27240112-Basic-Manual-M-R-302 B54F TN

B54F

77 11 191 770 November 1996 Edition Anglaise

Special notes for vehiclesfitted with the engines

N7U 700N7U 701

N.T. 2651A

Basic manual : M.R. 302

For sections not described in this manual refer to M.R. 302.

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

The methods may be modified as a result of changes introduced by themanufacturer in the production of the various component units and accessoriesfrom which his vehicles are constructed."

All copyrights reserved by Renault

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

C Renault S.A. 1996

17-1Distributed ignition

16-116-4

AlternatorStarter motor

14-114-3

Oil vapour rebreathingFuel vapour rebreathing

12-112-4

12-6

SpecificationsThrottle bodyInlet manifoldExhaust manifold

11-111-8

Timing beltCylinder head gasket

10-110-210-310-410-13

IdentificationOil consumptionOil pressureEngine and transmission assemblySump

07-107-307-607-7

Capacities - GradesAccessories belt tensionTiming belt tensionTightening the cylinder head

Contents

Air inletSupply pressureAntipercolation device

13-113-213-5

FUEL SUPPLY13

Pages

Engine and peripherals

General

VALUES AND SETTINGS07

ENGINE AND PERIPHERALS10

TOP AND FRONT OF ENGINE11

FUEL MIXTURE12

Power assisted steering pump 13-6

PUMPS

ANTIPOLLUTION 14

STARTING - CHARGING16

IGNITION17

17-417-6

17-917-1117-1217-13

17-14

17-1517-16

17-1717-1817-1917-2017-2617-3017-3317-5917-6517-7917-85

GeneralLocation of componentsSpecial notes on sequential injectionInjection fault warning lightEngine immobiliser functionComputer configuration Injection/automatic transmissionprogrammingInjection/air-conditioningprogrammingIdle speed correctionAdaptive idle speed RCO correctionRichness regulationAdaptive richness correctionOperating wiring diagramFault finding - IntroductionFault finding with the XR25Interpretation of XR25 bargraphsChecking conformityInterpretation of XR25 parametersFault finding - Customer complaintFault finding aid

INJECTION

Pages

05-105-2

EngineGearbox

DRAINING AND FILLING05

Contents (contd.)

Pages

19-119-219-319-519-619-10

19-14

Filling - bleedingDiagramRadiatorWater pump O ringThermostat mountingFan

Suspended engine mountings

COOLING19

Transmission

Pages

23-623-7

23-823-923-1223-1623-1923-2723-2823-3123-3223-3323-3423-3523-3723-4123-4323-44

23-4523-4623-4723-4923-5023-5123-52

23-5323-8023-8123-83

DrainingFilling - LevelsChecking torque converter settingpointOil pipesHydraulic distributorRadiatorRemoval - FittingStarter plateDifferential output sealTorque converter sealSelector shaft sealOil pressureComputerOil temperature sensorMulti-function switchSpeed sensor (Input)Speed sensor (Output)Kickdown switchAccelerator controlcompensatorSolenoid valveWiring diagramWiringWiring (Removal - Refitting)Fault finding - IntroductionFault finding with the XR25Interpretation of the XR25bargraphsChecking conformityFault finding aidFault finding - Customer complaints

ENGINE SUSPENSION

20-120-220-220-320-420-5

IdentificationExploded viewsConsumablesMechanism - DiscFlywheelGuide tube

CLUTCH20

21-121-221-321-4

21-421-521-1021-13

IdentificationRatiosLubricantConsumablesPart to be replacedsystematicallyRemoval - RefittingDifferential output sealReversing light switch

MANUAL GEARBOX21

23-123-223-223-323-4

23-423-423-5

IdentificationUseGear ratiosGear change thresholdConsumablesParts to be replacedsystematicallyOilOil change frequency

AUTOMATIC TRANSMISSION23

29-129-629-8

Front driveshaftWheel side gaiterGearbox side gaiter

DRIVESHAFTS29

62-162-462-662-762-8

GeneralCondenserCompressorDehydration canisterElectrical control

31-1Spring - shock absorber assembly

Contents (contd.)

Chassis

AIR-CONDITIONING62

Air-conditioning

Pages

37-137-337-5

Gear selection controlGear lever knobGear selection control cable

MECHANICAL ELEMENT CONTROLS37

FRONT AXLES31

DRAINING FILLING

Engine 05

10137R

DRAINING : plug (1) FILLING : plug (2)

10135R

05-1

DRAINING FILLING

Gearbox 05DRAINING : plug (A)

FILLING : plug (B) (by overflow)

10612R

10562R

NOTE : For draining and filling the SU0 automatictransmission refer to Section 23.

05-2

VALUES AND SETTINGS

Capacity - Grades 07

ComponentCapacity in

litres(approx.*)

Quality

Petrol engine(oil)

N7U

If draining

6.06.5 (1)

EEC countries

Other countries

0°C-30°C +10°C +20 °C-20°C -10°C

-15°C +25°C

CCMC-G5 5W30ACEA A2-96/A3-96 5W30

CCMC-G5 5W40-5W50ACEA A2-96/A3-96 5W40-5W50

API SH 10W40

API SH 10W30

0°C +30°C-30°C +10°C +20 °C-20°C -10°C

-15°C

API SH 5W30

API SH 15W40

* Adjust using dipstick(1) After replacing the oil filter

CCMC-G4 15W40-15W50ACEA A2-96/A3-96 15W40-15W50

CCMC-G5 10W30-10W40-10W50ACEA A2-96/A3-96 10W30-10W40-10W50

07-1

VALUES AND SETTINGS

Capacity - Grades 07

ComponentCapacity in litres

Quality Notes

GearboxV M 1S U 0

2.2-

Brake circuit Normal : 0.7ABS : 1

SAE J 1703and DOT 3

Brake fluids must be approved by our TechnicalDepartment

Fuel tank approx. 80 Unleadedfuel

Power assisted

steering

Separatereservoir

1.1

ELF Renault matic D2or

Mobil ATF 220

Coolingcircuit

N7U 8.5

Glacéol RX(type D)

Add demineralisedwater only

Protection down to - 25 °C ± 2 °C for warm,temperate and cold climates.Protection down to - 37 °C ± 2 °C for extreme

cold climates.

All countries : TRANSELF TRZ 75 W 80 W( API GL 5 or MIL - L 2105 G or D standards)See section 23

07-2

1148798586G

VALUES AND SETTINGS

Accessories belt tension 07

Special notes for removing the accessories belt

PROCEDURE BEFORE REMOVING THEACCESSORIES BELT

Check the belt tension using tool Mot. 1273 andadaptor Mot. 1273-01 . (Tighten the adaptor bymeans of the bolt (1) on the presser button).Place a flexible extension, with handle (for exam-ple R 222 from FACOM), on the end of adapterMot. 1273-01 so that the three clicks can be made.Carry out the measurement between the tensionwheel and the power assisted steering pulley ,even for an air-conditioning version. The measu-red value must be between 49 and 76 Seem Units.

If the value obtained is not within these limits, re-place the tensioner.

SPECIAL TOOLING REQUIRED

Mot. 1273 Tool for checking belt tension

Mot. 1273-01 Adaptor for tool Mot.1273

Mot. 1348 Accessories belt tensioner

EQUIPMENT REQUIRED

Flexible extension with handle (Example R 22 fromFACOM)

07-3

VALUES AND SETTINGS

Accessories belt tension 07ACCESSORIES BELT ROUTING

With air-conditioning

A Crankshaft pulleyB Air-conditioning compressorC PulleyD AlternatorE Power assisted steering pulleyF Tension wheel

98580R

10428R

Vehicle on a lift, disconnect the battery.

Remove:- the engine undertray,- the computer,- the computer mounting.

07-4

VALUES AND SETTINGS

Accessories belt tension 07

98571R

NOTE :The belt is removed and refitted using Mot.1348. The tension wheel must be locked byinserting the pin (1) in the hole (2).

Do not reassemble a belt which has been remo-ved.

RefittingRefitting is the reverse of removal.

07-5

VALUES AND SETTINGS

Timing belt tension 07SPECIAL TOOLING REQUIRED


98587R

Before removing the belt :

Check the belt tension using the tool Mot. 1273.(The measurement is carried out between the wa-ter pump pulley and the exhaust camshaft pulley).The measured value must be between 36 and 46Seem Units.

If the value obtained is not within these limits, re-place the timing tension wheel.

07-6

VALUES AND SETTINGS

Tightening the cylinder head 07TIGHTENING THE CYLINDER HEAD

REMINDER:For correct bolt tightening , use a syringe to drainany oil which may be present in the cylinder headmounting holes.

All the cylinder head bolts must be systematicallyreplaced after removal. The cylinder head is notretightened.

Lubricate the threads and underneath the boltheads with engine oil.

Tightening the cylinder head

Preseating the gasket :

- first tightening to 2 daN.m- a second tightening to 6 daN.m

Wait 3 minutes , which is the settling time.A third angular tightening of all the bolts is thencarried out (without prior slackening) by an angleof 150° ±5°.

There is no cylinder head retightening operation.

11818S

07-7

ENGINE AND PERIPHERALS

Identification 10

Type ofvehicle

Engine

Manualgearbox

andautomatic

transmission

Cubiccapacity

(cm3)

Bore(mm)

Stroke(mm)

Compressionratio

B54F N7U 700N7U 701

VM 1SUO 2435 83 90 10.5/1

Workshop Repair Manuals to be consulted : Mot. N (E) (in course of preparation).

10-1

ENGINE AND PERIPHERALSOil consumption 10

METHOD OF CHECKING

An oil consumption level of 1 litre per 1000 km isallowed.

Check that there is no oil leaking from the engine.

For an effective check, it is necessary to ensure cer-tain conditions when draining the engine oil:

- the engine must be warm,- remove the dipstick and the filler plug.

Then drain the engine and leave it for the oil todrip out for at least 15 minutes.

Replace the drain plug and "seal" it in (applying atouch of paint both to the plug and to the sump)in order to be able to check up later that it has notbeen removed.

Fill with engine oil to the maximum dipstick level.

Refit and seal the filler plug.

Ask the vehicle’s user to return the vehicle afterrunning for 500 miles (1000 km) and having regu-larly checked the oil with the dipstick.

When the vehicle is returned, check that the drainand filler plugs have not been removed.

Using a measuring cylinder, top up with oil to themaximum level and note the quantity of oil ad-ded.

10-2

ENGINE AND PERIPHERALSOil pressure

Put the vehicle on a lift, disconnect the battery :

Remove :- The engine undertray,

- the oil pressure switch using the 22 mm longsocket.

Fit parts E + C in position.

10CHECKING

87363R


Mot. 836 -05 Oil pressure testing kit

EQUIPMENT REQUIRED

22 mm long socket

The oil pressure must be checked when the engineis warm (approximately 80°C).

Composition of the kit Mot. 836-05.

USE:

N engines : F + E + C

Oil pressure

Idle speed 0.8 bar3000 rpm. 3.2 bars

98625R

10-3

ENGINE AND PERIPHERALSEngine and transmission assembly 10

10540R1

Put the vehicle on a 2 post lift.Remove:- the battery and its mounting,- the cover,- the acoustic tie-rod from the engine moun-

ting- the air filter unit by removing the clip located

on the cylinder head lifting bracket and thebolts (2),

- the engine undertray,- the two nuts (1) on the air filter unit, then re-

lease it from underneath.

Load positioning tool


Mot. 1202 Hose clip pliers

T. Av. 476 Ball joint extractor

EQUIPMENT REQUIRED

TIGHTENING TORQUES (in daN.m)

Brake caliper mounting bolt 3.5Shock absorber base bolt 25Bolt at edge of gearbox 5Wheel bolt 10Relay bearing locking bolt 2Engine tie-bar bolts 15Upper nut securing the rubber enginemounting pad to the front left sidemember 5.7Lower nut securing the rubber enginemounting pad to the front left side member 15Bolt securing suspended engine mounting pad to front left side member 5.7Acoustic tie-rod bolt 2Bolt securing the front right suspended engine mounting cover to engine 5.5Front right suspended engine mounting limiter nut 9.5Nut securing rubber mounting pad to thesuspended engine mounting cover, frontright side 5.5

10-4


11795R

BEFORE REMOVING THE DRIVESHAFT SEERECOMMENDATIONS IN SECTION 29.

- the two front wheels,- the right and left mudguards,

- the right and left side mudguards.

Drain the automatic transmission (see section 23).

Left hand side of the vehicle

Remove :- the ABS sensor (if fitted),- the brake caliper, securing it to the shock ab-

sorber spring,- the track rod end using the tool

T. Av. 476,- the shock absorber base bolt,- the lower ball joint nut.

PRC10.11

Right hand side of vehicle

Remove :- the ABS sensor (if fitted),-- the brake caliper, securing it to the shock ab-

sorber spring,- the track rod end using the tool

T. Av. 476,- the two drive shaft flange mounting bolts.

98315R

10-5


- the relay bearing locking bolt,

10560R1

- the lower ball joint nut

Release the hub and driveshaft assembly.

IMPORTANT : do not dismantle the driveshaft atthe relay bearing; it is not fitted with an anti-release plate.

97357S

Make sure that the gaiters are protected.

Remove :

- the three exhaust flange bolts,

- the direction indicators to gain access to thebrackets (12) on the radiator grille,

- the two bolts (3) to slide the clips (10) and (11)in the direction of the arrows,

- using a screwdriver, carefully separate thebrackets (12), then gently release the radiatorgrille assembly.

11237R1

11569R1

10-6


11236R1

If the vehicle is fitted with a headlight washer sys-tem, disconnect the union (13) located on theright-hand side of the right headlight.

Unclip the headlight washer cover.

11708R2

95094R

95096R2

Remove :- the front bumper after removing the two

mounting bolts (B) on each side of the vehicle,and the bottom mounting bolt (C).

10-7


- the upper front cross member , after disconnec-ting the lights and bonnet connectors, and af-ter removing the eight mounting bolts (D).

94994R1

10541-1R

Drain the air conditioning circuit.

Remove the bolt (7) from the flange supportingthe refrigerant connection pipes ensuring that thepipes and unions are blocked with plugs.

Disconnect the three connectors (8) and the earthwire (9).

10537R

Remove- the two mounting bolts (E) for the power assis-

ted steering pipe,

If the vehicle has automatic transmission, removethe bolt from the flange retaining the connectingpipes of the automatic transmission oil cooling ra-diator.Remove the top and bottom radiator hoses.

94995R

10-8


94995R1

Remove :- the two mounting bolts (G) for the cooling as-

sembly

- the air conditioning pipes from the compressor,taking care to block them ,

- the injection computer.

Disconnect :- the impact switch,- the canister bleed solenoid valve,- the canister bleed solenoid valve pipe,- the accelerator cable,- the connector of the cruise control pump.

11770R

Remove the expansion bottle.

Disconnect :- the coil feed,

11761R

11763S

- the brake servo pipe,- the wiring loom of the engine connection unit.

Remove :- the two mountings of the engine wiring loom

channel

10-9


-the heater hoses, using a screwdriver, press on (D)and pull sharply to the rear to disconnect the twohoses from the radiator .

TAKE CARE NOT TO LOSE to the two sleeve seals.

95049R

- the relay mounting plate,

11764R

10610R

Remove :- the computer mounting from the automatic

transmission,- the clutch cable by removing the two nuts and

the clip.

11765R1

Remove the pipe from the cruise control LDA.

Disconnect the connector from the oxygen sensor.

Clamp the power assisted steering oil return pipeand drain the reservoir.

Remove the power assisted steering high pressureoil pipe, remembering to remove the two moun-ting bolts from the steering pipe on the sump.

Remove the engine tie-bar.

10-10


Secure the bonnet in the raised position after un-clipping the cylinders.

90920S

Fit the load positioning tool and the workshopcrane.

98577S

Remove the mounting bolts (V) from the lowercross member.

95245R

11759S1R

Remove:

- the engine mounting and the earth strap,- the fuel inlet and return pipes,- nut (18) from the gearbox mounting,- then, using a copper hammer, knock to release

the stud from the left hand suspended enginemounting, then remove the rubber mounting(19).

NOTE : this cross member contributes to the rigidi-ty of the engine compartment structure. Beforecarrying out any work on it it is therefore essentialto take the weight of the engine off its suppor-ting points (since removal of the unsupported en-gine cross member would involve a displacementof the side members ).Using the workshop crane release the engine andtransmission assembly.

IMPORTANT : refit the lower cross member afterremoving the engine/transmission assembly.

10-11


Special notes on refitting :

Reposition the engine in its compartment, wi-thout securing it.

Refit:- the lower cross member ,- the fuel inlet and return pipes,- the left suspended engine mounting,- the right suspended engine mounting,- the engine tie-bar.

Proceed to tighten the engine tie-bar to a torqueof 15 daN.m, the two nuts for the rubber moun-ting to a torque of 5.7 daN.m, together with theupper rubber mounting nut and the suspendedengine mounting, as follows :

Order for tightening the suspended enginemounting (front right).

The mounting must be tightened in the order in-dicated below.

Refitting is the reverse of removal.

Carry out the following:- fill the gearbox with oil (see section 23),- fill the engine with oil,- fill the power assisted steering circuit,- fill and bleed the cooling circuit (see section

19),- fill the air-conditioning circuit (if fitted), new

refrigerant R134a.

Adjust:- the accelerator cable,- the gear selector cable (see section 37).

Fit the mounting bolts for the calipersusing Loctite FRENBLOC and tightenthem to the specified torque.

Depress the brake pedal several times to bring thepistons into contact with the pads.

NOTE : the lug in the relay bearing support plateMUST be at the top.

Order of tightening:

1 then 2 and 3 to a torque of 9.5 daN.m.5, 6 then 7 to a torque of 5.5 daN.m.

NOTE: the tapered nut is positioned at 1

10611R

11758R

10-12

10610R

ENGINE AND PERIPHERALSSump 10

EQUIPMENT REQUIRED

42 mm socket


Sump bolt 1.7Oil filter mounting bolt 6Bolt securing sump to gearbox housing 5

Put the vehicle on a lift.Disconnect the battery.

Remove:- the dipstick guide tube,- the engine undertray.

Drain the engine.

Disconnect the different sensors located on thesump.

Remove:

- the two sump mounting bolts (4) on the gear-box housing.

98316R2

- the two mounting bolts of the power assistedsteering pipe from the sump

- the oil filter mounting bolt (5) to gain access tothe sump bolt (6).

98208-1R1

10-13

ENGINE AND PERIPHERALSSump 10

98210R

Remove :

- the sump, retaining the two O rings (2).

98209R2

REFITTING

Apply Loctite 518 to the sealing face of the sumpusing a roller.

Fit new O rings (2).

Position the sump.

Secure the sump, starting by tightening the twogearbox housing bolts to a torque of 5 daN.m,then the sump bolts to a torque of 1.7 daN.m.

Tighten the oil filter mounting bolt to a torque of6 daN.m.

Reconnect the sump sensors.

Fill the engine with oil

10-14

TOP AND FRONT OF ENGINE

Timing belt 11

- the engine lifting bracket on the flywheel side,- the acoustic tie-bar from the engine mounting,- the right front wheel,- the front and right side mudguard.

Hexagonal long socket size 8

Tool for supporting engine

Angle measuring disc for angular bolt tightening

EQUIPMENT REQUIRED


Mot. 799-01 Camshaft sprocket locking tool


Mot. 1273-01 Adaptor for Mot. 1273

Mot. 1337 Camshaft clamping tool

Mot. 1340 TDC pin

Mot. 1347 Tool for compressing the timing belt tension wheel

Mot. 1348 Tool for removing and refitting the accessories belt

TIGHTENING TORQUES

(in daN.m or in degrees)

Suspended engine mounting cover nut 5.5Suspended engine mounting cover bolt 5.5Suspended engine mounting limiter nut 9.5Acoustic tie-bar bolt 2Wheel bolt 10Accessories belt tension wheel bolt 2.5Timing belt tension wheel bolt 2.5Crankshaft pulley bolt 2.5+30°Crankshaft pulley nut 18Camshaft pulley bolt 2TDC pin plug 4

REMOVAL

Put the vehicle on a 2 post lift.

Disconnect the battery.

Remove:- the engine cover,- the starter motor (see removal of starter mo-

tor in section 16),- the TDC pin plug (located behind the starter

motor) using a size 8 hexagonal long socket.

PRG1103

- the camshaft sensor and shield assembly (1),- the ignition assembly (2),

11-1


Timing belt 11

11760R

- the upper timing cover,

- the accessories belt tension wheel,

Remove the accessories belt (see removal of acces-sories belt in section 07).

Fit the tool for supporting the engine.

Remove:

- the engine mounting,

- the metal fuel pipes, by removing the twobolts (1).

11817S

98318R

- the crankshaft pulley, by removing the fourbolts (C) and the nut (D).

98224R3

11-2


Timing belt 11Positioning the engine as far as the timing settingpoint.

Position the camshaft slots as shown in the dia-gram below.

- the timing cover (11)

PRM1004R1

98219R

F inlet camshaftG exhaust camshaft

- the two anti-fall back bolts (13) and the plate(14).

98428R

98220R

Fit Mot. 1337 by means of the bolts (9) at the endof the camshaft.

Rotate the engine clockwise (timing side) until thetwo arms (10) of Mot. 1337 meet, at the same timeinserting the TDC pin Mot. 1340.

(Rotate the crankshaft in the opposite direction,without forcing it, until it is brought correctlyagainst the pin).

11-3


Timing belt 11

98199G

Fit bolt (2) to clamp Mot. 1337.

11767R1

Check that reference marks (A) and (B) line up.

98221-2R1

Check the belt tension using Mot. 1273 (measurebetween the water pump pulley and the exhaustcamshaft pulley). The measured value must bebetween 36 and 46 Seem units. If the value obtai-ned is not within these limits, replace the timingbelt tension wheel.

98587R

11-4


Timing belt 11Remove:- the tension wheel by removing the two bolts

(20),- the timing belt (21).

NOTE : remove the anti-fall back shim (2) fromthe tension wheel before clamping with the pin.

10882R

98225

REFITTING

Gently compress the timing belt tension wheel onthe press using Mot. 1347, thus preventing it frombeing marked, then clamp it with the pin.

98620R1

98221-2R2

Refit the timing belt tension wheel by tighteningthe two bolts to 2.5 daN.m.

Check that the crankshaft sprocket (A) and oilpump (B) reference marks line up (check that thecrankshaft is against the TDC pin Mot. 1340).

11-5


Timing belt 11Position the threads of the three camshaftsprocket bolts in the centre of the holes (C) (Toprevent the sprockets knocking against the bolts(19) during tensioning).

Fit the timing belt in the following order:- the crankshaft sprocket,- the pulley,- the inlet camshaft sprocket (try to keep the

thread in the centre of the hole (C)),- the exhaust camshaft sprocket (try to keep

the thread in the centre of the hole (C)),- the water pump,- the tension wheel.

