assembly support wiring,
the upper radiator hose,
the radiator grille,
the upper radiator mountings,
the radiator.
19-1
COOLING SYSTEM
Filling and bleeding 19
There is no heater matrix water control valve.
FILLING
BLEEDING
19-2
COOLING SYSTEM
K9K
Diagram 19
1 Engine
2 Radiator 9 Coolant pump
3 Hot bottle with degassing after thermostat
4 Heater matrix 10 Thermostat
5 Thermostat mounting
6 Fitting 3 mm 11 Bleed screw
12 Temperature switch
19-3
EXHAUST
Exhaust pipe 19
DIAGRAM OF THE EXHAUST PIPE AND LOCATION OF THE CUTTING AREA
K9K engine
1 Silencer
ZC Pipe cutting area
19-4
EXHAUST
Catalytic converter 19
TIGHTENING TORQUES (in daN.m)
REMOVAL
Remove:
the engine undertray
the engine cover,
the air filter unit, to do this:
Disconnect:
the air aspiration sleeve from the air filter unit,
the connector from the upstream air temperature
sensor (1).
Remove:
the air filter unit (3),
the four nuts (4) securing the catalytic converter to
the turbocharger.
19-5
EXHAUST
Catalytic converter 19
From the side Remove:
the side strut from the catalytic converter (6),
Remove the front right driveshaft, to do this: the mounting bolt (7) from the catalytic converter on
remove the clip from the mudguard screen to gain the rear strut,
access to the ABS sensor connector, catalytic converter.
disconnect the ABS sensor connector,
remove the brake caliper then hang it in the wheel
arch,
uncouple the steering ball joint,
remove the lower ball joint bolt,
remove the bolts of the shock absorber base,
remove the driveshaft.
From below:
REFITTING
Torque tighten:
the nuts securing the catalytic converter to the
turbocharger
the lower mountings.
Replace:
the exhaust pipe clamp,
the exhaust bracket seal.
19-6
ENGINE MOUNTING
Suspended engine mountings 19
TIGHTENING TORQUES (in daNm)
A 2.1
B 3.7
C 6.2
D 10.5
19-7