98221R

Fit the three bolts and tighten them to a torque of2 daN.m, immobilising the pulleys with Mot. 799-01.

98248R

Release the timing belt tension wheel pin with ahammer.

98220R2

Remove the TDC pin and refit the pin plug andtighten it to 4 daN.m.

Remove camshaft clamping tool Mot. 1337 andTDC pin Mot. 1340.

Rotate the engine two turns, and before the endof the two turns refit the camshaft clamping toolMot. 1337. Rotate the engine until the two arms(10) meet and at the same time insert the TDC pinMot. 1340.

The crankshaft (A) and oil pump (B) referencemarks must line up.

11-6


Timing belt 11Refit:- the anti-fall back shim (2) on the timing belt

tension wheel shaft.

- the protective plate with the two anti-fallback bolts,

- the timing covers,

- the fuel inlet and return hoses,

- the accessories belt tension wheel, tightenedto a torque of 2.5 daN.m,

- the crankshaft pulley, tightening the 4 boltsinitially to a torque of 2.5 daN.m, then makingan angle of 30o,

- the central nut of the crankshaft pulley, tigh-tened to a torque of 18 daN.m,

- the engine mounting, which must be tighte-ned in the following order:

10882R

11760R1

Order of tightening:

1 then 2 and 3 to a torque of 9.5 daN.m.5, 6 then 7 to a torque of 5.5 daN.m.

NOTE: the tapered nut is positioned at 1.

- the alternator belt,- the starter motor,- the camshaft sensor assembly (1),- the ignition assembly (2).

PRG1103


11-7


Cylinder head gasket 11

EQUIPMENT REQUIRED

Engine support tool

Roller

Size 8 hexagon long socket

Angle measuring disc for angular tightening of bolts


Mot. 591 -02 Index

Mot. 591 -04 Angular wrench for tightening cylinder head

Mot. 799-01 Tool for locking camshaft sprocket


Mot. 1273-01 Adapter for Mot. 1273

Mot. 1337 Camshaft clamping tool

Mot. 1338 Camshaft mounting

Mot. 1339 Cylinder head cover positioning tool

Mot. 1340 TDC pin

Mot. 1343 Tool for positioning camshaft seal on timing side

Mot. 1344 Tool for positioning camshaft seal on engine flywheel side

(camshaft sensor)

Mot. 1344-01 Tool for positioning camshaft seal on engine flywheel side

(ignition)

Mot. 1347 Tool enabling the timing belt tension wheel to be compressed

Mot. 1348 Tool for removing and refitting the accessories belt

Mot. 1349 Tool for tightening suspended cylinder head mounting bolts

TIGHTENING TORQUES(in daN.m or in degrees)

Suspended engine mounting cover nut 5.5Suspended engine mounting cover bolt 5.5Suspended engine mounting limiter nut 9.5Acoustic tie-bar bolt 2Cylinder head suspended mounting bolt 6Wheel bolt 10Accessories belt tension wheel bolt 2.5Timing belt tension wheel bolt 2.5Timing pulley bolt 3Crankshaft pulley bolt 2.5+30°Crankshaft pulley nut 18Camshaft pulley bolt 2TDC pin plug 4

REMOVAL

Put the vehicle on a 2-post lift.Disconnect the battery.Drain the cooling circuit via the drain plug (1) lo-cated on the water pump.

11769R

11-8


Cylinder head gasket 11Remove:- the timing belt (see Chapter 11 - timing belt),- the timing belt tension wheel, remove the

bolt (2),- the timing belt pulley (3),

98221-3R

- the two thermostat hoses,- the suspended cylinder head mounting (5

bolts), using Mot. 1349 to slacken the bolt.

98224R2

- the camshaft pulleys, locking them by meansof Mot. 799-01.

98248R1

- the inner timing cover,

98576R

11-9



- the dipstick guide tube,- the inlet manifold /cylinder block strut,

the exhaust down pipe mounting bolts.

Fit the tool for retaining the camshaft on the ti-ming side, Mot. 1338, securing it with the twobolts (A).

Disconnect:

- the injectors,- the vacuum and oil vapour rebreathing pipes

from the throttle body,- the accelerator cable,- the coolant temperature sensor on the cylinder

head side (engine flywheel side),- the idling speed regulating valve,- the throttle potentiometer,- the injection coolant temperature sensor on

the thermostat,- the oil vapour rebreathing pipe located on the

cylinder head cover, the canister bleed pipe lo-cated on the inlet manifold side,

- the brake servo pipe

Remove:

- the bracket between the power assisted stee-ring pump and the inlet manifold,

98319R4

11767R

Place the retaining shim (B) of the cylinder headcover on Mot. 1337 for clamping the camshaft onthe engine flywheel side.

Slacken the 40 bolts on the cylinder head coverand release it vertically (to avoid breaking theedges of the grooves (7) of the cylinder head) bygently tapping the lugs (6) with a copper ham-mer.

11766R1

98207R1

11-10


Cylinder head gasket 11Remove the 3 bolts of the rigid coolant pipe.

11769R1

Remove the cylinder head.

11816R

Remove Mot. 1337 and Mot. 1338 to facilitate cleaning of the parts.

11-11



11816-1R

Cleaning

It is very important not to scratch the sealing faces of the aluminium parts.

Use the product Decapjoint to dissolve the part of the gasket which remains.

Apply the product to the section to be cleaned; waiting about ten minutes, then re-move it with a wooden spatula.

It is advisable to wear gloves during this operation.

Do not allow the product to drip on to paintwork.

This operation must be carried out with great care to prevent foreign bodies frompenetrating the pipes feeding oil under pressure to the camshafts (pipes locatedboth in the cylinder block and in the cylinder head) and the oil return pipe.

NOTE: check carefully that the lubricating pipes for the cylinder head (8), cylinderhead cover (9), the camshaft bearings (10) and the hydraulic tappets (11) are notblocked.

11-12


Cylinder head gasket 11CHECKING THE GASKET FACE

Using a straight edge and a set of feeler gaugescheck whether there is any deformation of thesealing face.

Maximum deformation: 0.05 mm.

No regrinding of the cylinder head is permitted.

REFITTING - Special notesThe cylinder head is centred by two dowels.

98581-1S

11762R

Fit a new cylinder head gasket.

Tighten the cylinder head by means of Mot. 591-04 and MOT. 591-02, or by means of the anglemeasuring disc for angular tightening of thebolts.

Using a roller apply to the sealing face of the cy-linder head cover until it turns a "reddish" colour.

For method of tightening see section 07 "Valuesand settings", tightening of cylinder head.

Place the inlet and exhaust camshafts on the cylin-der head cover in their respective positions.

NOTE: the camshafts may be identified:

1) By a mark at the end of the camshaft on thegroove side.

98254R

This mark consists of:

- at G: reference reserved exclusively forthe factory

- at H: the letters PJ are also reserved exclu-sively for the factory

- at F: the identification letter of the cams-haft.Inlet: reference I (Inlet)Exhaust: reference E (Exhaust)

11-13



11756R

Place the groove (A) at the end of the camshaft horizontally (groove above the camshaft axis).

The cams of the cylinder (3) must be located to the left of the vertical axis (D).

Inlet

2°) By means of a reference mark in relation tothe cams.

11757R

Exhaust

Position the groove (B) at the end of the camshaft horizontally (groove above the camshaft axis).

The cams of the cylinder (5) must be located to the right of the vertical axis (C).

11-14


Cylinder head gasket 11Clamp the camshafts on the timing belt side withMot. 1338 , securing it with the two bolts (A), andon the flywheel side with Mot. 1337, securing itwith bolt (B).

11767R

Fit the O rings (Y) in the plug openings.

98207R2

Fit:- the cylinder head cover with its camshafts on

the cylinder head,- the Mot.1339 tools, then tighten them simul-

taneously until the cylinder head covertouches the cylinder head.

Fit the bolts and tighten them to 1.7 daN.m.

NOTE : the use of Mot. 1339 prevents damage tothe cylinder head cover when it comes intocontact with the cylinder head.

Remove the tools Mot. 1339, Mot. 1337 and Mot.1338.

Fit the camshaft gaskets.

Use Mot. 1343 for the seals on the timing beltside.

98569R

11768R

11-15


Cylinder head gasket 11Use the Mot. 1344 for the seal on the camshaftsensor side.

Use the Mot. 1344-01 for the seal on the ignitionside.

98573-1R

- the suspended cylinder head mounting, anduse the Mot. 1349 to tighten the bolts to a tor-que of 6 daN.m.


Refit:- the timing cover (1), then the camshaft pulleys

(2), refitting only two bolts per pulley.

98248-1R

11760R1

For the timing (see section on timing belt).

Refit the engine mounting, which must be tighte-ned in the following order

Order of tightening:1 then 2 and 3 to a torque of 9.5 daN.m.5, 6 then 7 to a torque of 5.5 daN.m.

NOTE: the tapered nut is located at 1.

Fill and bleed the cooling circuit (see Section 19 -Filling and bleeding).

11-16

FUEL MIXTURE

Specifications 12

Vehicle Gearbox

Engine

Type SuffixBore(mm)

Stroke(mm)

Capacity(cm3)

RatioCatalytic

converter

Depollutionstandard

B54 F VM 1 N7U 700 83 90 2435 10.5/1 C52 EU 96

B54 F SU 0 N7U 701 83 90 2435 10.5/1 C52 EU 96

* For a coolant temperature greater than 80°C and after stable engine speed of 2 500 rpm forapproximately 30 seconds.

** For legislative values, refer to specification for individual country.*** Compatible with OR 91 unleaded fuel.

Temperature in °C (± 1°) 0 20 40 80 90

Coolant temperature sensorType CTNResistance in Ohms

6700to 8000

2600to 3000

1100to 1300 260 to 300 190 to 230

Engine

Type Suffix

Tests carried out at idle speed *

Enginespeed[rpm]

Emission of pollutants**

CO (%) (1) CO2 (%) HC (ppm) Lambda (λ)

Fuel ***(minimum octane

rating)

N7U 700701 750±50 0.5

maximum14.5

minimum100

maximum 0.97<λ<1.03 Unleaded (OR 95)

(1) At 2500 rpm, CO should be 0.3 maximum.

12-1

FUEL MIXTURE

Specifications 12

DESCRIPTION MAKE/TYPE SPECIAL NOTES

Computer BOSCH M4.4. 88 tracks

Injection - Sequential regulated multipoint

Ignition -

DistributedOne coil :Primary circuit resistance 0.8 ΩSecondary circuit resistance 8.35 KΩOne power moduleTwo pinking sensorsTightening torque: 2 daN.m

TDC sensor Resistance 300 Ω

Spark plugsVolvo 3517980Bosch FR 7 DC

CHAMPION RC 9 YC

Gap : 0.7 mmTightening torque : 2.5 to 3 daN.m

Fuel filter - Mounted in front of the fuel tank under the vehicleReplace at major service

Fuel pump WALBROSubmerged in fuel tankFlow: 80 litres/hour minimum at regulated pressureof 3 bars and voltage of 12 volts

Pressure regulator BOSCHRegulated pressureZero vacuum : 3 ± 0.2 barsVacuum of 500 mbars : 2.5 ± 0.2 bars

Solenoid injector BOSCH Voltage 12 voltsResistance : 16.5 ± 1 Ω

Flowmeter BOSCH -

12-2

FUEL MIXTURE

Specifications 12DESCRIPTION MAKE/TYPE SPECIAL NOTES

Throttle body VOLVO -

Throttle potentiometer -

Voltage 5 VoltsResistance : track No load Full load

1 - 2 2060Ω 2060Ω1 - 3 1050Ω 2570Ω2 - 3 2660Ω 1140Ω

Idle speed regulation solenoidvalve BOSCH Voltage 12 Volts

Resistance between 2 - 1 and 2 - 3 : 12 Ω

Fuel vapour rebreathingcanisterSolenoid valve

CAN 8BOSCH

Voltage : 12 Volts (RCO control)Resistance : 25.5 ± 5 Ω

Heated oxygen sensor BOSCH

Voltage at 850 °CRich mixture : > 625 mvoltLean mixture : 0 to 80 mvoltHeating resistance, track: A - B 2 to 15 ΩTightening torque: 5 daN.m

Fault finding FICHE N° 47CODE D 13

SELECTOR S8

Throttle potentiometerIdle regulation : 0 ≤ # 17 ≤ 10Full load : 80 ≤ # 17 ≤ 90

R.C.O. idle speed : 10 ≤ # 12 ≤ 30 %Adaptive R.C.O. idle speed : -51 ≤ # 21 ≤ +51Adaptive richness operation : 0≤#30≤255Adaptive richness idle speed : 0≤#31≤255

12-3

FUEL MIXTURE

Throttle body 12


Throttle body mounting bolt onmanifold 1

REMOVAL - REFITTING

Method of adjusting the throttle body control


Elé. 1072 1.2 mm to 2.5 mm carburettor

gauges

EQUIPMENT REQUIRED

Set of adjusting shims

1 mm diameter drill

This operation must be carried out after thethrottle body has been replaced.

Disconnect the coil and throttle control lever.

Unscrew the plastic nut (1) retaining the lever rod.

11958R

Fit in the coil:- a gauge or 2.5 mm diameter drill for vehicles

fitted with a manual gearbox,- a 1 mm diameter drill for vehicles fitted with

automatic transmission.

11957R

12-4

FUEL MIXTURE

Throttle body 12

Reconnect the lever applying 33 MEDIUM greaseto the ball joints.

Tighten the nut retaining the lever rod.

Validate the full load programming operationsfor the automatic transmission using the XR25.

11956S

Fit a set of 0.3 mm shims between the the adjus-ting bolt and the throttle control.NOTE: DO NOT ALTER THE ADJUSTMENT OF THEBOLT.

12-5

FUEL MIXTURE

Inlet manifold 12


Manifold mounting bolt on cylinder head 1.7

NOTE : the bottom mounting holes of the mani-fold are open, thus it is not necessary to slackenthe bottom bolts fully.

Exhaust manifold


Manifold mounting studs on cylinder head 2Manifold mounting nuts on cylinder head 2.4

There are no special notes for removal - refitting.

12-6

FUEL SUPPLY

Air inlet

INLET CIRCUIT

The air inlet circuit is fitted with a silencer for reducing the inlet noise.

13

11815R

1 Thermostatic unit2 Air filter3 Throttle body4 Inlet manifold5 Flowmeter

11795-1R

13-1

FUEL SUPPLY

Supply pressure 13

11764-1R

Shunt terminals (3) and (5) of the pump relay(236). Check the pressure, it must be 3 +/- 0.2bars.


Mot. 1265 Pliers for removing the fuel unions

Mot. 1311-01 Fuel pressure test kit

Mot. 1311 -03 Pressure measuring union

CHECKING THE PRESSURE

Remove the upper plastic protective cover fromthe cylinder head cover which is retained by 4bolts.

A quick release union specially designed to carryout pressure measurements is fitted at the end ofthe injector gallery.

Use the tool Mot. 1311-03 to connect to thisconnection. Mot. 1311-03 must be integrated inkit Mot. 1311-01.

Connect Mot. 1311-03 to the 0; + 10 bar pressuregauge using the kit (Mot. 1311-01).

CHECKING THE FUEL SUPPLY PRESSURE AND PUMP FLOW

98548R1

EQUIPMENT REQUIRED

1 2000 ml measuring cylinder

13-2

FUEL SUPPLY

Supply pressure 13Reconnect the relay (236) and start the engine.

For an engine speed of 750 rpm the pressure mustbe 2.5±0.2 bars.

11811S

For a short while clamp the flexible fuel returnpipe located close to the bulkhead to check the sa-fety pressure of the fuel pump; it must be bet-ween 4.5 and 7.5 bars.

CHECKING THE PUMP FLOW

It is advisable to check the fuel pump flow ratethrough the fuel return pipe connected to thesender unit assembly.

To do this:

Lift up the boot carpet and remove the plasticplug.

95500R3

If a clip (1) is fitted it is necessary to remove it be-fore disconnecting the pipe.

13-3

FUEL SUPPLY

Supply pressure 13Disconnect the fuel return pipe (identified by ared quick release union and an arrow on the sen-der unit assembly) using the special pliers Mot.1265 (see diagram below for positioning of thesepliers).

96420R1

Connect one end of semi-rigid diameter 8 pipe tothe quick release union, and extend it in a 0 - 2000ml measuring cylinder.

Shunt terminals (3) and (5) (large section wires) ofthe fuel pump relay (236) and check the pumpflow rate. It must be greater than 1.3 litres per mi-nute.

NOTE : When refitting, make sure that the quick releaseunion engages correctly (presence of two O rings).

If the flow rate is low, check the supply voltage tothe pump (loss of flow approximately 10% for avoltage drop of 1 volt).

13-4

FUEL SUPPLY

Antipercolation device 13OPERATING PRINCIPLE

The injection computer controls the low speed ofthe fan for 5 minutes if the coolant temperatureexceeds 100 °C, when the ignition is turned off.

13-5

PUMPSMechanical power assisted steering pump 13

98319-1R

- the high pressure (HP) pipe,- the low pressure (LP) pipe.


Mot. 1348 Tool for removing and refitting

the accessories belt


High pressure union on pump 2.5Mounting bolt 8×25 2.5Mounting bolt 8×80 2.5

REMOVAL

With the battery disconnected, remove :- the belt with the tool Mot. 1348. Lock the belt

tension wheel using the 4 mm diameter pin atB.

98571R2

IMPORTANT

Fit a blanking cover on the reservoir (LP and HPcircuits) to prevent oil from escaping on to the al-ternator.

A Low pressure pipe

13-6

PUMPS

Mechanical power assisted steering pump 13REFITTING


Fit a new belt.

Remove the 4 mm diameter locking pin from thetension wheel using the tool Mot. 1348.

Belt tension adjustment is automatic.

Fill and bleed the circuit.

Remove:- the 3 bolts (arrows),

98318R4

- the 2 mounting bolts (1).

98319-1R1

Remove the pump-pulley-reservoir assembly.

13-7

PUMPS

Mechanical power assisted steering pump 13

97879R

Press on the pulley until the dimension: X = 0±0.1 mmis obtained.

REPLACING THE PULLEY (1st method)

EQUIPMENT REQUIRED

NAUDER Tooling for removal - refitting of

(2 tools) pulley (see equipment catalogue)

The pulley is grooved.

The use of the NAUDER tooling (presented in theequipment catalogue) is essential for removingand replacing the pulley on the new pump wi-thout damaging it.

REMOVAL

REFITTING

97880R

97539R2

13-8

PUMPS


90318-3S

REPLACING THE PULLEY (2nd method)

REMOVAL

Depending on assembly, remove the pulley afterhaving measured the dimension in relation to theend of the shaft.

Grooved pulley

Use an extractor.

91581S


Dir. 1083 Tooling for refitting the steering

pump pulley

Ungrooved pulley

Use the press with an extractor.

13-9

PUMPS


90318-2R

REFITTING

NOTE: before refitting the pulley it is essential toensure that the pump mounting can be installedafterwards, otherwise fit it before pressing on thepulley.

Press on the pulley, using the tool Dir. 1083, untilthe dimension determined during removal is ob-tained (liberally grease the thread and support onthe pulley).

88064-1R

13-10

PUMPS


10619R

Pressure values to be obtained :

CHECKING THE OIL PRESSURE


Ms. 583 Hose clamp pliers

Mot. 836 -05 Pressure testing kit

Mot. 836 -06 Sets of unions

Dir. 803 Pressure testing union

Fre. 1085

or Pressure gauge

Fre. 244 -03

Fre. 284 - 06 Connecting pipe

Place pliers Ms. 583 on the low pressure pumphose.

Disconnect the high pressure pipe (allow for theescape of oil).

Insert the union Dir. 803 (metric thread) betweenthe hose and the pump using the sleeve (E) of thekit Mot. 836-05 and the unions Mot. 836-06 sothat the union Dir. 803 is released from the reser-voir.

Connect the oil pressure gauge Fre. 1085 (at Fre.244-03 + Fre. 284-06).

Remove the pliers Mot. 583.

Top up the oil level and turn the engine over tocheck the pressure.

- Wheels in a straight line:Whatever the engine speed, the pressure mustnot exceed 5 to 7 bars.

- Full lock on one side:The maximum pressure must be 96 to 104bars.

IMPORTANT: this operation must be carried outas quickly as possible to prevent a rapid increase inoil temperature (at full lock).

Remove the unions and pressure gauge by cuttingoff the supply with pliers Ms. 583.

Reconnect the high pressure pipe and removepliers Ms. 583.

Top up the reservoir oil level.

13-11

ANTIPOLLUTIONOil vapour rebreathing 14

11814R

PRESENTATION OF THE CIRCUIT

PRD1401

14-1

ANTIPOLLUTIONOil vapour rebreathing 14

1 Air filter

2 Air pipe

3 Throttle body

4 Inlet manifold

5 Oil decanter

6 Cylinder head cover

7 Pipe draining oil vapours from the top ofthe engine (the outlet moulded on the cy-linder head cover has a diameter of 11 mm).

8 Pipe draining oil vapours from the bottomof the engine.

9 Connection enabling the oil to be returnedfrom the decanter to the engine.

10 Pipe rebreathing oil vapours via the engine(this pipe is connected to a T-union).

11 T-union. Its function is to bring togetherthe oil vapours and the manifold vacuum.To do this there are 2 rebreathing circuits.

• One circuit upstream from the throttlebody. This circuit is used for mediumand high loads. The vapours are recir-culated by the vacuum in the air pipe(2). They then pass through the insideof the tee mounted on the pipe.

• One circuit downstream from thethrottle body. This circuit is used forlow loads. The vapours are recirculatedby the vacuum prevailing between thethrottle and the engine. The vapourscross the tee before returning to thethrottle body via a pipe (12).The union on the throttle body has anozzle 4 mm in diameter.

To remove the tee rotate it 1/8 of a turnto the left, then pull it up. The tee alsohas a flame baffle function.

14-2

ANTIPOLLUTIONFuel vapour rebreathing 14

11813R

1 Engine2 Inlet manifold3 Solenoid valve4 Canister fitted with an air breatherR Fuel vapour collection pipe from fuel tank

DIAGRAM OF THE CIRCUIT

14-3

ANTIPOLLUTIONFuel vapour rebreathing 14

OPERATING PRINCIPLE

The fuel tank breathes through the canister.

Fuel vapour is retained by the active carbon in thecanister.

So that the fuel vapour contained in the canisterdoes not evaporate into the atmosphere whenthe fuel tank is opened, a valve isolates the canis-ter from the fuel tank when the fuel filler cap isremoved.

The fuel vapour contained in the canister is elimi-nated and burnt by the engine.

To do this, a pipe connects the canister and the in-let manifold. A solenoid valve is located on thispipe to control bleeding of the canister.

The operating principle for the solenoid valve is togive a variable passage diameter (depending onan RCO signal from the injection computer).

The variation in the selection of passage diameterfor the fuel vapour in the solenoid valve resultsfrom the balance between a magnetic field crea-ted by the feed to the coil and the force of a re-turn spring ensuring the valve remains closed.

CONDITION FOR BLEEDING THE CANISTER

The canister is bled if the coolant temperature isgreater than +50° C.

The cyclical opening ratio for the canister bleedsolenoid valve may be seen using the XR25 and#23. The solenoid valve is closed for #23 = 0.00% (minimum value).

LOCATION - REMOVAL

Canister bleed solenoid valve (1)

The valve is mounted at the front right under theinjection computer.

11812R

14-4

STARTING - CHARGING

Alternator

IDENTIFICATION

16

Vehicle Engine Alternator Current

B54 F N7U VALEO A 13 VI 118 120 A

CHECKING

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

engine rpm 120 amps

1 500 28 A

4 000 75 A

6 000 80 A

16-1

STARTING - CHARGING

Alternator 16

98319R5

REMOVING THE ALTERNATOR

Put the vehicle on a lift


Remove:- the belt from the alternator (see section 07,

"values and settings", accessories belt ten-sion).

Disconnect the connector from the cruise controlpump.

Remove:- the mounting (1) (two bolts)

- the two bolts mounting the steering pipe onthe sump and the nut on the wiring loom chan-nel.

- the five bolts (2) and release the power assistedsteering pump assembly.

10610R

98318R5

Disconnect the alternator.

16-2

STARTING - CHARGING

Alternator 16REMOVAL (contd.)

Remove:

- the pin (3) (bolt - nut),- the bolt (E), supporting the alternator and re-

leasing it from above.

98202R2

REFITTING

Place the 3 alternator mounting bolts in positionbefore tightening them and proceed to refit inthe reverse order of removal.

Special note

Do not refit a belt once it has been removed, re-new it.

16-3

STARTING - CHARGING

Starter motor 16IDENTIFICATION

Vehicle Engine Starter motor

B54 F N7U BOSCH 0001 108 166

16-4

STARTING - CHARGING

Starter motor 16

10539R

REMOVAL


Remove:- the air inlet pipe to the throttle body and air

filter unit outlet,- the hot air pipe,- the hot air tube mounting,

Disconnect the starter motor.

Remove:- the rear starter motor mounting bolt (on cy-

linder block),- the two starter motor bolts (1).

REFITTING


Special note

Check the centring dowel (A) is present.

16-5

IGNITION

Distributed ignition

The ignition system comprises :

- a power stage (1),- a resistance coil (2) :

primary circuit : 0.8 Ω,secondary circuit : 8.35 KΩ,

- an anti-interference condenser (3),

17

- a distributor (4).

The firing order is 1 - 2 - 4 - 5 - 3 (cylinder N° 1 onthe timing belt side)

11763-1R 11810R

11809R


Elé 1382 Spark plug kit

17-1

IGNITION

Distributed ignition 17- plugs, to remove them use plug kit Elé 1382.

Tightening torque : from 2.5 to 3 daN. m.

11808R

VOLVO : 3517980.

BOSCH : FR7DC.

CHAMPION : RC9YC.

Gap : 0.7 mm.

17-2

IGNITION

Distributed ignition 17The injection computer controls the power stage (1) via its track 25.

PRG1701

17-3

INJECTIONGeneral 17

SPECIAL NOTES ON THE BOSCH M4.4 INJECTION.

88 Track computer

Standard type 2nd generation coded engine immobiliser. In order to operate the injection computer needsto programme the immobiliser code.

Use of a hot film flowmeter to replace the pressure sensor and air temperature sensor.

Injection is cylinder by cylinder (sequential).

Distributed ignition.

Canister bleed solenoid controlled by RCO.

Idle speed correction depending on:- the battery voltage,- the air conditioning.

The injection warning light on instrument panel is operational.

The coolant temperature warning light on the instrument panel is controlled by the injection computer if thecoolant temperature is greater than 120 ° C.

Use of fault finding fiche no. 47.

Computer configuration depending on the equipment:- with automatic transmission or manual gearbox,- with or without air conditioning.

To achieve this configuration consult the fault finding fiche "Reminder C".

17-4

INJECTIONGeneral 17

1 Injection computer 2 Pinking sensor 3 Coolant temperature sensor 4 TDC sensor 5 Fuel vapour recirculation solenoid valve 6 Camshaft sensor 7 Idle speed regulation solenoid valve 8 Throttle position potentiometer 9 Air filter10 Flowmeter11 Anti-interference condenser12 Coil13 Distributor

LOCATION OF THE COMPONENTS

14 Ignition power stage15 Injection locking relay (238)16 Fuel pump relay (236)

17-5

INJECTIONLocation of the components 17

11807R

To remove the coolant temperature sensor (3), re-move:

- the cover,- the engine tie-bar (1).

Protect the alternator.

Fit hose clamp pliers at (R).

Remove the cover from the thermostat (A).

Disconnect the coolant temperature sensorconnector.

When refitting, change the coolant temperaturesensor seal as well as the thermostat seal.

Top up the coolant, then bleed the circuit.

7 Idle speed regulation solenoid valve

11 Anti-interference condenser12 Coil14 Ignition power stage

11763-1R1

5 Fuel vapour recirculation solenoid valve.

10428-1R1

17-6

INJECTION

Location of components 17

11794R

2 Pinking sensor, tightening torque :2 daN.m

18 Oxygen sensor, tightening torque :5 daN.m

11762-1R

15 Locking relay (238)16 Fuel pump relay (236)

11764-1R1

4 TDC sensor8 Throttle potentiometer

10 Flowmeter

11806R

17-7

INJECTIONLocation of components 17

A Camshaft sensor

11805R

17-8

INJECTIONSpecial notes on sequential injection 17

11805R

SPECIAL NOTES ON SEQUENTIAL INJECTION

Presentation

The N7U engine is fitted with sequential injection.

Injection of fuel is not carried out simultaneouslyto the five cylinders as with conventional injec-tion, but cylinder after cylinder when they are atthe start of the inlet phase.

To do this, it is necessary for:- each injector to be connected separately to

the computer (injector n° 1 is at the timingend),

- the computer to know which cylinder is at theinlet phase.

To determine the cylinder at the inlet phase, thecomputer uses 2 sensors:- the TDC sensor,- the camshaft sensor.

If the camshaft sensor is faulty it is impossible tostart the engine.

Description

The camshaft sensor (A) is located at the end ofthe exhaust camshaft. It is mounted on to the cy-linder head with two bolts.

The sensor is opposite a long target (B) of 180°.This is mounted on the end of the camshaft. Thesensor and the target cannot be adjusted.

If the target is located within the sensor air gap,12 V is sent to the computer.

If the target is not in the sensor air gap, 0 V is sentto the computer.

Sensor operating principle

The sensor is supplied with 12 Volts. The computersends it a 12 V feed on track 2.

Depending on the position of the target, the sen-sor closes the circuit and earths this voltage (thecomputer receives 0 V), or the sensor leaves thecircuit open (the computer receives 12 V).

17-9

INJECTIONSpecial notes on sequential injection 17

PRD1701

CONNECTION OF THE CAMSHAFT SENSOR

TRACK ALLOCATION

1 Earth

2 Information to injection computer on track 44

3 Sensor feed via computer on track 45

17-10

INJECTIONInjection fault warning light 17

PRINCIPLE FOR ILLUMINATION OF THE INJECTION FAULT WARNING LIGHT ON THE INSTRUMENT PANEL

• Vehicle with engine immobiliser system deactivated

When the ignition is turned on, the injection warning light illuminates for 3 seconds then extinguishes

When the doors are unlocked the red engine immobiliser warning light, which was previously flashing,extinguishes. When the ignition is turned on, it illuminates for 3 seconds then extinguishes (generally theengine starts, then stalls).

• Vehicle with engine immobiliser system activated

When the ignition is turned on, the computer does not identify the code and prevents the engine frombeing started. The injection warning light illuminates for 3 seconds then extinguishes.

Before the ignition is turned on the red immobiliser warning light flashes. When the ignition is turned onthis same warning light flashes twice as quickly.

If a fault in the engine immobiliser system is detected whilst the engine is running, the injection warninglight will flash in the engine speed range from idle speed to 1500 rpm approximately.

• Fault with an injection system component

Faults in the following components cause the warning light to illuminate:- throttle position potentiometer,- injectors,- idle speed regulation solenoid valve,- coolant temperature sensor,- flowmeter,- camshaft sensor (the engine does not start),- oxygen sensor,- computer fault,- fault in engine cooling fan assembly control- oxygen sensor overheating,- fault with control of ignition module by injection computer,- AC out information (AC compressor allowed or prevented from being turned on by injection computer),- torque information transmitted to automatic transmission computer.

17-11

INJECTIONEngine immobiliser function 17

This vehicle is fitted with a 2nd generation engineimmobiliser system. The engine immobiliser codeMUST have been programmed into the injectioncomputer for it to operate.

REPLACING THE INJECTION COMPUTER

The computers are supplied uncoded. Afterreplacing the computer, the vehicle code must beprogrammed in and it must then be checked thatthe immobiliser system is operational.

To do this, carry out the following operations:

• Vehicle fitted with a PLIP engine immobilisersystem

- Lock and unlock the doors using the PLIP.

- Turn the ignition on for a few seconds.

- Lock the doors using the PLIP, theimmobiliser function is operational.

• Vehicle fitted with a coded key engineimmobiliser system (with PLIP)

Turn the ignition on for a few seconds thenturn it off again.

CHECKING THE IMMOBILISER FUNCTION

• Vehicle fitted with a PLIP engine immobilisersystem

- Turn the ignition off, lock the doors frominside the vehicle using the PLIP. The redimmobiliser warning light should flash.

- Turn the ignition on, the red immobiliserwarning light should flash twice as fast.

• Vehicle fitted with a coded key engineimmobiliser system (with PLIP)

Remove the key from the ignition switch,after 10 seconds the red immobiliser warninglight should flash.

TESTING AN UNCODED INJECTION COMPUTERFROM STOCK(you are strongly advised not to carry out this ope-ration)

IMPORTANT: Before testing an injection compu-ter the vehicle’s engine immobiliser code musthave been programmed in for the computer tooperate. After the test the computer MUST BEDECODED before being returned to stock. If thisthis is not done the computer would beUNUSABLE. This operation must be carried out bypersonnel who have received adequate training.To decode the computer consult the technicalnote on the "2nd generation" SAFRANE engineimmobiliser system.

SPECIAL NOTES

Using the XR25 it is possible to see if the injectioncomputer is coded. The computer is uncoded ifbargraph 2 right hand side is illuminated and if*22 = 2 DEF

A CODED COMPUTER FITTED TO A VEHICLE WITHAN ENGINE IMMOBILISER MAY NOT BE USED FORTESTING ANOTHER VEHICLE, REGARDLESS OFWHETHER THIS VEHICLE HAS AN ENGINEIMMOBILISER OR NOT.

17-12

INJECTIONComputer configuration 17

The computer must be configured using the XR25,connected, ignition turned on, with the enginenot running, depending on the equipment:- with automatic transmission or manual gear-

box,- with or without air conditioning.

To determine the command modes to be appliedconsult the fault finding fiche "Reminder C".

17-13

INJECTIONInjection / automatic transmission programming 17

AUTOMATIC TRANSMISSION / INJECTION COMPUTER CONNECTION

There are four different torque reduction requests. These requests are transmitted on two wires (tracks 62and 63 of the injection computer).

The reduction request may be displayed by means of the XR25 using the fault finding fiche No. 47, status side(the injection computer retards the ignition advance by 3 to 20% when the gear is changed. The value of theretarding action depends on the information it receives from the computer).

The Park/neutral information is transmitted on track 81.

INJECTION COMPUTER/AUTOMATIC TRANSMISSION COMPUTER CONNECTION

There are four connections:- the torque and engine speed information is transmitted on track 20,- the throttle position information is transmitted on track 38,- the torque reduction confirmation information is transmitted on track 60. After receiving a reduction

request, the injection computer informs the automatic transmission computer when it executes an ignitionadvance retard.

17-14

INJECTIONInjection / air conditioning programming 17

THE COMPRESSOR IS OF THE VARIABLE OR FIXED CAPACITY TYPE (depending on version)

AIR CONDITIONING / INJECTION COMPUTER CONNECTION

The electrical connection:

- from the air conditioning computer to the injection computer is by two wires (tracks 64 and 65). Two setsof information are transmitted on these tracks:

- the fast idle speed request (track 64). To ensure that this information is transmitted to the injectioncomputer, two conditions must be met:• the air conditioning must be selected on the instrument panel,• the pressure in the air conditioning circuit must exceed a certain threshold.If this information has been transmitted, the fast idle speed is obtained (thus there is sometimes nofast idle speed when the air conditioning has been turned on and the engine is idling. This isnormal).

- Input information (track 65). The information has no effect on the idle speed. It simply informs theinjection computer of the torque value taken by the compressor. The computer controls the idleregulation valve to anticipate this torque requirement. It is possible to display the input using theXR25. With the air conditioning turned on, there must be between 0.4 and 5 at gate 44.

- from the injection computer to the air conditioning computer is by one wire (track 48). This track

transmits the compressor operation authorisation and prevention information .

PROGRAMMING FOR OPERATION OF THE COMPRESSOR

During certain operating phases, the injection computer prevents operation of the compressor.

Starting the engineThe compressor is prevented from operating for 7 seconds after the engine has been started.

Thermal protectionThe compressor clutch is prevented from engaging if the coolant temperature is greater than or equal to + 112°C

Over-revving protection The compressor may not operate if the engine speed is greater than 6 000 rpm.

17-15

INJECTIONIdle speed correction 17

IDLE SPEED CORRECTION DEPENDING ON THE BATTERY VOLTAGE

This correction compensates for the drop in voltage due to operation of consumers when the battery is poorlycharged. To do this, the idle speed is increased, allowing the alternator to rotate more and consequentlyincrease the charging voltage.

The lower the voltage, the greater the degree of correction. Correction of the engine speed is thereforevariable. It begins when the voltage drops to below 12.7 Volts. Correction begins at the nominal enginespeed and may reach a maximum of 900 rpm.

IDLE SPEED CORRECTION DEPENDING ON HEATED WINDSCREEN INFORMATION

If the heated windscreen function is selected, the computer receives + 12 V information on track 61. The idlespeed is not accelerated.

IDLE SPEED CORRECTION DEPENDING ON AIR CONDITIONING

The injection computer increases the idle speed to 850 rpm if it receives the fast idle speed information fromthe air conditioning computer.

17-16

INJECTIONAdaptive idle speed RCO correction 17

PRINCIPLE

Under normal warm engine operating conditions, the RCO idle speed value using #12 varies between an up-per and a lower value to obtain the nominal idle speed.

If the engine operating conditions are different (running in, engine contaminated...) the RCO idle speed va-lue may be situated close to the upper or lower value.

Adaptive correction (#21) for the RCO idle speed (#12) allows compensation to be made for slow variationsin the engine’s air requirements.

This correction is only operational if the coolant temperature is greater than 80°C, if the engine is in the no-minal idle speed regulation phase, and if the vehicle speed is equal to 0 km/h.

RCO IDLE SPEED VALUES AND ADAPTIVE CORRECTION

Nominal idle speed(#06) X = 750 rpm

R.C.O. idle speed(#12) 10 %≤X≤30 %

Adaptive idle speed(#21)

Threshold :- minimum : - 51- maximum : +51

INTERPRETATION OF THE GATE VALUES

If there is an excess of air (air leak, throttle stop incorrectly set...) the idle speed increases, the RCO idle speedvalue for #12 decreases to return to the nominal idle speed; the RCO idle speed adaptive correction value for#21 reduces.

If there is a lack of air (pollution, etc.), the strategy is reversed:The RCO idle speed for #12 increases and adaptive correction for #21 also increases.

IMPORTANT : after erasing the computer memory (disconnecting the battery), the engine must be allowed torun at idle speed before returning the vehicle to the customer so that the adaptive correction may correctlyreset itself (approximately 15 minutes).

17-17

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 ex-pressed in Volts (the value actually varies between 0 and 1 000 millivolts).

When the engine is in the richness regulation phase, the voltage value should oscillate rapidly and should bebetween 50±50 mV (lean mixture) and 850 ± 50 mV (rich mixture) and vice versa.

The smaller the gap between the upper and lower oscillating values, the poorer the information from thesensor (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 thecomputer depending on the richness of the burnt mixture as seen by the oxygen sensor (the oxygen sensor ac-tually 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 un-der 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 + 40°C.- outside no load conditions if the coolant temp.exceeds 30°C.

Non-loop mode

When richness regulation is occurring, the operating phases when the computer ignores the voltage informa-tion from the oxygen sensor are:

- for full load : #35 = 128- sharp accelerations : #35 = 128- decelerations with the no load information : #35 = 128- oxygen sensor fault : #35 = 128.

INJECTIONRichness regulation 17

provided that the oxygen sensorsignal is correct

17-18

INJECTIONAdaptive richness correction 17

PRINCIPLE

In the loop mode (see section 17 "Richness regulation"), richness regulation (# 35), corrects the injection ti-ming to give fuel metering which is as close as possible to richness 1. The correction value is close to 128, withlimit 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 128and 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 thefollowing threshold values:

0≤ #30 ≤ 255

0 ≤ #31 ≤ 255

Adaptive correction only takes place when the engine is warm (70°) in the loop phase (#35 variable).

17-19

INJECTIONOperating wiring diagram 17

KEY TO DIAGRAM

COMPONENT NO DESCRIPTION

109119120146188

193 to 197218222225236238242244247260272273310319341371679737746927957

On board computerAutomatic transmission computerInjection computerPinking sensor Cooling fan assemblyInjectorsFuel pumpThrottle position potentiometerDiagnostic socketFuel pump relayLocking relayOxygen sensorCoolant temperature sensorInjection fault warning light, coolant temperature warning light and rev counter Engine fuse boxHot film air flow meterEngine speed sensorIgnition power moduleAir conditioning control panelIdle speed regulation solenoid valveCanister bleed solenoid valveRadio anti-interference condenserVehicle speed sensorCamshaft sensorImpact switchEngine immobiliser unit

17-20


DI11431

17-21


Tracks ALLOCATION

1 Command for fuel pump relay via earth

2 Command for idle speed regulation solenoid valve closing via earth

3 Command for injector n° 1 via earth



6 Computer earth

7 Command for fan slow speed relay via earth

8 Injection fault warning light on instrument panel

9 Not used

10 Oxygen sensor signal earth

11 Not used

12 Not used

13 Not used

14 Flowmeter signal earth

15 Not used

16 Engine speed information

17 Not used

18 Not used

19 Not used

20 Torque and engine speed information to automatic transmission computer

21 Not used

22 Coolant temperature warning light

23 Not used

24 Not used

25 Command for ignition power module

17-22


Tracks ALLOCATION

26 +12V before ignition

27 Command for locking relay via earth

28 Computer earth

29 Command for idle speed regulation solenoid valve opening via earth

30 Not used



33 Not used

34 Computer earth

35 Command for fan fast speed relay via earth

36 Command for canister bleed solenoid valve opening via cyclic ratio

37 Not used

38 Throttle position information supplied to automatic transmission computer

39 Oxygen sensor signal

40 Not used

41 Flowmeter signal

42 Vehicle speed information

43 Engine speed information

44 Camshaft sensor information

45 Camshaft sensor supply

46 Consumption information for on-board computer

47 Engine speed information for the rev counter on instrument panel

48 Authorisation (0 V) or prevention (12V) of air conditioning compressor operation

49 Not used

17-23


Tracks ALLOCATION

50 Not used

51 Not used

52 Not used

53 Command for oxygen sensor heating via earth

54 Monitoring of feed for injectors and fuel pump from relay (236)

55 Flowmeter earth

56 Not used

57 Not used

58 Not used

59 + 12 V after ignition feed for computer

60Confirmation of torque reduction by the injection computer for the automatic

transmission computer

61 Signal for heated windscreen (12V)

62 Torque reduction request

63 Torque reduction request

64 Fast idle speed request by air conditioning computer

65 Information on power absorbed by air cond. compressor supplied by air cond. computer

66 Coded electrical engine immobiliser information supplied by transponder

67 Not used

68 Feed for throttle position potentiometer

69 Pinking sensor n° 2 information

70 Pinking sensor n° 1 information

71 Pinking sensor earth

72Common earth for coolant temperature sensor, camshaft sensor, throttle position

potentiometer and earth strap for engine speed sensor

17-24


Tracks ALLOCATION

73 Throttle position potentiometer information

74 Not used

75 Not used

76 Not used

77 Not used

78 Coolant temperature sensor information

79 Not used

80 Not used

81 Park/neutral information

82 Not used

83 Not used

84 Not used

85 Not used

86 Not used

87Uni-directional diagnostic line L for entry into diagnostic mode only

(looking for computer)

88Bidirectional diagnostic line K for entry into diagnostic mode (looking for computer),

transmission of the diagnostic signal originating from the computer, application of thecommand (G..*), memory erasure (G0**) and end of fault finding (G13*) modes

17-25

JMO011.1

INJECTIONFault finding - introduction 17N7U

engine

SETTING UP A DIALOGUE BETWEEN THE XR25 AND THE COMPUTER

- Connect the test kit to the diagnostic socket.

- Ignition on.

- ISO selector on S8

- Enter D13 11.INJ

COMPUTER IDENTIFICATION

The computer is not identified by reading a fault code but by reading the Part Number directly from thecomputer. 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. Each sequence is repeated twice. (To find thenumber, refer to the Workshop Repair Manual, section 12).

ERASING THE MEMORY (engine off, ignition on)

After the injection system has been worked on, the computer’s memory can be erased by using the codeG0** (Erasing memorised faults in diagnostic mode D13, ISO selector in position S8, enter G0**).

The memories of other components on the vehicle are not erased when this operation is used.

17-26


engine

DESCRIPTION OF THE FAULT FINDING STAGES

The procedure described below must be adopted for all faults (even if the vehicle does not start), particularlythe conformity check.

XR25 FAULT CHECK

This stage must be the starting point for any work on the vehicle.

Processing the bargraphs is subject to several conditions:

- Priority in the order of processing when several bargraphs are illuminated.- Interpretation of a bargraph according to whether it is illuminated or flashing.

1 - Order of priority

A group of illuminated bargraphs corresponding to sensors having the same 12 V or the same earthmeans that there is a fault in that source. These priorities are discussed in the "NOTES" section in thefault finding of the bargraph concerned.

2 - Input/Output fault bargraphs

a) Illuminated continuously:

The fault is present: process the fault as per the procedure indicated in the section "TREATMENT OFBARGRAPHS".

b) Illuminated, flashing:

Note the bargraphs displayed on the XR25.

Erase the computer memory and try to re-illuminate the bargraph : ignition turned on, idling (or atstarter speed) or by means of a road test.

If the bargraph is re-illuminated (continuous or flashing):

The fault is present again. In this case process the fault bargraph (the section on "NOTES" in the faultfinding of the bargraph concerned, may help you determine the illuminating conditions of thebargraph).

If the bargraph is not re-illuminated, check:

- The electrical lines corresponding to the flashing fault,- The connectors of these lines (oxidation, bent pins...).- The resistance of the component detected as being faulty.- The cleanliness of the wires (insulation melted or cut, friction...)

NOTE: If the customer complaint does not relate to the fault bargraph which is flashing (example:Fault bargraph for air temperature sensor flashing, but no customer complaint), ignore thismemorised fault and erase it. Consult the table in the section "FAULT FINDING - ASSISTANCE".

3 - Erasing the memory

For this vehicle the G0** command mode must be used to erase the computer memory.

17-27


engine

4 - Absence of bargraphs

If no further bargraph is illuminated on the XR25, a conformity check should be carried out. This mayhelp you locate a problem (see: XR25 INSPECTION OF STATUSES AND PARAMETERS).

XR25 INSPECTION OF STATUSES AND PARAMETERS

This inspection is carried out in the form of a conformity check.

Conformity check:

The purpose of the conformity check is to verify the statuses and parameters which do not illuminate a faultbargraph when they are outside tolerances. This stage therefore enables:

- Faults which may relate to a customer complaint to be diagnosed without illumination of a fault bargraph( example: lack of no load information causing the idle speed to be unstable).

- The satisfactory operation of the injection to be verified and a check to be made to ensure that there is norisk of a fault occurring shortly after the repair.

This section therefore includes fault finding for the statuses and parameters under the conditions prevailingwhile they are being inspected (example: fault finding using gate 01, ignition on and fault finding using gate01, engine running).

If a status is not operating normally, or if a parameter is out of tolerance, you must consult the fault findingpage indicated in the "Fault finding" column.

CORRECT XR25 INSPECTION

If the XR25 inspection is correct, but the customer complaint persists, the problem must be dealt with byCustomer Complaint.

Treatment of the customer complaint

This section differs from the previous definition given in the Workshop Repair Manuals. Instead of proposingfault location diagrams it gives a series of possible causes of the problem. These lines of investigation canonly be given priority in the following cases:

- No fault bargraph appears on the XR25.- No fault is detected during the conformity check.- The vehicle is not operating correctly.

This section comprises two tables.

The first table cross-references the customer complaint with the possible causes.

Example 1 : Customer complaint = irregular idlingPossible causes = EGR leakage or canister bleed leakage...

Example 2 : Customer complaint = irregular idling and engine stalls at idle speed.It is established that the idle speed is too low.A common cause of these problems is: Pressure regulator locked closed.

The second table indicates the method of checking the operation of a given component.

Example : A pressure regulator locked closed may be checked with a pressure gauge.

17-28

JMO011.1


engine

INSPECTION AFTER REPAIR

This operation is a simple inspection of the repair (by means of a command, an XR25 command mode, ..).

It provides a check that the system on which the operation has been carried out is operating correctlyelectrically.

It is a preliminary to the road test.

Example : The fan assembly command circuit has been repaired. In this case it must be verified that afterthe repair the fan assembly rotates if the command mode is activated. This enables you to saythat the system is satisfactory electrically.

INSPECTION ON ROAD TEST

A road test is essential for guaranteeing the satisfactory operation of the vehicle and testing the quality ofthe repair. Its purpose is to verify that no fault occurs (or will occur) while driving.

In order to be considered significant the road test is carried out under special running conditions.

Running conditions for programming in the variables:

During the road test, stabilise the engine speed for a few moments between 2000 and 4000 rpm at a manifoldpressure of between 400 and 700 mbars. Allow the engine to idle for a few minutes.

NOTE: The road test inspection may be carried out at the same time as the conformity check. It should benoted that if the battery is disconnected after the road test, the variables are erased.

17-29

JMO011.1

INJECTIONFault finding - XR25 fiche 17

REPRESENTATION OF THE BARGRAPHS

Illuminates when a dialogue has been established with the product computer. If it remainsextinguished:- 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 isoff, the ignition is on and there is no operator action

- If on the fiche the bargraph is represented as

- If on the fiche the bargraph is represented as

- If on the fiche the bargraph is represented as the test kit should give as information

either or

Engine running

Extinguishes when the function or condition given on the fiche can no longer be performed.

Illuminates when the function or condition given on the fiche is performed.

FUNCTION V9

Fiche n° 47 side 1/2 and side 2/2 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 injectioncomputer, after having set up a dialogue with the computer, press the V and 9 buttons simultaneously. Thebargraphs 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.

the test kit should giveas information

the test kit should giveas information

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17-30

JMO011.0


PRESENTATION OF FICHE N° 47 SIDE 1/2 WITH FAULT BARGRAPHS

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FI21647-1

17-31

JMO011.1


PRESENTATION OF FICHE N° 47 SIDE 2/2 WITH STATUS BARGRAPHS

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FI21647-2

17-32

JMO011.1

INJECTIONFault finding - Interpretation of XR25 bargraphs 17N7U

engine

Bargraph 1 RH extinguished Fiche n° 47 side 1/2

XR25 CIRCUIT

XR25 assistance : no connection, CO, CC EARTH, CC + 12

1

For fault finding, this bargraph should be illuminated

Carry out a conformity checkAFTER

REPAIR

NOTES

Check:- the injection, Passenger Compartment and Engine fuses- the connection between the XR25 and the diagnostic socket,- the position of the selector (S8),- the conformity of the cassette.

Repair if necessary.

Check:- the presence of + 12 V on track 16 and the earth on track 5 on the diagnostic socket.- the connection between the XR25 and the diagnostic socket.

Diagnostic 15 4 XR25socket 7 8 socket


Connect the bornier instead of the computer and check the insulation and continuity between the tracks:

Bornier 87 15 Diagnostic socket88 7 Diagnostic socket8 18 Fault warning light

59 F14 20 A fuse26 F1 15 A fuse6 NK NK earth

28 MH MH earth34 MH MH earth1 2 Fuel pump relay

Repair.

17-33

JMO011.1

INJECTIONFault finding - Interpretation of XR25 bargraphs 17

Bargraph 2 LH illuminated Fiche n° 47 side 1/2

COMPUTER CIRCUIT

XR25 assistance: Computer fault if bargraph 2LH illuminated

2

NoneNOTES

Computer is not correct or is faulty.

Replace the injection computer.

Carry out a conformity checkAFTER

REPAIR

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17-34

JMO011.1


Bargraph 2 RH illuminated Fiche n° 47 side 1/2

ENGINE IMMOBILISER CIRCUITXR25 assistance*22 = 1dEF CO, CC EARTH or CC +12 V line 66 of the computer

*22 = 2 dEF Consult the engine immobiliser fault finding

2

NoneNOTES

If the fault persists, refer to "Engine immobiliser fault finding".

Connect the bornier instead of the computer and check the insulation and continuity of line:

Bornier 66 of the infrared transmitter


Erase the computer memory using GO**.Carry out a conformity check

AFTER

REPAIR

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17-35

JMO011.1



OXYGEN SENSOR CIRCUIT

XR25 assistance : CO line 10 or 39 or 53

3

NoneNOTES

Erase the computer memory (when engine is cold) using GO**.Carry out a conformity check

AFTER

REPAIR

Check the connection and the condition of the connector of the oxygen sensor.

If the fault persists, replace the oxygen sensor.

If the fault persists, replace the computer.

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Connect the bornier instead of the computer and check the continuity of the wiring.

Bornier 10 3 sensor connector39 4 sensor connector53 2 sensor connector54 1 sensor connector

If necessary, repair the electrical wiring.

17-36

JMO011.1



COOLANT TEMPERATURE SENSOR CIRCUITXR25 assistance: #04 = 1 dEF computer problem

#04 = 2 dEF CO, CC-, CC+ line 78 or 72

4

See "Fault finding - Assistance" for the resistance values.NOTES

Check the resistance of the coolant temperature sensor.

Replace the sensor.

Connect the bornier instead of the computer and check the continuity andinsulation of the electrical wiring between the tracks :

coolant temperature sensor 1 78 borniercoolant temperature sensor 2 72 bornier



Erase the computer memory using GO**.Carry out a conformity check

AFTER

REPAIR

The resistance isnot correct

The resistance iscorrect

*04 = 2 dEF If the BG 6 RH is also illuminated, track 72 may be the cause of this.NOTES

The injection computer is faulty, but it is essential to find the cause of the problem before replacing thecomputer (another bargraph illuminated, a customer complaint, .. which is the cause of the problem).

*04 = 1 dEF NoneNOTES

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17-37

JMO011.1



VEHICLE SPEED SENSOR CIRCUIT

XR25 assistance : CO or CC LINE 42

4

NoneNOTES

If the value read is incoherent:- Check that the sensor is correctly mounted.- Check the insulation and continuity and check for absence of interference resistance on the electricalline, track 42 of the injection computer.

The injection is no longer faulty, check the different functions using this information.

Erase the computer memory using GO**.Carry out a road testCarry out the conformity check.

AFTER

REPAIR

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17-38

JMO011.1



FLOWMETER CIRCUITXR25 assistance: CO or CC- or CC+ line 55, 14, 41

5

If the BG 8LH is also illuminated, line 27 of the computer is in CONOTES

Erase the computer memory using GO**.

Carry out the conformity check.

AFTER

REPAIR

N7Uengine

Check that there is + 12 V, ignition on, on track 3 of the flowmeter connector.Check the insulation and continuity of the line:

computer 14 2 flowmeter 41 455 1

Repair.

If the fault persists, replace the flowmeter .

17-39

JMO011.1


Bargraph 5 RH illuminated or flashing Fiche n° 47 side 1/2

FLYWHEEL SIGNAL CIRCUITXR25 assistance : *25 = 1 dEF mechanical fault

*25 = 2 dEF CO line 16 or 43

5

Disconnect the sensor connector and check the resistance of the sensor between terminals A and B.

Replace the sensor.

Connect the bornier instead of the computer and check the continuity andinsulation of the wiring between the tracks:

Flywheel signal sensor 1 16 bornierFlywheel signal sensor 2 43 bornierSensor earth earth 72 bornier



AFTER

REPAIR

The resistance isincorrect

The resistance iscorrect.

See "Fault Finding - Assistance" for the resistance values.NOTES

N7Uengine

Check that sensor is in correct position and that the target is in good condition (particularly if replaced)

*25 = 1 dEFAfter repair of *25 = 1 dEF, an electrical fault may be present *25 = 2 dEFNOTES

If the fault persists, replace the sensor.

*25 = 2 dEF NoneNOTES

17-40

JMO011.1



PINKING SENSOR CIRCUIT

XR25 assistance : CO, CC+, CC-, interference, line 70 or 69 or 71 *06 = 1 dEF = sensor 1 = tracks 70 and 71

*06 = 2 dEF = sensor 2 = tracks 69 and 71

6

In some faults the BG 6LH can only be illuminated when the engine is running at aspeed of 2500 rpm.NOTES

Check the connections of the faulty sensor.


Connect the bornier instead of the computer and check the insulation and the continuity of the electricalwiring between the tracks:

*06 = 1 dEF sensor 1 : 1 692 71

*06 = 2 dEF sensor 2 : 1 702 71

If the fault persists, replace the faulty pinking sensor.



AFTER

REPAIR

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17-41

JMO011.1


Bargraph 6 RH illuminated or flashing Fiche n° 47 side 1/2

THROTTLE POTENTIOMETER CIRCUITXR25 assistance: CO, CC-, line 68 or 72 or 73

6

If the BG 4LH is also illuminated, track 72 may be faulty.

See "Fault finding - Assistance" for the resistance values.NOTES

Check the resistance of the throttle potentiometer between tracks A and B

Check the variation of the throttle potentiometer between tracks B and C.

Replace the throttle potentiometer.

R between Aand B is correctand B-C varies.

Connect the bornier instead of the computer and check the insulation andcontinuity between the tracks:

potentiometer 1 72 bornierpotentiometer 2 68 bornierpotentiometer 3 73 bornier

Replace the computer.



AFTER

REPAIR

R between Aand B is

incorrect or B-Cdoes not vary

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17-42

JMO011.1




AFTER

REPAIR


CAMSHAFT SENSOR CIRCUITXR25 assistance: CO, CC+, CC-, line 44, 45, 72

7


If the fault persists, replace the sensor.

Check the insulation and continuity of the line:

computer 44 2 sensor45 372 1

Repair.

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17-43

JMO011.1




AFTER

REPAIR


PARK/NEUTRAL POSITION CIRCUIT

XR25 assistance : Signal received on track 81 of the computer incoherent.

7

Check that the computer is correctly configured:- Status BG 19 LH for automatic transmission- Status BG 19 RH for a manual gearbox

NOTES

Refer to the automatic transmission fault finding.


injection computer 81 11 AT computer

Repair.

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17-44

JMO011.1



FUEL PUMP RELAY CONTROL CIRCUITXR25 assistance: *08 = CO.0 CO or CC- line 1

*08 = CC.1 CC+ line 1

8

In some faults the BG 8LH can only be illuminated when the engine is running.NOTES



AFTER

REPAIR

N7Uengine

With the fuel pump relay in position, ignition on, check for the presence of + 12 V between tracks 1 and2 during the timed phase.

Replace the relay.

Ignition on, check for the presence of + 12V on track 1 of the fuel pump relay.

If the fault persists, replace the injection computer.

Check the line of track 1 of the fuel pump relay as far as track 5 of the main relay.

Connect the bornier instead of the computer and check the continuity andinsulation of the line:

bornier 1 2 fuel pump relaybornier 27 2 main relay


There is +12Vbetween 1 and 2

No + 12 V between 1 and 2

No + 12 V ontrack 1

There is + 12 Von track 1

17-45

JMO011.1



MAIN RELAY CIRCUITXR25 assistance: CO line 54

8

NoneNOTES



AFTER

REPAIR

N7Uengine

Ignition on, check for the presence of 12 V on tracks 1 and 3 of the main relay.

Repair the wiring as far as fuse F53 if necessary.

Ignition on and with the relay in position, check that there is earth on track 2 and 12V on track 5.

If there is earth on track 2 but no 12 V on track 5, replace the relay.

Connect the bornier instead of the computer and check the insulation and continuity of the line:

Bornier 1 2 locking relay54 5 locking relay

Repair the wiring.

17-46

JMO011.1


Bargraph 9 LH or 9 RH illuminated Fiche n° 47 side 1/2

FAN ASSEMBLY CIRCUITXR25 assistance : *09 or *29

CC.0 = CO or CC- line 35 or 7CC.1 = CC+ line 35 or 7

9

BG 9LH, *09, track 7 of the computerBG 9RH, *29, track 35 of the computerNOTES

Erase the computer memory using GO**

Carry out the conformity check

AFTER

REPAIR

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Bornier 7 fan assembly relay , low speed35 fan assembly relay high speed


Check the condition of the fan assembly relay detected as being faulty.

17-47

JMO011.1


Carry out the conformity check using GO**


AFTER

REPAIR

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FAULT WARNING LIGHT CIRCUITXR25 assistance: *10 = CO.0 CO, CC- line 8

*10 = CC.1 CC + 12 V line 8

10

NoneNOTES

Check the insulation and continuity of the line :

bornier 8 warning light fuse

If the fault persists replace the computer.

17-48

JMO011.1



COOLANT TEMPERATURE WARNING LIGHT CIRCUIT

XR25 assistance : *30 = CO.0 CO or CC- line 22 *30 = CC.1 CC+ line 29

10

If BG 19LH is also illuminated, check line 29 of the computer.NOTES

Erase the computer memory using GO**


AFTER

REPAIR

N7Uengine


computer 22 warning light fusecomputer 29 3 idle speed regulation solenoid valve

Repair.

17-49

JMO011.1



Carry out a conformity check

AFTER

REPAIR

N7Uengine

Bargraph 11LH illuminated Fiche n° 47 side 1/2

CANISTER BLEED CIRCUITXR25 assistance : *11 = CO.0 CO or CC- line 36

*11 = CC.1 CC+ line 36

11


Check the conformity of the pipes, repair if necessary.

Replace the canister bleed valve.

Engine idling, check for the presence of + 12V on track 1 of the canister bleedvalve.

If the fault persists, replace the injection computer.

Repair the electrical wiring between track 1 of the canister bleed valve and track5 of the main relay.

Connect the bornier instead of the computer and check the insulation andcontinuity of the electrical wiring between track 2 of the canister bleed valve and36 of the bornier.




There is not +12 V on track 1

There is + 12Von track 1

Check the resistance of the canister bleed valve.

17-50

JMO011.1


Bargraph 11 or 12 or 13 or 14 or 15 RH Fiche n° 47 side 1/2illuminated

INJECTION CIRCUITXR25 assistance *31 or *32 or *33 or *34 or *35

CO.0 = CO or CC- line 3 ; 4 ; 5 ; 31 ; 32CC.1 = CC+ line 3 ; 4 ; 5 ; 31 ; 32

11 or 12 or 13or 14 or 15

Erase the computer memory using G0*


AFTER

REPAIR

N7Uengine

BG 11RH, *31, injector 1, track 3 of the computerBG 12RH, *32, injector 2, track 31 of the computerBG 13RH, *33, injector 3, track 4 of the computerBG 14RH, *34, injector 4, track 32 of the computerBG 15RH, *35, injector 5, track 5 of the computerSee "Fault finding - Assistance" for the resistance values

NOTES

Check the resistance of the injector concerned.

Replace the faulty injector.

Connect the bornier instead of the computer and check the continuity andinsulation between the injector connector on track 2 and the computer track

Repair the wiring if necessary.

The fault persists! Replace the computer

The resistance isincorrect.

The resistance iscorrect.

During the timed phase, check for 12 V on track 1 of the injector concerned.

Repair the wiring if necessary.

17-51

JMO011.1



IDLING ADAPTIVE CIRCUIT

XR25 assistance : None

There is no electrical problem.NOTES

Make sure that the air hose is clean.

Erase the computer memory using G0**


AFTER

REPAIR

N7Uengine

13

If the air hose is correct, replace the idle regulation valve.

17-52

JMO011.1



Carry out a conformity check.

AFTER

REPAIR

N7Uengine


INJECTION <--- HEATED WINDSCREEN CONNECTION CIRCUITXR 25 assistance : Implausible signal.

14

Select Heated Windscreen on the air conditioning control panel for 17 minutes todisplay the fault.NOTES


injection computer 61 air conditioning control panel

Repair.

Refer to the air conditioning fault finding.

17-53

JMO011.1



AC INJECTION CONNECTION CIRCUITXR25 assistance : *15 = 1dEF CO line 64

*15 = 2dEF CO, CC-, CC+ line 65 *15 = CC.1 CC+ line 48

15

Check that the vehicle is fitted with air conditioning. If not, consult the otherpriority bargraphs. NOTES

AFTER

REPAIR


Bornier 48 Air conditioning control panel64 Air conditioning control panel65 Air conditioning control panel


N7Uengine

If the fault persists, refer to to the air conditioning fault finding.


Carry out a conformity check.

17-54

JMO011.1


AFTER

REPAIR

N7Uengine


IGNITION COIL CIRCUITXR25 assistance *16 = CC.1 CC+ line 25

16

Detection of CC + 12 V onlySee "Fault finding - Assistance" for the resistance values.NOTES

Check the resistance of the coil.

Replace the coil.

The fault persists! Replace the computer.

Connect the bornier instead of the computer and check the insulation andcontinuity of the line:

bornier 25 4 coil

Check for the presence of + 12 V on track 3 of the coil and ensure the insulationand continuity of lines 1 and 2 of the coil.

Repair the faulty line.



Erase the computer memory using G0*Carry out a conformity check

17-55

JMO011.1


AFTER

REPAIR

N7Uengine


INJ ---> A.T .CIRCUIT XR25 assistance : *17 = CC.1 CC+ line 20

17

Only the CC+ can be detected by the computer.NOTES

Check the insulation of the line :

injection computer 20 23 A.T. computer.

Repair.


17-56

JMO011.1


AFTER

REPAIR

N7Uengine


OXYGEN SENSOR HEATING CIRCUITXR25 assistance : *18 = CO.0 CO or CC- line 53

*18 = CC.1 CC+ line 53

18

See "Fault Finding - Assistance" for the resistance valuesNOTES

Check the resistance of the oxygen sensor between track 1 and 2 of its connector.

Check for the presence of 12 V on track 1 of the oxygen sensor connector.


injection computer 53 2 oxygen sensor connector

Repair.


17-57

JMO011.1


AFTER

REPAIR

Bargraph 19 LH or 19 RH illuminated Fiche n° 47 side 1/2

IDLE REGULATION VALVE CIRCUITXR25 assistance: *19 or *39 = CO or CC.0 or CC.1

CO or CC-or CC+ line 29 or 2

19

BG 19LH, *19, track 29 of the computer. BG 19RH, *39, track 2 of the computer.If BG 10RH is also illuminated with *30 = CO.0 ---> CC + 12 line 29.See "Fault finding - Assistance" for the resistance values.

NOTES

N7Uengine

Check the resistance of the coils of the idle speed regulation valve.

If the resistance is incorrect replace the solenoid valve.



Bornier 2 1 idle speed solenoid valve29 3 idle speed solenoid valve54 2 idle speed solenoid valve.

Erase the computer memory using G0**


17-58

JMO011.1

INJECTIONFault finding - Checking conformity 17

Engine stopped, ignition onNOTES

Order ofoperations

Function to bechecked

Action Bargraph Display and Notes Fault finding

1 Dialogue with XR25

D13(selector on

S8)

Fault test

11.NJ

Use fiche n° 47 fault test side

Code present

Deal with fault

bargraph

2 Switching tostatus test G01*

12.NJ

Status test

None

3 Computer

configuration

With A.C.

Without A.C.

With A.T.

With manualgearbox

See XR25 fiche

"Reminder C"to configurethe vehicle

4 Battery

voltage# 04 11.8 V < X < 13.2 V DIAG 1

5 Engine

immobilisersystem

Deactivatethe engineimmobiliser

if active

Illuminated if the engine immobiliser

has been released.

Engineimmobiliserfault finding

1

1

18

1

18

19

19

N7Uengine

3

17-59

JMO011.1

INJECTIONFault finding - Checking conformity 17N7U

engine

Engine stopped, ignition onNOTES

Order ofoperations



6Throttleposition

potentiometer

No load# 17

Acceleratorpedal lightly

pressed

Full load# 17

0 < X < 10°

80 < X < 90°

DIAG 2

7Coolant

temperaturesensor

# 02

If illuminated,overheating

X = Engine temperature± 5°C

DIAG 3

8A.T. selector

lever

Move theselector

leverIlluminated in park or

neutral position

Consult Fault findingfor the A.T.

9 Air flowmeter # 19 X = 0 kg/h DIAG 4

10

Fan

low speed

high speed

G27 * 1 *

G27 * 2 *

Fan, low speed

Fan, high speed

Use thewiring

diagram forfault findingfor the fan

11 AC if present

Select AC then G12* The compressor clutch is

clicking

Consult Faultfinding for

the AC

2

2

2

5

4

17-60

JMO011.1


engine

Order ofoperations



1 TDC sensor Startermotor

Detection of the TDCinformation

DIAG 5

2 Fuel pump G10* The fuel pump is running DIAG 6

3 Canister bleed G16* The canister bleedsolenoid valve is clicking DIAG 7

4 IgnitionConnect the

OptimaStation

Starting test.

Complete guide on theOptima Station

Use OptimaStation 5800

5 Fuel pressure

Connect apressure

gauge to the

gallery andactivate the

starter

The pressure gauge mustindicate 2 ± 0.5 bars

For fuelpressure seeWorkshop

RepairManual or

section

3

Carry out the actions below if the engine does not start,

otherwise consult the following pages.NOTES

17-61

JMO011.1


engine

Order ofoperations



1 Chargingcircuit

# 04If

# 04then# 06

13 V < X < 14.5 V

X < 12.7 V

750 < X < 900 rpm

DIAG 1

2 Throttle

potentiometerNo load Illuminates

(does not flash!) DIAG 2

3 Idle speed

regulation

# 12

# 21

# 06

10 < X < 30 %

-51 < X < +51 kg/h

700 < X < 800 rpm(X varies slightly)

DIAG 8

4 Air flowmeter # 19 6 < X < 15 kg/h DIAG 4

2

Carry out the actions below if the engine starts.Otherwise consult the preceding pages.

Engine warm, at idle speed, no consumers. NOTES

6

17-62

JMO011.1


engine

Order ofoperations



5 Richnessregulation

Fiche A1G03*

2500 rpmstabilised

# 02# 01# 03

D

# 35

02 / SO2- - - Max. calcul.

--- Min. calcul.

Period calcul.

X < 200 mVX > 700 mVX < 1100 mS

Return to Fault findingmode

X varies ≈ 128

DIAG 10See alsoDIAG 9

6 Airconditioning

A.C.selected

# 06

# 44

Illuminated if the Airconditioning

requests operation of the

compressor

Illuminated if theinjection authorises

operation of thecompressor

Fast idle speed active

800 < X < 900 rpm1 < X < 5

DIAG 11

10

Carry out the actions below if the engine starts.Otherwise consult the preceding pages.

Engine warm, at idle speed, no consumers. NOTES

6

9

10

17-63

JMO011.1


engine

Order ofoperations



1Vehiclespeed

information# 18 X = speed read on the

speedometer in km/h DIAG 12

2 Reduction intorque if A.T.

Illuminates whenchanging gear in

automatic transmission

Consult theFault findingfor the A.T..

3 Adaptiverichness

After

program-

ming

# 30

# 31

0 < X < 255

0 < X < 255

DIAG 13

4 Emission ofpollutants

2500 rpmafter

running

At idlespeed, wait

forstabilisation

CO < 0.3 %CO2 > 13.5 %

O2 < 0.8 %HC < 100 ppm

0.97 < λ < 1.03

CO < 0.5 %HC < 100 ppm

0.97 < λ < 1.03

DIAG 9See alsoDIAG 10

Checking during road testNOTES

13

14

17-64

JMO011.1

INJECTIONFault finding - Interpretation of XR25 parameters 17N7U

engine

DIAG 1

Fiche n° 47 side 2/2BATTERY VOLTAGE

XR25 assistance : 11.8 < # 04 < 13.2 V battery voltage, ignition on 13.0 < # 04 < 14.5 V battery voltage at idle speed

No fault bargraph must be illuminated.

No consumer.

Restart the conformity check.AFTER

REPAIR

NOTES

If# 04 < 11.8 V, the battery is discharged :Check the charging circuit to detect the cause of this problem.

Ignition on

If # 04 > 13.2 V, the battery may be overcharged:Check that the charging voltage is correct with and without consumers.

If # 04 < 13.5 V, the charging voltage is too low :Check the charging circuit to detect the cause of this problem.

At idle speed

If# 04 > 14.5 V, the charging voltage is too high :The alternator regulator is faulty. Remedy this problem and check the electrolyte level in the battery.

NOTE :The battery and charging circuit may be checked using OPTIMA Station 5800 (a measurement which doesnot require disconnecting the battery, thus enabling the computer memories to be retained).

17-65

JMO011.1


engine

DIAG 2

THROTTLE POTENTIOMETER Fiche n° 47 side 2/2

XR25 assistance : 0 < # 17 < 10 ° no load80 < # 17 < 90 ° full loadVaries according to the position of the acceleratorStatus BG 2LH or 2RH incorrectly illuminated


Ignition on or engine running.


REPAIR

NOTES

# 17 is fixed NoneNOTES

Check the resistance of the throttle potentiometer by actuating the throttle.

If the resistance varies, check the electrical lines of the sensor.

If the resistance does not vary, check that the sensor is mechanically connected to the throttle.Replace the sensor if necessary.

# 17 is outside tolerance NoneNOTES

Check the high and low stops of the throttle.Check the accelerator control (point of resistance and friction).Repair.

17-66

JMO011.1


engine

DIAG 3

Fiche n° 47 side 2/2COOLANT TEMPERATURE

XR25 assistance : # 02 = Engine temperature ± 5°C Status BG 5LH incorrectly illuminated

No fault bargraph must be illuminated.The engine must not actually be overheated!See "Fault Finding - Assistance" for the resistance values.


REPAIR

NOTES

If the value read is incoherent :- Check that the sensor correctly follows the standard table "resistance as a function of temperature".- Replace the sensor if its values are offset (Note : a sensor with offset values often results from an

electric shock).- Check the insulation, continuity and absence of interference resistance on the electrical line.

17-67

JMO011.1


engine

DIAG 4

Fiche n° 47 side 2/2AIR FLOWMETER SENSOR

XR25 assistance : # 19 = 0 kg/h ignition on 6 < # 19 < 15 kg/h engine running

No fault bargraph must be illuminated


REPAIR

NOTES

Check for the presence of 12 V, ignition on, on track 3 of the flowmeter connector.Check the insulation and continuity of the line:

computer 14 2 flowmeter41 455 1

Check the condition of the air circuit (there must be no leakage or contamination).Check the tightness of the canister bleed.Check that the idle speed regulation valve is not contaminated.Check the engine compressions.Replace the faulty part if necessary.

17-68

JMO011.1


engine

DIAG 5

Fiche n° 47 side 2/2TDC DETECTION

XR25 assistance : Status BG 3LH incorrectly illuminated


Starter motor activated.


REPAIR

NOTES

Check that the sensor is correctly mounted.Check the condition of the target (if it has been removed).Check the insulation, continuity and absence of interference resistance on the electrical line on track 43,track 16, track 72 of the injection computer.Replace the sensor if necessary.

17-69

JMO011.1


engine

DIAG 6

Fiche n° 47 side 2/2FUEL PUMP

XR25 assistance : G10* = Fuel pump control, ignition on



REPAIR

NOTES

Check that the impact sensor is correctly engaged.

Check the insulation and continuity of the wiring:

Fuel pump relay 5 1 Impact sensorImpact sensor 1 3 Impact sensorImpact sensor 3 B Fuel pump


Check for cleanliness and the presence of an earth on track A of the fuel pump.

Replace the fuel pump.

17-70

JMO011.1


engine

DIAG 7

Fiche n° 47 side 2/2CANISTER BLEED

XR25 assistance : G16* = Canister bleed control

No fault bargraph must be illuminated.Ignition on.# 12 and 21 offset, starting problem when engine is warm.


REPAIR

NOTES

Check the insulation and continuity of line 36 of the computer.Repair.

Replace the canister bleed solenoid valve.Note: When replacing the valve, shake it over a white sheet of paper, together with the pipe.

If pieces of carbon fall from it the canister must also be replaced.

17-71

NOTES

JMO011.1

NOTES


engine

DIAG 8

IDLE SPEED REGULATION Fiche n° 47 side 2/2

XR25 assistance : 10 < # 12 < 30 % RCO idle speed- 51 < # 21 < + 51 kg/h adaptive RCO idle speed700 < # 06 < 800 rpm Engine speedStatus BG 6RH incorrectly illuminated



REPAIR

NOTES

# 12 too high or # 21 too high or # 06 < 700 rpm

The idle speed is too low.

The idle speed regulation is not sufficient to maintain the idle speed.- Clean the air supply circuit (throttle body, idle speed regulation valve) because it is probably

contaminated.- Check the engine oil level (too high ---> splashing).- Check and ensure that the fuel pressure is correct.- Check the engine compression with the Optima 5800 Station- Check the clearance of the valves and timing.If all these points are correct, replace the idle speed regulation valve.

# 12 too low or # 21 too low or # 06 > 800 rpm or status BG 6RH exting.

The idle speed is too high

An air leak may interfere with the idle regulation programming.- Check the connections on the manifold.- Check that the pipes connected to the manifold are clean.- Check the pneumatic control solenoid valves.- Check the manifold gaskets.- Check the seals on the throttle body.- Check the tightness of the brake servo.- Check for the presence of restrictions in the oil vapour rebreathing circuit.- Check the fuel pressure.If all these points are correct, replace the idle speed regulation valve.

17-72

JMO011.1

NOTES


engine

DIAG 9

Fiche n° 47 side 2/2EMISSION OF POLLUTANTS

XR25 assistance : None



REPAIR

NOTES

0.97 ≤ λ ≤ 1.03at 2500 rpm The oxygen sensor loops correctly at 2500 rpm.

If CO > 0.3 % at 2500 rpm

NOTES0.97 ≤ λ ≤ 1.03

at 2500 rpm The oxygen sensor does not loop correctly at 2500 rpm

This is an injection or sensor problem.

The catalytic converter is faulty. Note: it is essential to find the cause of thedestruction to the catalytic converter to avoid destroying the new one.

If 0.97 ≤ λ ≤ 1.03 at idle speed. CO < 0.3 % at 2500 rpm and 0.97 ≤ λ ≤ 1.03 at idle speed

CO > 0.5 or HC > 100 ppm, this indicates that the catalytic converter is toocold, if it is de-primed it is not a fault!

If λ < 0.97 or λ > 1.03 at idle speed

Check the earth and heating of the sensor.Check that there is no air leakage at the manifold.

17-73

JMO011.1


engine

DIAG 9

CONTD.

Fiche n° 47 side 2/2



REPAIR

NOTES

NOTESλ > 1.03

at 2500 rpm None

The oxygen sensor loops correctly at 2500 rpm.

NOTESλ < 0.97

at 2500 rpmThe oxygen sensor does not loop correctly at 2500 rpm, CO >0.3 % at 2500 rpm.

Check the pressure sensor.Check the sensor.Check that there is no injector leakage.

Check that there is no leakage from the exhaust.Check that no injector is seized.Check that the fuel flow is not too low.

The oxygen sensor does not loop correctly at 2500 rpm.

Check that there is no injection problem.Check that there is no ignition problem.Check that there is no sensor problem.Check the fuel pressure.

17-74

JMO011.1


engine

DIAG 10

Fiche n° 47 side 2/2RICHNESS REGULATION

XR25 assistance : Test fiche A1Status BG 6LH incorrectly illuminated# 35 does not vary ≈ 128

No fault bargraph must be illuminated.Engine warm, # 19 and # 06 correct, idle regulation active, ignition correct (checkpossible using the OPTIMA 5800 Station.).


REPAIR

NOTES

Check the tightness of the canister bleed (a leak will interfere considerably with the richness).Check the tightness of the exhaust pipe upstream from the oxygen sensor (if necessary, check the airinjection valve at the exhaust).Check the tightness of the inlet manifoldIf the vehicle is only driven in urban traffic, the sensor must be contaminated (try running under load).Check the fuel pressure.If the idling is unstable, check the clearance of the valves (if necessary, check the EGR, risk of leakage).Check the injectors (flow and shape of the jet).If necessary replace the oxygen sensor.

17-75

JMO011.1


engine

DIAG 11

Fiche n° 47 side 2/2AIR CONDITIONING

XR25 assistance : Status BG 10LH or 10RH or 9RH incorrectly illuminated.800 < # 06 < 900 rpm1 < # 44 < 5

No fault bargraph must be illuminated.There must be no fault in the automatic transmission.Engine warm at idling speed.


REPAIR

NOTES

Check the insulation and continuity of the line, track 48, track 64 and track 65 of the injection computer.Repair if necessary.Refer to the fault finding for the air conditioning.

17-76

JMO011.1


engine

DIAG 12

Fiche n° 47 side 2/2VEHICLE SPEED

XR25 assistance : # 18 = Speed read on the speedometer in km/h


Check during road test.


REPAIR

NOTES

If the value read is incoherent:- Check that the sensor is correctly mounted.- Check the insulation, continuity and absence of interference resistance of the electrical line, track 42

of the injection computer.

The injection is no longer faulty, check the different functions using this information.

17-77

JMO011.1


engine

DIAG 13

Fiche n° 47 side 2/2ADAPTIVE RICHNESS

XR25 assistance : 0 < # 30 < 2550 < # 31 < 255


Carry out the programming.


REPAIR

NOTES

Check the tightness of the canister bleed.

Enter G0**.When the engine is warm, in idle speed regulation, look at # 35.- If # 30 or # 31 moves to MAXIMUM stop, there is insufficient fuel.- If # 30 or # 31 moves to MINIMUM stop, there is too much fuel.

Make sure that the following are clean and operating correctly :- Filter.- Fuel pump.- Fuel circuit.- Tank.

17-78

JMO011.1

INJECTIONFault finding - Customer complaint 17N7U

engine

17-79

JMO011.1


engine

17-80

JMO011.1


engine

17-81

JMO011.1


engine

17-82

JMO011.1


engine

17-83

JMO011.1


engine

17-84

JMO011.1

INJECTIONFault finding - Assistance 17

Injector resistance = 16.5 Ω

Idle Speed Regulation solenoidvalve resistance = 2-1 = 12 Ω

2-3 = 12 Ω

Canister Bleed Valve Resistance = 25.5 ± 5 Ω

Ignition Coil Resistance : Primary = 0.8 Ω

Secondary = 8.35 kΩ

Flywheel Signal Resistance = 300 Ω

Throttle Potentiometer Resistance : No load 1-2 2060 Ω Full load 1-2 2060 Ω

1-3 1050 Ω 1-3 2570 Ω

2-3 2660 Ω 2-3 1240 Ω

Oxygen Sensor Resistance : A-B = 2 to 15 Ω

Fuel pressure = 3 bars or 2.5 bars at idling speed

Value of : CO = 0.3 % max

HC = 100 ppm maximum

CO2 = 14.5 % minimum

Lambda (λ) = 0.97 < λ < 1.03

N7Uengine

Coolant temperature sensor resistance

Temperature in °C 0 20 40 80 90

Resistance in ohms6700

to8000

2600to

3000

1100to

1300

260to

300

190to

230

17-85

JMO011.1

INJECTIONFault finding - Assistance 17N7U

engine

17-86

JMO011.1

INJECTIONFault finding - Assistance 17N7U

engine

17-87

COOLINGFilling - bleeding 19

Coolant circulates continuously in the heater ma-trix, assisting with engine cooling.

FILLING

The following bleed screws must be opened:- on the top of the radiator,- on the heating hose,- on the upper radiator hose.

Fill the circuit at the expansion bottle opening.

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

Start the engine (2 500 rpm).

Adjust the level by overflow for approximately4 minutes.

Close the expansion bottle.

BLEEDING

Let the engine run for 20 minutes at 2 500 rpm,until the engine cooling fan operates(time required for automatic degassing).

Check the fluid level is close to the "Maximum"mark.

NEVER OPEN THE BLEED SCREWS WHEN THEENGINE IS RUNNING.

TIGHTEN THE EXPANSION BOTTLE CAP WHEN THEENGINE IS WARM.

19-1

98589R

COOLINGDiagram 19

1 Engine 2 Radiator 3 "Hot" expansion bottle with permanent

degassing 4 Heater matrix 6 1.5 mm diameter restriction 7 11 mm diameter restriction 8 9 mm diameter restriction

Water pump

Thermostat

Bleed screw

Temperature switch

The rating of the expansion bottle cap is 1.2 bar(brown).

19-2

COOLINGRadiator 19

SPECIAL NOTES

On this version there is no radiator temperatureswitch, the starting of the engine cooling fansbeing controlled by the injection or air conditio-ning computer.

The fan assembly has two operating speeds. It iscontrolled either by the injection computer or bythe air conditioning computer, the computerscontrolling the fans by earthing the fan assemblyrelays.

The low speed is controlled either by track 7 of theinjection computer, when the coolant tempera-ture reaches 99 ° C ( cutout takes place at 97 °C) orby track B2 of the air conditioning computer.

At low speed the two fans are controlled in series.It is possible to control the low fan speed from theinjection computer using the G27*1* mode of theXR25.

The high speed is controlled either by track 35 ofthe injection computer, when the coolant tempe-rature reaches 104 ° C ( cutout takes place at 97 °C)or by track B3 of the air conditioning computer.

At high speed the two fans are controlled in paral-lel. It is possible to control the high fan speedfrom the injection computer using the G27*2*mode of the XR25.

REPLACING THE RADIATOR

REMOVAL

Place the vehicle on a two -post lift.

Remove:- the cover,- the air filter housing, by removing the clip on

the cylinder head lifting bracket and the bolts(2),

- the engine undertray,- the two nuts (1) from the air filter unit, then

release it from below.

11797R

11795R

19-3

COOLINGRadiator 19

Then unclip the cover, pushing it to the right.

Remove the upper and lower radiator hoses.

Remove the four mounting bolts of the radiatorand remove it upwards.

- the top cover of the radiator, rotating themountings (3).

10541R2

REFITTING

Refitting is the reverse of removal..

Fill and bleed the cooling circuit.

NOTE: the following three bleed screws must beopened:

- on the top of the radiator,

- on the heating hose,

- on the upper radiator hose.

10541R

19-4

COOLINGWater pump O ring 19

REPLACEMENT OF THE WATER PUMP O RING

REMOVAL

Put the vehicle onto a lift.


Remove:- the hot air pipe from the air filter,- the hot air pipe mounting.

Remove the two hoses from the water pipe at (2).

Drain the engine block cooling circuit by means ofbolt (3).

Slacken the mounting bolts (4) of the coolantpipe, then remove it.

Extract the O ring (1).

98196R

11769R2

Remove the engine undertray.

REFITTING

Apply grease to the end of the pipe (water pumpside) to avoid damaging the O ring during refit-ting.



NOTE: the following three bleed screws must beopened:

- on the top of the radiator,

- on the heating hose,

- on the upper radiator hose.

19-5



Remove:- the cover,- the acoustic tie-rod from the suspended en-

gine mounting support,- the air filter unit by removing the clip on the

cylinder head lifting bracket and the bolts (2),- the engine undertray,- the two nuts (1) of the air filter unit, then re-


COOLINGThermostat support 19



Mot. 1273-01 Adaptor for Mot. 1273

Acoustic tie-rod bolt 2


11795R

- the cover of the thermostat support.

Disconnect the coolant temperature sensor.

Remove:- the injection computer,- the injection computer support.

11797R

10428R

19-6

Check the tension of the accessories belt, then re-move it (see section 07: accessories belt tension"value and settings").

Remove:- the bracket (5),


98318R6

Remove the pin (B) (nut - bolt)

98318R2

Lift the vehicle :

Disconnect the alternator.

Remove bolt (E), while holding the alternator.

98319R6

- the power assisted steering pump, removingbolts (6) and (7).

98202R2

Remove the accessories belt tension wheel sup-port.

19-7

For vehicles equipped with air conditioning, it isnecessary to move the compressor to one side.

Remove the compressor bolts (1).


98202-1R

- the thermostat support.

REFITTING

Refit:- the compressor support (2), apply Loctite

Frenetanch to bolt (22), and tighten the boltsto a torque of 2.5 daN.m.

98203R1

Remove:

- the multi-function support (21)

98204-1R

98203R

Make sure that part (2) does not fall out.

- the compressor.

19-8

REFITTING (contd.)

Insert the three alternator mounting bolts, thentighten them and carry out the refitting as the re-verse of removal.


NOTE: it is essential to open the following threebleed screws:- on the top of the radiator,- on the heating hose,- on the upper radiator hose.

NOTE : never refit the removed belt, but replaceit.


19-9

COOLING

Fan 19

11797S

- the indicators, in order to reach the radiatorgrille brackets (12).

-- the two bolts (3), then slide the clips (10) and(11) in the direction of the arrows, with the aidof a screwdriver,

- using a screwdriver, move the brackets (12)slightly apart, then gently release the radiatorgrille assembly.

11237R1



Remove:- the cover,- the acoustic tie bar from the engine moun-

ting,- the air filter unit, removing the clip on the cy-

linder head lifting bracket and the bolts (2).- the engine undertray,- the two nuts (1) of the air filter unit, then re-


11795S

11569R1

11236R1

19-10

COOLING

Fan 19

95099-1S

- the right-hand and left-hand protective wheelarch covers,

- the engine undertray,

- the front bumper, after removing the twomounting bolts (B) on each side of the vehicleand the lower mounting bolt (C).

PRC10.11

95094R

95096R2

19-11

COOLINGFan 19

- the upper front cross member, after disconnec-ting the two headlights and the bonnetswitches and removing the eight mountingbolts (D).

94994R1

Remove the label holder (7).

Move the engine cooling radiator to one side, af-ter removing the four bolts (14).

Remove:- the relay cover (15),- the cover (11) after removing the four bolts

(10),

10541R1

- the four mounting bolts (12) of the condenser,

- the three mounting bolts (13) of the dehydra-tion canister and of the condenser/ canisterconnection.

10542R

Attach the condenser and the engine cooling ra-diator to the engine.

10535S

19-12

COOLING

Fan 19Disconnect the three connectors (8) and the earthwire (9).

10537R

- the two mounting bolts (E) of the power assis-ted steering pipe.

94995R

- the two mounting bolts (G) of the cooling as-sembly,

94995R1

- the fans.

REFITTING

There are no special notes for refitting.


19-13

ENGINE SUSPENSIONSuspended engine mountings 19

10543-1R

DESCRIPTION

1 Front left hand suspended engine mounting pad2 Suspended mounting support on gearbox3 Suspended mounting support on cylinder head4 Longitudinal movement limiter5 Suspended mounting cover6 Front right hand suspended engine mounting pad7 Engine tie bar

CONSTITUTION

The engine is suspended from two rubber mounting pads (1 and 6). Torque is taken up in the lon-gitudinal direction by:

- the engine tie bar (7) at the bottom of the engine and transmission assembly,- the movement limiter (4) at the top of the engine and transmission assembly.

NOTE : to avoid damaging the rubber mounting pads, do not exceed 20° angular movement inrelation to the vertical.

19-14


11760R1

Order of tightening the suspended engine moun-ting supportTightening must be carried out in the order des-cribed below.

Tightening order:

1, then 2 and 3 to a torque value of 9.5 daN.m.

5,6 then 7 to a torque value of 5.5 daN.m.

NOTE: the tapered nut is positioned at 1.

19-15


11759-1R

TIGHTENING TORQUES (in daN.m or in degrees)

* Engine removed: 3.5 daN.m + 75°±5°Engine in place in the compartment : 6 daN.m

ENGINE N7U MANUAL

19-16


11759S2R

TIGHTENING TORQUES (in daN.m or in degrees)

* Engine removed: 3.5 daN.m + 75°±5°Engine in place in the compartment : 6 daN.m

ENGINE N7U A.T.

19-17

CLUTCHIdentification 20

VEHICLE

TYPE

ENGINE

TYPEMECHANISM DISC

235 HR 4700 94990R1

85873S

B54 F N7U

20 splinesD = 235 mmE = 8.2 mm

90693-2

20-1

PRC20.5

CLUTCHExploded diagrams 20

Consumables

Clutch controlFork pivotFork padsClutch thrust pad guideClutch friction splines

MOLYKOTE BR2 77 01 421 1451 kg tin

Type Packaging Part Number Component

20-2

CLUTCHMechanism - Disc

REMOVAL

Fit the stop plate Mot. 582.

Remove the mounting bolts of the mechanism,then remove it and the clutch disc.


Mechanism mounting bolts 2.5

Mot. 582 Stop plate

REFITTING (Special notes )

Fit the disc in place: offset (A) on the hub on thegearbox side.

20REPLACEMENT

This operation must be carried out after disconnecting the gearbox from the engine.


Check visually :- the absence of scratches on the surface of the

engine flywheel,- the engine flywheel wear,- the condition of the starter motor ring gear,- the tightness of the crankshaft lip seal.

Replace any faulty parts and clean the clutch shaftsplines.

98205R

74413R

Use the plastic centring device supplied with thekit for fitting the disc.

Fit the mechanism.

Tighten the bolts in a star arrangement, then tor-que tighten the mounting bolts of the mecha-nism.

Remove the stop plate Mot. 582.

Smear the bore of the clutch thrust pad, the guidetube, the fork pads, the clutch splines and the pi-vot with MOLYKOTE BR2 grease.

20-3

CLUTCH

Flywheel

REMOVAL


Remove the flywheel mounting bolts. Thesecannot be re-used.

Remove the flywheel and the stop plate Mot. 582.

Regrinding of the flywheel friction surface is notpermitted.

Replace the flywheel if there is any damage.


Flywheel bolt 4.5+65°±5°

Mot. 582 Stop plate

REFITTING

Clean the threads of the flywheel mounting boltson the crankshaft with a dry cloth.

Remove any grease from the flywheel bearingface on the crankshaft.

Bond the flywheel with AUTOFORM Loctite.


Smear the new bolts with FRENETANCH Loctiteand tighten them to the correct torque.

Remove the stop plate Mot. 582.

20REPLACEMENT

This operation must be carried out after disconnecting the gearbox from the engine and removing theclutch.

TIGHTENING TORQUES

(in daN.m and in degrees)

98205R

20-4

CLUTCHGuide tube 20

REMOVAL

Remove the guide tube (bolt 1).

Use a 2 mm diameter drill to make a hole in theseal.

Extract the seal by inserting a screw into the hole.


B. Vi. 1236 Tool for fitting the seal on the

primary shaft

REPLACEMENT

This operation must be carried out after disconnecting the gearbox from the engine and removing theclutch.

10562R1

NOTE: - place the unit in a horizontal position to

prevent chips of metal dropping into theprimary shaft bearing.

- avoid scratching the primary shaft or thesealing surface.

- blow air into the seal groove in order to removeany metal chips.

REFITTING

Position the seal using tool B. Vi. 1236.

20-5

DI2121

MANUAL GEARBOXIdentification 21

The type VM1 manual gearbox is fitted to the B54F vehicles.

A self-adhesive label shows:

At A : the gearbox type,At B : the gearbox suffix,At C : the supplier’s code reference,At D : the factory of manufacture,At E : the fabrication number.

XX XX XXX XXX

BA

C

ED

21-1

MANUAL GEARBOXRatios 21

43 (3) 38

14 and 3914

43B54 F

90

19

V M 1

Reverse1stSpeedometerdrive gear

3rd 4thStepdown

Suffix Vehicle 5th

22

39

(3) There are four pinions in the reverse gear kinematic chain with an overall ratio of approx:

VM1*001 : 11/33

001 electronic

2nd

40

28

38

33

31

37

21-2

10612R

MANUAL GEARBOXLubricants 21

LUBRICANT

CAPACITY (in litres): 2.2

VISCOSITY GRADE

TRANSELF TRZ 75 W 80W

OIL CHANGE FREQUENCY

Refer to the vehicle documents.

Drain plug (A)

Filling plug (B)

10562R

CHECKING THE LEVEL

Fill to the overflow level.

21-3

MANUAL GEARBOXConsumables 21

TYPE PACKAGING PART No COMPONENT

Clutch control:

Fork pivotFork padsClutch thrust pad guideClutch friction spline

MOLYKOTE BR2 77 01 421 1451 kg tin

Parts needing to be systematically replaced

When they have been removed,- left-hand engine mounting nut.

21-4

T.Av.476 Ball joint extractor

T.Av. 1380 Lever

MANUAL GEARBOXGearbox (Removal - Refitting) 21

EQUIPMENT REQUIRED


REMOVAL

Put the vehicle on a 2 post lift.


Remove:- the cover on the engine,- the battery and its plastic base,- the label holder,- the air filter, nut and bolt (1).

Drain plug 3.5Filling or level plug 3.5Track rod end nut 4Lower ball joint nut 6.5Driveshaft flange bolt 0.8Relay bearing pressure bolt 2Shock absorber base bolt 25Bolt at edge of gearbox 5Nut at edge of gearbox 5Starter motor bolt 5Bolt for rubber mounting on gearbox 5.7Engine tie-bar bolt 15Brake calliper bolt 3.5

Engine support tool

Component jack

98310R1

Remove the circlip (7) holding the air filter sleeve.

11797R


21-5


Remove:- the plastic engine undertray. It is essential to

remove the air filter from the bottom,- the front wheels,- the front mudguards,

PRC10.11

10612R

- the wheel arch protectors,

Drain the gearbox through plug (A).

Left-hand side

IMPORTANT : measure dimension X with a drillbit, before removal; this will allow the driveshaftto be properly located in the gearbox during refit-ting.

10577R

Slacken the shock absorber base.

Fully slacken the nut of the lower ball joint and re-lease it .

Remove the brake calliper and hook it onto thesuspension spring in order to protect the hose.

Release the track rod end.

Extract the driveshaft without pulling on thebrake disc. For more information see Section 29.

TAKE CARE with the driveshaft gaiters on thegearbox side: they are made of rubber and aretherefore very fragile.

NOTE: if the spring ring shows no sign of damage(cracks, broken ring, etc...), it is not systematicallyreplaced. If it is replaced, the new ring must befitted onto the end of the splines.

Remove the "brake disc / stub axle carrier / drives-haft" assembly by removing the shock absorberbase bolts and the lower ball joint nut.

For any removal or handling of the driveshafts, itis essential to keep all the components as closelyin line as possible, in order to avoid pinching thegaiters and to reduce the risk of them comingapart.

21-6


Right-hand side:


Slacken the shock absorber base bolts.


Remove the relay bearing plate

10560R

Slacken the relay bearing pressure bolt (4) (elasticdeformation bearing with a maximum tighteningtorque of 2 daN.m).

Remove:- the driveshaft taking care not to cut the gear-

box output lip seal,- the air filter mounting,- the wiring mounting brackets, and disconnect

the gearbox connectors.

On the top:

Remove the hot air pipe.Disconnect the throttle potentiometer.Release the expansion bottle, pulling it towardsthe scuttle panel grille.

Remove:- the starter motor, two bolts (6) plus one at the

rear,- the upper mounting bolts on the edge of the

gearbox (7).

10539-1R

NOTE: Do not remove the two studs at (7).

10613R1

Remove the bolt (5) of the wiring mounting fromthe clutch slave cylinder pipe.

Release the hydraulic clutch control slave cylinder(1 circlip).

21-7


Remove:- the primary exhaust pipe from the manifold

(1),- the engine tie-bar (2).

Insert a block (3) of 120 mm , of wood or rub-ber, between the sump and the half sub-frame.

Remove the gear control cables (one clip, one balljoint).

Fit the engine retaining tool and strap the engine.

11817S

Remove the three bolts of the mounting pad onthe gearbox.

10543-1S1R

11929R

Fit the component jack.

97520S

Remove the lower mounting bolts on the edge ofthe gearbox.

+20 0

21-8


11758R

Disconnect the gearbox from the engine and tiltthe gearbox downwards.

Lower the gearbox and complete the operationby bringing it towards the front of the vehicle.

REFITTING (Special notes)

Check for the presence of the centring dowels.

Refit:- the mounting pad on the gearbox,- the engine tie-bar- the exhaust downpipe.

Engage the left-hand driveshaft in the gearboxand tap it in, keeping it as in-line as possible.

When refitting the right-hand driveshaft thenotch in the bearing retaining plate must be fa-cing upwards.

Observe the tightening torque of the relay bea-ring pressure bolt.

Check that the dimension (X) measured during re-moval remains unchanged at ± 1 mm.

10577R


21-9

MANUAL GEARBOXDifferential output seal 21

REMOVAL OF THE SEALS

Note: it is not necessary to drain the gearbox.

Left-hand side:Put the vehicle on a 2 post lift.Disconnect the battery.

Lift the vehicle to mid-height.

Remove:- the front wheel,- the front wheel arch protector.

Fully lift the vehicle.


IMPORTANT : before removal, measure dimensionX with the aid of a drill bit; this will allow the pro-per location of the driveshaft in the gearbox to bechecked during refitting.


B. Vi. 1401 Tool for fitting differential output seals

(in kit B.Vi. 1400-01)

T. Av. 476 Ball joint extractor

T. Av. 1380 Lever

Track rod end nut 4Driveshaft flange bolt 0.8Relay bearing pressure bolt 2Shock absorber base bolts 25Brake calliper bolt 3.5


10577R

Slacken:- the shock absorber base bolts,- the nut of the lower ball joint as far as possi-

ble, and release it.



21-10


Right-hand side:Remove the brake calliper and hook it onto thesuspension spring in order to protect the hose.

Slacken the shock absorber base bolts.


Remove the relay bearing plate (bolt 3).

95579S

10560R

Slacken the relay bearing pressure bolt (4) (elasticdeformation bearing; maximum tightening tor-que 2 daN.m)

Remove the shock absorber base bolts, the lowerball joint nut (release it with a ball joint extractor)and remove the driveshaft.

Extract the seal with a screwdriver, taking care notto damage the housing.

95579S

Note: if there is no damage to the spring ring(cracks, ring broken, etc...) it need not be systema-tically replaced.

Remove the "disc/stub axle/driveshaft" assemblyby removing the shock absorber base bolts andthe lower ball joint nut.

Whenever the driveshafts are removed or han-dled, it is essential to keep all the components aswell aligned as possible in order to avoid pinchingthe gaiters and to limit the risk of them comingapart.

Extract the seal with a screwdriver, taking care notto damage the housing.

10637R

Extract the driveshaft from the gearbox, usingtool T. Av. 1380.

IMPORTANT: the driveshaft gaiter on the gear-box side is made of rubber, and therefore veryfragile.

21-11


10577R

Refitting the seal (left and right-hand)

Fit a new seal using the side marked V M 1 on toolB.Vi. 1401.

Refitting the left-hand driveshaft

Insert the left-hand driveshaft into the gearboxand tap it in, keeping it as closely as possible inline.To ensure that the driveshaft and the circlip (14)are correctly positioned, check that dimension (X)recorded during removal is the same to within +/-1 mm.

DI21.22

IMPORTANT:

on the relay bearing:- ensure that the lug on the flange is facing up-

wards,- it is essential to tighten the flange mounting

bolts first before tightening the pressure boltto a torque value of 2 daN.m

Replace and tighten the brake calliper mountingbolts to the correct torque.

Fill the gearbox with oil.

21-12

MANUAL GEARBOXReversing light switch 21

REMOVAL

Put the vehicle on a 2-post lift,Disconnect the battery.Disconnect the reversing light switch.

Remove:- the engine undertray,- the left-hand front wheel,- the left-hand front mudguard (1),- the side protection (2),

EQUIPMENT REQUIRED

Engine support tool

Wheel bolt 10Gearbox support nuts onrubber engine mounting 5.7


11783S

Remove:- the gearbox support nut on the left-hand rub-

ber engine mounting pad.

Lower the engine and transmission assembly, ta-king care not to touch the driveshaft gaiter on thesub-frame.

96470R

- the cover ( removing the oil filler plug).

Release the expansion bottle.Position the engine support tool and take theweight of the engine and transmission assembly.

PRC21.3

21-13

MANUAL GEARBOXReversing light switch 21

Remove the reversing light switch.

PRC21.4

REFITTING


TIGHTEN ALL THE NUTS AND BOLTS TO THERECOMMENDED TORQUE VALUE.

21-14

AUTOMATIC TRANSMISSION

Identification 23Automatic transmission identification plate A Manufacturer (Aisin Warner)

B Year of production

C Month of production (Eg: A=1,

B=2....M=12, except I)

D Driveshaft model (50-42 LE)

E Sequential number for one month’s

production

F Automatic transmission suffix

N7U engine

11800G1

VEHICLE A.T. TYPE ENGINETORQUE

CONVERTERSTEP

DOWNDIFFERENTIAL

RATIOCOMPUTER*

B54 F SU0 001 N7U 701 241 57/56 21/65 Part No. 77 00 874433

* For identification with the XR25 (see Fault finding - Conformity checking section)

23 - 1

AUTOMATIC TRANSMISSIONUse 23

DRIVING

As the automatic transmission is lubricated underpressure, it only happens if the engine is running.

Consequently, it is essential to observe the follo-wing instructions, to avoid serious damage:

- never drive the vehicle with the ignition off(on a slope for example); we cannot over-emphasize the danger of doing this;

- never push the vehicle along (to reach apetrol pump, for example) without takingthe precautions indicated in the "Towing"paragraph.

Additionally, the vehicle drive is only engaged ifthe engine is running. It is therefore impossible tostart the engine of a vehicle with automatic trans-mission by pushing the vehicle.

TOWING

It is always preferable to have the vehicle towedon a trailer or with the front wheels lifted.However, if this is not possible, towing may excep-tionally be carried out at a speed of less than 12mph (20 km/h) and for a maximum distance of 18miles (30 km) (lever in N).

TOWABLE LOAD (towing a caravan, boat, etc.)

The load being towed must not exceed 750 kg.

If this load is exceeded on a 7% gradient, it willcause the engine oil to overheat, followed by adrop in oil pressure and rapid damage to the en-gine.

Gear ratios

Gear 1st 2nd 3rd 4th Reverse

Gear reduction 3.672 2.098 1.391 1 4.022

Gear reduction + step-down 3.606 2.061 1.366 0.982 3.951

Overall reduction 11.165 6.380 4.231 3.041 12.228

Speed in km/h at 1000 rpm with 195/65-15 tyres 10.366 18.14 27.35 38.06 9.46

N7U engine

23 - 2

AUTOMATIC TRANSMISSIONGear change thresholds 23

The figures shown in the table are the theoreticalaverage gear change threshold values in km/h.Tolerances = ± 10 %.

PL : No load.PF : Full load.RC : Kickdown (changing to a lower gear).

A : Normal speed gear change thresholds (se-lector switch (1) disengaged - light "S" ex-tinguished).

B : Shifted gear change thresholds (selectorswitch (1) engaged - light "S" illuminated).

N7U engine

95501-3R

VEHICLE A.T.TYPEACCELER-

ATORPOSITION

Converterbridging

solenoid valveÊ

A B

4 → 3

A B

3 → 2

A B

2 → 1

A B

PL 54 58 32 32 18 18 10 10

PF 126 142 118 118 70 70 32 32

RC

VEHICLE A.T. TYPEACCELER-

ATORPOSITION

1 → 2

A B

2 → 3

A B

3 → 4

A B

Converterbridging

solenoid valve‰

A B

PL 11 11 22 22 35 35 58 62

PF 43 45 88 90 144 145 139 149

RC

B54 F 52

SU0

97

B54 F

SU0

108 165 165

155 155 48

23 - 3

AUTOMATIC TRANSMISSIONConsumables 23N7U engine

NAME COMPONENT CONCERNED

MOLYKOTE BR2 greaseDriveshaft relay shaft splinesTorque converter centring device

FRENBLOC Loctite Brake calliper mounting bolt

FRENETANCH Loctite Distributor bolt

Loctite 518 Distributor housing

Parts needing to be systematically replaced

Parts needing to be replaced when they havebeen removed:- lock nuts,- seals,- rubber seals.

Oil

The SUO automatic transmission is a transmission system requiring a particular oil quality and level.

TRANSMISSION

Oil specified in the DEXRON 2E standard.

23 - 4

AUTOMATIC TRANSMISSIONOil change frequency 23

The oil level must be checked every 6000 miles (10,000 km) if there is a slight oil leakage.

It only needs to be topped up in case of a slight leak.

CAPACITY IN LITRES

N7U engine

Mechanism

Total volume * 7.6

Volume after draining * 3.3

Radiator volume 0.4

Oil pipe volume 0.3

* The capacities are given only as an indication. They are liable to vary according to the temperature.

23 - 5

AUTOMATIC TRANSMISSIONDraining 23

DRAINING

Automatic transmission:

Draining is carried out by removing the plug (V).

11796R

N7U engine

Drain plug 4

TIGHTENING TORQUE (in daN.m)

Measure the quantity of oil that has been drained(this quantity measurement will be used as a refe-rence when refilling).

23 - 6

AUTOMATIC TRANSMISSIONFilling - Levels 23N7U engine

FILLING - LEVELS

Filling is carried out through pipe (D).

11807-1R

Use a funnel fitted with a 15/100 filter in order toprevent the introduction of impurities.

The level MUST be checked using the methoddescribed below:

1. Park the vehicle on a horizontal surface.

2. Fill the automatic transmission with the samequantity of oil as measured when draining, inorder to top up approximately to the full level(about 3.3 litres).

3. Run the engine at idle speed.

4. Connect up the XR25 and enter: :

5. As soon as a temperature of 80°C ±1°C hasbeen reached, remove the dipstick and the le-vel should be in the area of the two upper gra-duations (G) ( 80 °C side).If it is not, add oil with the engine running(make sure that the checking is done at 80 °C,and check the level again).

11804R

D 1 then # 0 44

Special note:

When removing the oil cooler it is vital to put backthe quantity of oil collected during the operation,in order to top up to full level using the methodindicated previously.

NOTE : the dipstick has an indication at 40 °C; itcan only be used for an approximate check andtop up with the engine running, and it is essentialto confirm it with the XR25.

G = maximum level area

23 - 7

AUTOMATIC TRANSMISSIONChecking the converter setting point 23N7U engine

Put the vehicle onto a 2-post lift.

Lift the vehicle until the wheels have been raiseda few centimetres off the ground.

Connect the XR25.

Select S8 on the ISO selector.

Enter the A4.2 transmission code.

in order to display the oil temperature.

The check must be carried out at an oil tempera-ture of between 60 °C and 80 °C.

Start the engine, move the lever to position D.

Enter the code :

to display the engine speed.

Accelerate hard, keeping the brakes on.

The front wheels must not turn.

WARNING: the full load position must not bemaintained for more more than 5 seconds.Beyond this, there is a major risk of destroying thetorque converter or the automatic transmission.

The engine speed should stabilise at :2 300 ± 150 rpm

IMPORTANT :Once the measurement has been made, releasethe accelerator and keep the brakes on until theengine has stabilised at idle speed (risk of damageto the automatic transmission unless this is done).

A setting point outside the permitted tolerancerequires replacement of the torque converter.

D 1 then # 0 44

# 0 6

23 - 8

AUTOMATIC TRANSMISSIONOil pipes 23

- the cover on the engine,- the air pipe (A) on the unit,- the hot air pipe,

Disconnect the flow meter (8).

Disconnect the hoses.

Remove the bolts (3) and extract the air filter frombelow.

N7U engine

11795R

11796R

Oil pipe flange bolt 0.8Oil pipe mounting bolt on radiator 0.74Oil pipe nut 4±1


REMOVAL




Drain the automatic transmission through plug(V).

Remove:- the two bolts (1) of the air filter unit,

11797R2

23 - 9

AUTOMATIC TRANSMISSIONOil pipes 23

Remove the pipes on the radiator (bolt 3) andrelease them.

Slide the rubber mounting pad (J) down andrelease the oil pipes.

N7U engine

11791R5

11703R1

Remove:- the automatic transmission computer and its

casing,- the air filter unit and computer mounting.

Place a clean container underneath the automatictransmission to recover the oil.

Remove:- the oil pipes support (F),- the oil pipe (H).

Release the oil pipe (G), taking care to recover theseal. Plug the hole with a lint-free cloth toprevent the entry of any impurities.

Disconnect and unclip the connectors (D).

Remove:- the clip (C) of the automatic transmission wi-

ring,- the electric wiring channel support (E), and re-

lease it,- the protection beneath the automatic trans-

mission

11790R

11798R2

23 - 10

AUTOMATIC TRANSMISSIONOil pipes 23N7U engine

REFITTING


Special notes:

It is essential to replace the oil pipe seals and totighten to the correct torque value.

Replace the oil pipe seal on the automatic trans-mission, if it is faulty.

If the oil pipe union on the timing cover is faulty,it must be replaced.

Fill up the automatic transmission with oil,following the recommendations (refer to therelevant section).

23 - 11

AUTOMATIC TRANSMISSIONHydraulic distributor 23

11796R

N7U engine

Housing mounting bolt 1.2Distributor mounting bolt 1Oil pipe flange bolt 0.8Oil pipe nut 4±1


REMOVAL

Put the vehicle onto a 2-post lift.Disconnect the battery.



Remove:- the two bolts (1) of the air filter unit,

11795R

- the cover on the engine,- the air pipe (A) on the unit,- the hot air pipe,

Disconnect the flowmeter (8).


Remove the bolts (3) and extract the air filter frombelow.

11797R2

23 - 12


11703R1

N7U engine

11790R4

Remove:- the automatic transmission computer and its

casing.- the air filter unit and computer mounting.

11791R5

Disconnect and unclip the connectors (D).

Remove:- the clip (C) of the automatic transmission wi-

ring,- the electric wiring channel support (E), and re-

lease it,- the protection beneath the automatic trans-

mission

Place a clean oil container underneath theautomatic transmission

Remove the oil pipes (F) taking care to recover theseal, and plug the hole with a lint-free cloth toprevent the entry of impurities.

Remove:- the housing (bolt 3) of the hydraulic distribu-

tor, detaching it with an extra-flat chisel (wi-thout damaging the contact surfaces.

Disconnect and release the sealed connector (G).Remove:- the bolts (4) of the hydraulic distributor,

11788R

23 - 13


11786R1

N7U engine

- the distributor, tilting it slightly in order to free thecontrol (H) of the automatic transmission selector.

- the two seals (J), ensuring that no impuritiesget into the automatic transmission.

11789R

11788R1

REFITTING

Clean the sealing surfaces on the automatic trans-mission, avoiding any damage to them.

Clean the sealing surface on the hydraulic distri-butor housing.

Clean the hydraulic distributor bolts, taking careto remove any remaining particles of adhesive.

It is essential to replace the seals (J).


Retighten the distributor bolts in the order givenbelow, putting a drop of FRENETANCHE LOCTITEonto them, and tighten to the correct torque va-lue.

WARNING: the bolts are of different lengths; seebelow.

P = 16 mmQ = 50 mmR = 55 mm

23 - 14

AUTOMATIC TRANSMISSIONHydraulic distributor 23N7U engine

Clean the surfaces of the automatic transmissionhousing.

Apply a bead of LOCTITE 518 approximately 3 mmthick.

Apply one drop of LOCTITE FRENETANCH to thebolts of the hydraulic distributor housing andtighten them to the correct torque in the orderbelow.

11801R

Replace the oil pipe seal if faulty.

Fill up the automatic transmission with oil,following the recommendations (refer to therelevant section).

23 - 15

AUTOMATIC TRANSMISSIONRadiator 23

11703R1

N7U engine

TIGHTENING TORQUE (in daN.m)

Oil pipe mountingbolt on radiator 0.74

REMOVAL



Remove:

- the engine undertray,- the bolts of the air filter unit and computer

mounting,

- the two bolts (1) of the air filter.

11795R

- the lower bolt (2) of the oil radiator,

11798R1

23 - 16


11797R2

N7U engine

- the air pipe (A) on the unit,- the hot air pipe.

Disconnect the flowmeter (B).Disconnect the hoses.

Remove the bolts (3) and extract the air filterfrom below.

- the indicators in order to reach the brackets(12) of the radiator grille,

- the two bolts (3), then slide the clips (10) and(11) in the direction of the arrows.

- Using a screwdriver, move the brackets (12)slightly apart, then gently release the radiatorgrille assembly.

11236R1

- the air filter unit/computer mounting,- the computer,

11703R1

11237R1

23 - 17


Remove the left-hand headlight unit.

Place an oil container underneath the vehicle.

Remove:

- the engine radiator bolts (3),- the oil pipes bolt,- the oil radiator bolts (4).

11798R3

N7U engine

11569R1

Move the engine cooling radiator slightly aside inorder to release the automatic transmission oil ra-diator.

REFITTING


Special notes:

It is essential to replace the oil pipe seals and totighten to the correct torque value.

Radiator oil capacity: 0.4 litre.

Measure the quantity of oil collected whenremoving the radiator, which will allow anapproximate topping up to be carried out, thenfill the automatic transmission to the full level,following the recommendation (see relevantsection).

If the removal was carried out following damageto the automatic transmission or to one of itscomponents, it is recommended to flush theradiator with automatic transmission oil.

23 - 18


Automatic transmission (Removal-Refitting) 23

11796R

N7U engine


T.Av. 476 Ball joint extractor

T.Av. 1380 Tool for removing driveshaft

EQUIPMENT REQUIRED

Engine support tool

Component support

Wheel bolts 10Brake calliper mounting bolts 3.5Shock absorber base mounting bolt 25.5Track rod end mounting nut 4Lower ball joint mounting nut 6.5Front mounting bolt of the front sub-frame, diameter 10 4.5Rear mounting bolt of the rear sub-frame, diameter 16 24Engine tie-rod bolt 15Relay bearing plate bolt 0.85Relay bearing pressure bolt 2A.T. support mounting bolt 5.5A.T. support nuts on rubber engine mounting 5.7Control cable mounting bolt 1.9Bolt at edge of automatic transmission 4.8Nut at edge of automatic transmission 4.8Oil pipe flange bolt 0.8Oil pipe nut 4±1Starter plate mounting bolt ontorque converter 3.5


Remove:

- the front wheels,- the mudguards (1) and the side protectors (2).

96470R

Removal from below

Put the vehicle onto a 2-post lift and select leverposition N.

Remove the battery and its mounting.


Drain the automatic transmission through plug(V) and measure the quantity of oil recovered.

23 - 19



10637R

N7U engine

10577R


Fully slacken the nut of the lower ball joint as faras possible and release it.

Remove the brake calliper and hook it onto thesuspension spring to protect the hose.

Release the track rod end using tool T.Av. 476.

Remove the ABS sensor and hook it onto theshock absorber spring.

Extract the driveshaft using tool T.Av. 1380.

WARNING: the driveshaft gaiter on the gearboxside is made of rubber, and therefore very fragile.

Remove the "brake disc / stub axle carrier /driveshaft" assembly, removing the shockabsorber base bolts and the lower ball joint nut.

Remove the driveshaft, keeping it straight toavoid damaging the seal of the differential.

Plug the driveshaft hole with a lint-free cloth inorder to prevent the entry of any impurities.

Right-hand side:

Remove the ABS sensor and hook it onto thesuspension spring.



Slacken the nut of the lower ball joint as far aspossible, and release the ball joint.

Remove the relay bearing plate (bolt 4).

Remove the relay bearing pressure bolt (3) (elasticdeformation bearing).

10560R2

Left-hand side:

IMPORTANT : measure dimension X with the aidof a drill bit; this will allow the driveshaft to beproperly located in the automatic transmissionduring refitting.

23 - 20



11797R2

N7U engine

- the air pipe (A) on the air filter unit.

Disconnect the flowmeter (B).

11795R

Remove the bolts of the shock absorber base, thelower ball joint nut and the driveshaft, taking careto support the end of the driveshaft so that thesplines do not cut the automatic transmissionoutput lip seal.

Plug the driveshaft opening with a lint-free clothto prevent the entry of impurities.

Remove:- the two bolts (1) of the air filter unit.

Remove:- the hot air pipe,- the bolts (3) and extract the filter from be-

neath.

- the hot air pipe mounting (bolt E) on the cylin-der head, and unclip the connector (F) of theTDC sensor,

- the TDC sensor wiring mounting (G) under-neath the cruise control LDA , and remove theTDC sensor (H).

11794R1

23 - 21

AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION (Removal-Fitting) 23

- the starter,- the three upper bolts of the automatic trans-

mission.

Position the engine support tool and support theweight of the engine and transmission assembly.

11703R2

N7U engine

-- the dipstick guide tube taking care to recoverthe seal and plug the hole with a lint-free clothto prevent the entry of any impurities.

Disconnect the throttle body and the idle speedregulation valve.

Remove:

- the automatic transmission control cable, bolt(7) and clip (L) and release it,

- the supports (J) and (K) of the electric wiringand release the wiring.

11765R

Remove:

- the engine tie-bar,- the steering box heat shield,the steering box, and attach it.

Unclip the rubber exhaust downpipe mountings.

Place a component jack under the front subframe(as a safety measure, secure the assembly bymeans of a chain).

11783S

23 - 22

AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION (Removal-Refitting) 23

Disconnect and release the connectors (B).

Remove:- the wiring supports (1) and (2),- the protection (C) underneath the automatic

transmission.

N7U engine

Remove:- the lower ball joint nuts (K) on the anti-roll

bars,- the four mounting bolts (N) of the front sub-

frame on the body,

96564R1

- the bolts (A) and the subframe/bodyconnecting element.

95132R

Disconnect and release the ABS cable from thesubframe.

Progressively lower the component jack andrelease the assembly from below the vehicle.

11791R3

- the mounting (L) of the oil pipes,- the oil pipes (D),

11790R3

23 - 23

AUTOMATIC TRANSMISSIONAUTOMATIC TRANSMISSION (Removal-Refitting) 23N7U engine

- the six bolts (E) of the torque converter, turningthe engine in its direction of rotation using asocket wrench on the crankshaft pulley, (neverturn the engine in the opposite direction) andlock the starter plate with the aid of ascrewdriver.

11799R

Release the expansion bottle.

Remove the left-hand rubber engine mountingnut.Lower the assembly and remove the three bolts(E) of the suspended engine mounting, thenremove it.

11759S1R2

Position the component jack underneath theautomatic transmission.

11906S

Remove the lower bolts at the edge of theautomatic transmission assembly, and extract it.

23 - 24


Automatic transmission (Removal-Refitting) 23REFITTING

Place the vehicle and the automatic transmissionin position N.


Special notes:Check that the drive plate is undamaged(permitted run-out 0.2 mm).

Check that the centring dowels (F) are present.

11784R

Lubricate the torque converter centring device inthe crankshaft with MOLYKOTE BR2.

IMPORTANT : check that the torque converter hasbeen properly inserted into the transmissionusing a straight edge and a rule, ensuring that thedistance (X) between the end of the straight edgeand the rule is about 14 mm and that the contactsurfaces are clean.

N7U engine

11911R

It is essential to replace the six torque convertermounting bolts.

Position the drive plate with the aid of a socketwrench on the crankshaft pulley .

23 - 25


Automatic transmission (Removal-Refitting) 23N7U engine

11758R

IMPORTANT : the lug in the plate holding therelay bearing must face upwards.

TIGHTEN ALL NUTS, BOLTS AND SCREWSTO THE RECOMMENDED TORQUEVALUES.

Fit the calliper mounting bolts using FRENBLOCLOCTITE and tighten them to the correct torque.

Check and adjust the control cable if necessary(see relevant section).

Fill the automatic transmission with oil and checkthe level (see relevant section).

Press several times on the brake pedal to bring thepistons into contact with the brake pads.

Hand tighten the torque converter through hole(O) and put in the mounting bolts one by one,taking care to guide them properly, then tightenthem to the correct torque.

11799R1

NOTE : when removing driveshafts, ensure thatthey are guided straight in order to prevent da-mage to the differential seals.

23 - 26

AUTOMATIC TRANSMISSIONStarter plate 23

The maximum permitted run-out on the starterplate is 0.2 mm.

REFITTING

Refit the starter plate, ensuring that it is positio-ned in relation to the centring pin (3).

NOTE : apply FRENBLOC LOCTITE to the threads ofthe bolts before refitting them.

Insert the bolts into the starter plate then tightenthem to the correct torque value (angular tighte-ning).

Use tool Mot. 582 in order to lock the starterplate in position.

TIGHTEN ALL THE NUTS, BOLTS ANDSCREWS TO THE RECOMMENDED TORQUEVALUE.

This operation can only be carried out when theautomatic transmission has been removed (seerelevant section).

REMOVAL

Fit the Mot. 582,

Remove:

- the ten bolts (V),- the starter plate.

11784R1

N7U engine


Mot. 582 Locking tool

EQUIPMENT REQUIRED

Engine support tool

Starter plate bolt 4.5±50°±5°

TIGHTENING TORQUE

(in daN.m and in degrees)

23-27

AUTOMATIC TRANSMISSIONDifferential output seal 23

In order to remove the differential output seals, itis necessary to remove the driveshafts; theoperation will be made easier by removal of thefront driveshafts.

REMOVAL OF THE FRONT DRIVESHAFTS



Drain the automatic transmission (V).

Remove:

- the front wheels,- the mudguards (1) and the side protectors (2).

Wheel bolts 10Brake calliper mounting bolt 3.5Shock absorber base bolt 23.5Track rod end mounting nuts 4Lower ball joint mounting nuts 6.5Relay bearing plate bolt 0.85Relay bearing pressure bolt 2


N7U engine



B.Vi. 1402 Tool for centring the torqueconverter ring (in kit B.Vi. 1400-01)

EQUIPMENT REQUIRED

Engine support tool

11796R

96470R

23-28


Left-hand side:

IMPORTANT : measure dimension X with the aidof a drill bit; this will allow the driveshaft to beproperly positioned in the automatic transmis-sion during refitting.

10637R


Fully slacken the nut of the lower ball joint andrelease it.



Remove the ABS sensor and hook it onto theshock absorber spring.

Extract the driveshaft from the automatictransmission using tool T.Av. 1380.

N7U engine

10577R

WARNING: the driveshaft gaiter on the gearboxside is made of rubber, and therefore very fragile.


Remove the driveshaft, keeping it straight toavoid damaging the seal of the differential.

Plug the driveshaft hole with a lint-free cloth inorder to prevent the entry of any impurities.

Right-hand side:

Remove:

- the brake calliper and hook it onto the suspen-sion spring to protect the hose,

- the ABS sensor and hook it onto the suspensionspring.


Slacken the nut of the lower ball joint as far aspossible and release it.

Remove the relay bearing plate (bolt 4).Slacken the relay bearing pressure bolt (3) (elasticdeformation bearing).

10560R2

23-29



Remove the driveshaft, keeping it straight toprevent damage to the differential seal.

REMOVAL OF THE DIFFERENTIAL OUTPUT SEALS

The removal of the differential output seals isidentical on the right and left-hand sides.

REMOVAL

Remove the differential output seal with the aidof a screwdriver, taking care to avoid damage tothe bearing surfaces, and be careful not to dropthe spring of the seal into the automatictransmission.

REFITTING

The lip seal is refitted using tool B.Vi. 1401.

Fit the seal (previously lubricated with transmis-sion oil) onto the centring tool (L) on the side mar-ked BVA (automatic transmission).

Insert the sleeve (M).

Guide the assembly into the differential.

Tap in carefully until the tool touches theautomatic transmission housing.

The refitting of the driveshafts is in the reverseorder to removal.

IMPORTANT : the lug in the plate holding therelay bearing must face upwards.

11758R

11913R

N7U engine

TIGHTEN ALL NUTS, BOLTS AND SCREWSTO THE RECOMMENDED TORQUEVALUES

Fit the calliper mounting bolts using FRENBLOCLOCTITE and tighten them to the correct torque.

Fill the automatic transmission with oil and checkthe level (see relevant section).

Press several times on the brake pedal to bring thepistons into contact with the brake pads.

23-30

AUTOMATIC TRANSMISSIONConverter seal 23

REFITTING

The (oiled) lip seal is refitted using tool B.Vi 1402;take care that no impurities are introduced whenthe seal is refitted.

This operation must be carried out with the auto-matic transmission removed.

REMOVAL

Remove:

- the torque converter,- the sealing ring (A) with the aid of tool

B.Vi. 1405, with the ring marked 1, holding itstraight, rotate about half a turn and extractthe seal, gradually tightening the extractorbolt.

IMPORTANT : MAKE SURE that the seal spring hasactually been removed.

11969G

Refit the torque converter, lubricating its groovewith transmission oil.

N7U engine


B.Vi.1405 Tool for extraction of the converter seal (in kit B.Vi.1400-01)

B.Vi.1402 Tool for centring the torque converter ring (in kitB.Vi. 1400-01)

11954R

Use a rule to check distance X, which should beapproximately 14 mm.

11911R11955

23-31

AUTOMATIC TRANSMISSIONSelector shaft seal 23

This operation is carried out after removal of themulti-function switch (see relevant section).

REMOVAL

Remove the selector shaft seal (A) using a smallscrewdriver, taking care not to damage the shaftand the sealing surface.

11907R

11786R

N7U engine


B.Vi. 1401 Guide sleeve

REFITTING

Refit the seal (lubricated with transmission oil).Engage tool B.Vi. 1401 and tap it gently with arubber mallet as far as it will go.

23-32

AUTOMATIC TRANSMISSIONOil pressure 23

The oil pressure is not adjustable.

CHECKING

The transmission is provided with an oil pressureconnection (P).

Connect tool B.Vi. 1404 to (P).

Run the engine at idle speed.

Pressure gauge B.Vi. 1215 should indicate :

In position D = 3.5 to 4.2 bars

In position R = 6.0 to 7.2 bars

11800G

N7U engine

11803

23-33

AUTOMATIC TRANSMISSIONComputer (Removal - Refitting) 23

REMOVAL

Put the vehicle onto a 2-post lift.Disconnect the battery.

Remove:

- the engine undertray,- the two bolts (1) of the air filter unit.

11795R

N7U engine

- the air pipe on the unit(A),- the hot air pipe.

Disconnect the flowmeter at (B).


Remove:

- the two bolts and extract the filter frombeneath.

11797R3

- the computer unit.

REFITTING


Refer to Fault Finding ("Assistance" section) inorder to validate the "no load / full load"operation.

23-34

AUTOMATIC TRANSMISSIONOil temperature sensor 23

REMOVAL





- the engine cover,- the air pipe (A),- the hot air pipe.

Disconnect the flowmeter at (B).


Remove the bolts of the air filter and extract thefilter from beneath.

11795R

11796R

N7U engine

Oil temperature sensor 2.5

TIGHTENING TORQUE (in daN.m) Remove:

- the two bolts (1) of the air filter unit.

11797R3

23-35

AUTOMATIC TRANSMISSIONOil temperature sensor 23

Remove the multi-function switch (see relevantsection) and disconnect the plug (3), taking careto properly note the wiring routing.

11787R

N7U engine

Disconnect and unclip the plugs (D).Remove:- the clip (C) of the automatic transmission

wiring,- the protection underneath the automatic

transmission

11791R2

Place a clean oil container underneath theautomatic transmission.

Remove the oil temperature sensor (E).

11790R1

REFITTING


Apply vaseline to the seal of the oil temperaturesensor.

Tighten the nut and bolts to the correct torque.

Special notes:

Adjust the multi-function switch (see relevant sec-tion).


NOTE : the seal of the oil temperature sensor mustbe replaced if faulty, and tightened to the correcttorque.

Fill up the automatic transmission with oil, follo-wing the recommendations (see relevant sec-tion).

Check the operation and gear changing of theautomatic transmission.

23-36

AUTOMATIC TRANSMISSIONMulti-function switch 23

11791R4

REMOVAL


Select gear position N.

Remove:- the battery,- the battery tray,- the engine undertray,- the wiring mounting.

Unclip and disconnect the connections (A).

N7U engine

Multi-function switch mounting bolt 2.5Dipstick guide tube mounting bolt 1.9Control cable mounting nut 1.9Selector lever mounting bolt 1.5

TIGHTENING TORQUES (in daN.m) Remove:

- the air pipe on the air filter unit,- the channel mounting (bolt B) and release the

channel.

11800R

11765R

- the control cable, releasing bolts (7) and clip (L).

23-37


Remove:

- the dipstick guide tube, making sure torecover the seal,

- the selector lever (D), holding it with a openwrench at (E) on the selector shaft, andslacken nut (2).

Move the brake washer back and remove nut (3).

WARNING: Never slacken the bolts of the selectorlever unless it is held with an open wrench, as thismight damage the automatic transmission.

Remove the two bolts (4) and release the multi-function switch.

REFITTING


Pay attention to the wiring positions whencarrying out the refitting.

Replace the seal of the selector lever if it is faulty(see relevant section).

Replace the seal of the dipstick guide tube iffaulty.

NOTE : it is important not to forget to lock the nutof the selector lever.

11787R2

11787R1

N7U engine

Tighten all nuts and bolts to the recommendedtorque values.

Adjust the multi-function switch (see relevantsection).



23-38


ADJUSTMENT

Select position N.

Remove:

- the battery and its tray,- the air pipe (A)

N7U engine

Multi-function switch mounting bolt 2.5Dipstick guide tube mounting bolt 1.9Control cable mounting nut 1.9Selector lever mounting bolt 1.5


11797R4

11765R

- the control cable, releasing bolts (7) and clip (L)


B. Vi. 1403 Multi-function switch adjust-

ment tool (in kit B.Vi. 1400-01)

- the dipstick guide tube, taking care to recoverthe seal,

- the selector lever (D), holding it with an openwrench at (E) on the selector shaft, and slackennut (2).

11787R1

WARNING: Never release the bolts of the selectorlever unless it is held with an open wrench, as thismight damage the automatic transmission.

23-39


Slacken the two bolts (4).

N7U engine

11908R

REFITTING


Pay attention to the wiring positions whencarrying out the refitting.

Replace the seal of the dipstick guide tube iffaulty.

Tighten the bolts to the correct torque.


Re-tighten the two mounting bolts of the multi-function switch.

11787R2

Check that the selector lever is in position N, thenposition tool B.Vi 1403 on the selector shaft.

The notch in the tool should be lined up with themark (M) engraved on the multi-function switch.

23-40

AUTOMATIC TRANSMISSIONAutomatic transmission speed sensor (Input) 23



Remove:- the battery,- the battery tray,- the selection control cable retaining clip,- the engine undertray,- the left-hand front wheel,- the mudguard (1),- the side protector (2),

96470R

N7U engine

- the power assisted steering pipe mounting boltunderneath the side member,

- the cover,- the upper air pipe (A) on the unit,- the hot air pipe.

Disconnect the selection control cable.

Release the expansion bottle.

Position the engine support tool and take theweight of the engine and transmission assembly.

Engine support tool

EQUIPMENT REQUIRED

11783S

11797R4

23-41

AUTOMATIC TRANSMISSIONAutomatic transmission speed sensor (Input) 23

Remove:- the automatic transmission mounting nut on

the left-hand rubber mounting.

Lower the engine and transmission assembly, ta-king great care not to touch the transmission gai-ter on the subframe, and remove the three bolts(E) of the automatic transmission mounting.

Free the automatic transmission mounting and at-tach it at the top, allowing the rubber mountingpad to slide .

REFITTING

Lubricate the speed sensor O ring.


TIGHTEN ALL THE BOLTS TO THERECOMMENDED TORQUE VALUE.Speed sensor: 0.5 daN.m.

11759S1R1

N7U engine

Unclip the speed sensor (A) and remove it.

PRC23.1

23-42

AUTOMATIC TRANSMISSIONAutomatic transmission speed sensor (Output) 23

REMOVAL


Clean the area around the sensor to preventimpurities entering the automatic transmission.

Disconnect and remove the sensor (A).

N7U engine

REFITTING

Lubricate the sensor O ring.


Tighten the speed sensor to a torque valueof 0.5 daN.m.

11785R

23-43

AUTOMATIC TRANSMISSIONKickdown switch (Removal - Refitting) 23

REMOVAL

Remove the kickdown switch by releasing thefloor carpet underneath the accelerator pedal,and disconnect the connector located above thepedal mounting.

PRC2302

REFITTING


N7U engine

23-44

AUTOMATIC TRANSMISSIONAccelerator control compensator 23

99555R

A : CableB : SheathC : 1st notchD : Direction

ADJUSTMENT

After any work carried out on the acceleratorcable and kickdown switch, it is essential to checkthe adjustment of the compensator as indicatedbelow.

N7U engine

Vehicle Engine DriveClip position

(No. of notches)

B54 F N7U

LHD

RHD

4

2

23-45

AUTOMATIC TRANSMISSIONSolenoid valves 23

REMOVAL

This operation must be carried out with the hy-draulic distributor removed (see distributor sec-tion).

The method of removal of the solenoid valves hasno special features and is identical for all of them:

S1 = sequence solenoid valve.S2 = sequence solenoid valve.S3 = converter bridging solenoid valve.

Remove:

- the plug (D),- the bolt (1),

and release the solenoid valve.

11788R2

REFITTING

Refitting is the reverse of removal; tighten thebolts to the correct torque.

Check that the wiring has been properly attachedto its clips.

Special notes:

Apply vaseline to the solenoid valve seals toensure the best location.

N7U engine

Housing mounting bolt 1.2Distributor mounting bolt 1Solenoid valve mounting bolt 1


Fill up the automatic transmission with oil,following the recommendations (see relevantsection).

23-46


Wiring diagram 23KEY

104 Ignition switch119 Automatic transmission computer120 Injection computer163 Starter motor182 Reversing light, right hand side183 Reversing light, left hand side225 Diagnostic socket247 Instrument panel260 Fuse box363 Voice synthesiser unit466 Shunt unit476 Integral transmission unit485 Multi-function switch569 Automatic transmission kickdown775 Automatic Transmission

Connections

R149 Engine / Left front wingR150 Passenger compartment / Left front wing

Earths

MH Engine electrical earthMJ Front right pillar electrical earthNK Electronic earth

N7U engine

23-47

AUTOMATIC TRANSMISSIONWiring diagram 23

DI10638

N7U engine

23-48

AUTOMATIC TRANSMISSIONWiring 23

11922S

N7U engine

Identification of the connector tracks

N° Allocation

12

3456

789

10

11121314151617181920212223

EarthConverter bridging solenoid valve controlNot used- pressure modulation solenoid valveStop switch signal Eco/Sport operating mode informationNot used+vehicle speed sensorNot used Torque reduction confirmation information- INJ/ATP/N information - AT/INJAT/Instrument panel display linkMulti-function switch logic state "PA"Not usedComputer earth+pressure modulation solenoid valveSequence solenoid valve N° 1 controlKickdown signal-AT oil temperature sensorNot usedDiagnostic line K-AT speed sensorTorque and engine speed info INJ/AT

N° Allocation

2425

2627282930313233

343536373839

404142

Vehicle speed output for instrument panelTorque reduction requestinformation No. 2 AT/INJMulti-function switch logic state "C"Multi-function switch logic state "A"Not usedProtected + after ignition feedProtected Bat + feedN° 2 sequence solenoid valve controlNot usedLow adhesion starting mode selection+AT oil temperature sensorDiagnostic line L-vehicle speed sensor+AT speed sensor INJ/AT throttle opening signalTorque reduction requestinformation No. 1 AT/INJNot usedMulti-function switch logic state "B"Not used

23-49

AUTOMATIC TRANSMISSIONWiring (Removal - Refitting) 23N7U engine

1 - Multi-function switch2 - A.T. speed sensor ( AT input)3 - A.T. speed sensor ( AT output)4 - Oil temperature sensor5 - Connector: temperature sensor, solenoid

valves (11 tracks)6 - Multi-function switch connector (9 tracks)

11785R1

REMOVAL

In order to remove the wiring, it is necessary toremove:

- the multi-function switch,- the automatic transmission protection,- the oil pipes,- the distributor cover, and to release the

automatic transmission support.

Disconnect and release the sealed connector (A)and remove it from above.

11788R3

Release the wiring from above, afterdisconnecting the two speed sensors.

NOTE : pay attention to the routing of the wiring,as it must be refitted in the same position (thespeed sensors have no foolproofing).

REFITTING

Refitting is the reverse of removal; follow thevarious adjustment instructions given in thevarious sections referring to this operation.

Fill up with oil (see "filling / levels" section).

23-50

SUO541.0

AUTOMATIC TRANSMISSIONFault finding - Introduction

N7U/SU0 engine

Conditions for applying the tests defined in this fault finding

The tests defined in this fault finding are only to be applied when the description of the fault dealt with cor-responds exactly to the display given on the XR25.

If a fault is dealt with due to a bargraph flashing, the conditions for confirming the actual presence of thefault (and the need to apply fault finding) are given in the "Notes" box or at the start of the bargraph inter-pretation procedure.

If a bargraph is only interpreted when it is permanently illuminated, applying the tests recommended in thefault finding when the bargraph is flashing will not allow the reason why this fault was memorised to be lo-cated. In this case, only the wiring of the faulty component should be checked.

Note: - the ignition must have been turned off before the XR25 is used.- the selection lever must be in position P or N.

Special tooling required for working on the SU0 automatic transmission:

- XR25 test kit.- Cassette XR25 n° 16 minimum (the fault finding takes into account all updates added to cassette 16 with

respect to 15).- Multimeter.

Special notes: After replacing a computer, apply the procedure for programming the no load and full loadvalues by starting command mode G20*. This command mode must be started with theengine stopped but the engine must be started at the end of the procedure so that the valuesare memorised (the no load value stays on the XR25 display for as long as the engine is notstarted).The measurements and checks to be performed on the computer connector are easier toperform when working underneath the vehicle.

23

23-51

SUO541.0

AUTOMATIC TRANSMISSIONFault finding - XR25 fiche

FI21644

23N7U/SU0 engine

23-52

REPRESENTATION OF THE BARGRAPHS

- Faults (always on a coloured background):

If illuminated, there is a fault on the product tested. The associated textdefines the fault.This bargraph can be:- Illuminated : fault present.- Flashing : fault memorised.- Extinguished : fault absent or not found.

- Status (always on a white background):

Bargraph always located at the top right.If illuminated, there is a problem setting up the dialogue with the product computer.If it remains extinguished:- The code does not exist.- There is a fault with the XR25, the computer or the XR25 / computer connection.

The representation of the following bargraphs gives their initial status:Initial status: (ignition on, engine stopped, no operator action).

Undefinedis illuminated when the function or condition specified on thefiche is fulfilled

Extinguished

Illuminated extinguishes when the function or condition specified on thefiche is no longer fulfilled

Additional details:

Some bargraphs have a *. The command *.., when the bargraph is illuminated is used to display additionalinformation about the type of fault or status present.

SUO541.0

AUTOMATIC TRANSMISSIONFault finding - XR25 fiche

or

23N7U/SU0 engine

23-53

AUTOMATIC TRANSMISSIONFault finding - Interpretation of XR25 bargraphs

Fiche n° 44

Bargraph 1 RH extinguished

Code present

1

AFTER REPAIR

Ensure the XR25 is not faulty by trying to communicate with a computer on another vehicle. Check the ISO interface is in position S8 and that you are using the latest version of the XR25 cassette andthe correct access code (D14).Check the battery voltage and carry out any necessary repairs to obtain a correct voltage (U battery >10.5 volts).

Check whether the 5A fuse on the passenger compartment connection unit is not blown (if a replaced 5Afuse blows again when the ignition is turned on the next time, search as a matter of priority for a shortcircuit to 12 volts of the oil temperature sensor circuit on track 19).Check the connection and the condition of the wiring in the computer connector and the engine / frontLH wing (R149) + passenger compartment / front LH wing (R150) connections.Check that the computer is correctly fed:- Earth on tracks 1 and 15 of the computer connector.- + after ignition on track 29.

If dialogue is still not established after these various tests, replace the computer and erase the faultmemory at the end of the operation (refer to the "assistance" section for programming the no load/fullload values).

SUO541.0

When communication has been established, deal with any illuminated faultbargraphs.

None.NOTES

23N7U/SU0 engine

Check that the diagnostic socket is correctly fed:- Earth on track 5 of the diagnostic socket (new 16 track socket).- + before ignition on track 16 of the diagnostic socket (new 16 track socket).Check and ensure the continuity and the insulation of the line of the diagnostic socket / computerconnection:- Between track 35 of the computer connector and track 15 of the diagnostic socket (new socket).- Between track 21 of the computer connector and track 7 of the diagnostic socket (new socket).

23-54


Fiche n° 44Bargraph 2 LH illuminated (cc) or flashing (co/dEF)Oil temperature sensor circuitXR25 assistance: *02: co : Open circuit or short circuit to 12 volts.

cc : Short circuit to earth or short circuit.dEF : Oil temperature too high (t° > 150°C).

2

None.

AFTER REPAIR

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the oil temperature sensor between tracks 4 and 10 on the sensor side.

If the resistance measured is not around 900 ohms at 20°C (125 ohms at 80°C), perform the samemeasurement on the 2 track connector of the oil temperature sensor. If the resistance is not correct,replace the sensor. If the resistance of the sensor is correct, repair or replace the wiring in question.

Check the wiring on the computer and on the 12 track connector.

If the connections are correct, check the continuity of the following connections:- Between track 19 of the computer connector and track 10 of the 12 track connector.- Between track 34 of the computer connector and track 4 of the 12 track connector.Replace the wiring of the AT in question in the event of a fault.

If the fault persists after these checks, replace the oil temperature sensor.

If the "oil temperature" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation.Apply the procedure for programming the no load and full load values using command G20* (refer to the"assistance" section).

SUO541.0

Erase the memory of the computer (G0**), turn off the ignition then perform aroad test. Complete the operation by checking using the XR25.

CO

NOTES

The oil temperature sensor circuit fault is present if the value on#04 of the oil temperature is - 50°. In this case, the bargraphilluminates after waiting 10 minutes with the ignition on.

NOTES

23N7U/SU0 engine

23-55


Fiche n° 442

The value on #04 of the oil temperature must be 180°.

AFTER REPAIR

NOTES

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the oil temperature sensor between tracks 4 and 10 on the sensor side.

If the resistance measured is not around 900 ohms at 20°C (125 ohms at 80°C), perform the samemeasurement on the 2 track connector of the oil temperature sensor. If the resistance is not correct,replace the sensor. If the resistance of the sensor is correct, repair or replace the wiring in question.

Check the insulation with respect to earth of the connection between track 34 of the computer connectorand track 4 of the 12 track connector.Check the insulation between the 2 lines of the oil temperature sensor circuit:- Between track 19 of the computer connector and track 10 of the 12 track connector.- Between track 34 of the computer connector and track 4 of the 12 track connector.

Replace the wiring of the AT in question in the event of a fault.

If the fault persists after these checks, replace the oil temperature sensor.

If the "oil temperature" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation.Apply the procedure for programming the no load and full load values using command G20* (refer to the"assistance" section).

SUO541.0


CC

Continued

This fault is taken into account when the oil temperature exceeds150°C.NOTESdEF

Check the oil temperature sensor: turn off the ignition and disconnect the 12 track connector under theautomatic transmission and measure the resistance of the oil temperature sensor between tracks 4 and 10on the sensor side.If the resistance measured is not around 900 ohms at 20°C (125 ohms at 80°C), replace the sensor.

If the resistance of the sensor is correct, search for a reason for this excessive reading increase in oiltemperature (oil level, engine compartment cooling, usage conditions...). Drain the automatictransmission and check the oil condition (smell, colour...).

If the oil condition points to an internal fault, replace the automatic transmission.If the oil is of normal appearance, replace the automatic transmission oil, perform a full road test toensure that the automatic transmission does not present the characteristic symptoms of internaldegeneration. Replace the automatic transmission if necessary.

23N7U/SU0 engine

23-56


Fiche n° 44Bargraph 2 RH flashingVehicle speed sensor circuit (AT output)XR25 assistance: *22: 1.dEF : incorrect signal.

2.dEF : no signal

2

The vehicle speed sensor circuit fault is present if the bargraph illuminates during aroad test.

AFTER REPAIR

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the vehicle speed sensor between tracks 6 and 12 on the sensor side.

If the resistance measured is not around 430 ohms ± 100, perform the same measurement directly on the2 track connector of the sensor (refer to the replacement method in the Technical Note).- If the resistance is not correct, replace the sensor.- If the resistance of the sensor is correct, repair or replace the wiring in question.

Check the wiring on the computer and on the 12 track connector.

If the connections are correct, check the continuity and the insulation of the following connections:- Between track 8 of the computer connector and track 6 of the 12 track connector.- Between track 36 of the computer connector and track 12 of the 12 track connector.Also check the insulation between the 2 lines of the vehicle speed sensor circuit.


If the fault persists after these checks, replace the vehicle speed sensor.

If the "vehicle speed" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation.Apply the procedure for programming the no load and full load values using command G20* (refer to the"assistance" section).

SUO541.0


2.dEF

NOTES

None.NOTES

Check the assembly of the vehicle speed sensor (position and tightness).Check the condition of the wiring and the conformity of its routing (risk of signal interference).Also check the conformity and the condition of the high voltage circuits.

1.dEF The signal is present but incorrectNOTES

23N7U/SU0 engine

23-57


Fiche n° 44

Bargraph 3 LH illuminated

Kickdown switch circuit

3

AFTER REPAIR

This fault is linked to track 18 of the computer connector being permanently earthed or to anincoherence between the status of the switch and the load value .

Disconnect the kickdown switch.- If the bargraph 13 LH extinguishes, check the operation and the assembly of the

kickdown switch (contact normally open). Replace if necessary.- If the bargraph 13 LH remains illuminated, ensure the insulation with respect to earth

of the connection between track 18 of the computer connector and the connector ofthe kickdown switch.

SUO541.0

None.NOTES

Check the status of bargraph 13 LH ("kickdown active").Is the kickdown permanently active without pressing the accelerator pedal?

yes

In the full load position, check the status of bargraph 13 LH ("kickdown active").If the bargraph 13 LH does not illuminate in the full load position, check the operationand the assembly of the kickdown switch (contact closed). Ensure the continuity of theswitch circuit with the RH front pillar earth and with track 18 of the computer connector.

no

Check on #40 the load value at full load.If is not greater than 186 for N7U engines and 189 for N7Q engines at full load,acoherence check will cause bargraph 3 LH to illuminate.

- Check the accelerator control and the cable adjustment.- Check the conformity of the injection potentiometer.- Program the no load and full load values using command G20* (refer to the

"assistance" section).


23N7U/SU0 engine

23-58


Fiche n° 44Bargraph 3 RH illuminated flashingGearbox sensor circuit (gearbox input speed)XR25 assistance: *23: 1.dEF : incorrect signal

2.dEF : no signal

3

The gearbox speed sensor circuit fault is present if the bargraph illuminates duringa road test.

AFTER REPAIR

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the vehicle speed sensor between tracks 5 and 11 on the sensor side.

If the resistance measured is not around 430 ohms ± 100, perform the same measurement directly on the2 track connector of the sensor (refer to the replacement method in the Technical Note).- If the resistance is not correct, replace the sensor.- If the resistance of the sensor is correct, repair or replace the wiring in question.

Check the wiring on the computer and of the 12 track connector.

If the connections are correct, check the continuity and the insulation of the following connections:- Between track 37 of the computer connector and track 5 of the 12 track connector.- Between track 22 of the computer connector and track 11 of the 12 track connector.Also check the insulation between the 2 lines of the gearbox speed sensor circuit.


If the fault persists after these checks, replace the gearbox speed sensor.

If the "gearbox speed" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation.Apply the procedure for programming the no load and full load values using command G20* (refer to the"assistance" section).

SUO541.0


2.dEF

NOTES

None.NOTES

Check the assembly of the gearbox speed sensor (position and tightness).Check the condition of the wiring and the conformity of its routing (risk of signal interference).Also check the conformity and the condition of the high voltage circuits.

1.dEF The signal is present but incorrect.NOTES

23N7U/SU0 engine

23-59


Fiche n° 44


+ before ignition feed

4

AFTER REPAIR

This fault is linked to the absence of + before ignition on track 30 of the computer connector.

SUO541.0

None.NOTES

Ensure the continuity between track 30 of the computer connector and the 15A fuse referenced by thesymbol of a clock.Check the condition of the fuse and its feed in +before ignition.


23N7U/SU0 engine

23-60


Fiche n° 44

Bargraph 4 RH illuminated

Poor adherence selector circuit (one-touch button)

4

AFTER REPAIR

SUO541.0

None.NOTES

This fault is linked to track 33 of the computer connector being earthed for more than 25 seconds. Checkthe status of bargraph 15 LH.Bargraph 15 LH should be permanently illuminated without any action on the low adherence modebutton.


Disconnect the low adherence mode selection button.- If the bargraph 15 LH extinguishes, check the operation and the assembly of the selection button

(contact normally open). Replace it if necessary.- If the bargraph 15 LH remains illuminated, ensure the insulation with respect to earth of the

connection between track 33 of the computer connector and the connector of the low adherencemode selection button (track B5).

23N7U/SU0 engine

23-61


Fiche n° 44Bargraph 5 LH illuminatedLoad informationXR25 assistance: *05: co.1 : Open circuit or short circuit to 12 volts.

cc.0 : Short circuit to earthdEF : Poor signal from the injection computer.

5

None.

AFTER REPAIR

Check the wiring on the injection computer and the automatic transmission computer.Ensure the continuity and the insulation with respect to 12 volts of the connection between track 38 ofthe AT computer connector and the connector of the injection computer (track 41 on N7Q engines and 38on N7U engines).

SUO541.0


co.1

NOTES

None.NOTES

Ensure the insulation with respect to earth of the connection between track 38 of the AT computerconnector and the connector of the injection computer (track 41 on N7Q engines and 38 on N7U engines).

cc.0 None.NOTES

Switch to fault finding of the injection computer to see if the load potentiometer is declared to be faulty.If it is declared as faulty, apply the associated fault finding in the database in question.After the operation on the injection side, return to automatic transmission fault finding to apply theprocedure for programming the no load and full load values using command G20* (refer to the"assistance" section).

dEF None.NOTES

If the load potentiometer is not declared as faulty, check the conformity of the routing of the enginecompartment wiring (risk of interference of the connection).Replace the injection computer if the fault persists.

23N7U/SU0 engine

23-62


Fiche n° 44

Bargraph 5 RH illuminated or flashing

Torque reduction

5

AFTER REPAIR

SUO541.0

The torque reduction fault is present if the bargraph which may be flashingilluminates during a road test (heavy load / use of the kickdown at full loadfunction).

NOTES

When the automatic transmission computer gives on tracks 25 and 39 a torque reduction request to the injectioncomputer, the injection computer sends it a reduction conformation on track 10.The torque reduction fault is taken into account if this confirmation is not received.


Ensure the continuity and the insulation of the 3 lines of the connection between the injection computer and the ATcomputer for the torque reduction function:- Between track 39 of the AT computer connector and track 62 of the injection computer connector.- Between track 25 of the AT computer connector and track 63 of the injection computer connector.- Between track 10 of the AT computer connector and track 60 of the injection computer connector.

Check the wiring on the injection and AT computers.

If all the previous checks are correct and if the fault persists, the faulty computer will have to be defined:- Start the engine and put the lever in P.- Establish a dialogue with the AT computer and enter #63 (this allows the reduction requests, the sending of the

confirmation, the recognition of the P/N positions and the control of the solenoid valves to be displayed).

Reference of the functions on the display of the XR25:(only the vertical lines have a function)- 0 : Solenoid valve 1.- 1 : Solenoid valve 2.- 2 : Converter bridging solenoid valve.- 3 : P/N position.- 4 : Torque reduction information 1.- 5 : Torque reduction information 2..- 6 : Torque reduction INJ confirmation.

With the engine running and the lever in the P/N position, the only two lines which should be illuminated are 1 and3 (solenoid 2 controlled and P/N position recognised).

- Perform a road test with high load and use the full load kickdown function whilst watching the display of theXR25 when changing gear.Every time lines 4 and/or 5 illuminate, line 6 should illuminate at the same time.

Replace the injection computer if line 6 does not illuminate every time lines 4 and/or 5 illuminate.Replace the AT computer if line 6 systematically illuminates upon every torque reduction request.

7 6 5 4

0123

23N7U/SU0 engine

23-63


Fiche n° 44Bargraph 6 LH illuminated flashingEngine torque and speed informationXR25 assistance: *06: 1.dEF : Pulse too long.

2.dEF : No signal - Poor signal.

6

The torque information fault is present if the bargraph illuminates during a roadtest.

AFTER REPAIR

Ensure the continuity and the insulation of the connection:- N7Q engine : Between track 9 of the AT computer connector and track 1 of the injection computer

connector.- N7U engine : Between track 23 of the AT computer connector and track 20 of the injection

computer connector.

Check the wiring on the AT and injection computers.

SUO541.0


2.dEF

NOTES

None.NOTES

Check the condition of the wiring and the conformity of its routing (risk of signal interference).Also check the conformity and the condition of the high voltage circuits.

1.dEF None.NOTES

Disconnect the injection computer then remove the plastic cover from its connector in order to be able toaccess the rear of the connector clips.Reconnect the injection computer.Set up the XR25 so as to be able to use it in pulse detection mode (function G, terminal Vin).Start the engine.Put the measuring pin on the clip of track 1 of the computer connector for N7Q engines or track 20 forN7U engines.

Replace the injection computer if the XR25 indicates a zero value (correct value when idling: 36 ± 10 µs).Replace the automatic transmission computer if the value is correct then apply the procedure forprogramming the no load and full load values using command G20* (refer to the "assistance" section).

23N7U/SU0 engine

23-64


Fiche n° 44Bargraph 7 LH illuminated (c0.1) or flashing (cc.0)Sequence solenoid valve EVS1 circuitXR25 assistance: *07: co.1 : Open circuit or short circuit to 12 volts.

cc.0 : Short circuit to earth.

7

AFTER REPAIR

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measure the resistanceof the sequence solenoid valve n° 1 coil between earth and track 1 on the solenoid valve side.If the resistance measured is not around 14 ± 2 ohms at 20°C, uncover and perform the same measurement directlyon the solenoid valve. If the resistance is not correct, replace the solenoid valve. If the resistance is correct, repair orreplace the wiring in question.

SUO541.0


co.1 None.NOTES

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measure the resistanceof the sequence solenoid valve n° 1 coil between earth and track 1 on the solenoid sideIf the resistance measured is not around 14 ± 2 ohms at 20°C, uncover and perform the same measurement directlyon the solenoid valve. If the resistance is not correct, replace the solenoid valve. If the resistance is correct, repair orreplace the wiring in question.

cc.0 The fault is present if the bargraph which may be flashing illuminateswhen moving the lever to position 3 and when switching on the lowadherence mode (snow button).

NOTES

Check the continuity and the insulation with respect to 12 volts of the connection between track 17 of the computerconnector and track 1 of the 12 track connector on the wiring side. Repair or replace the wiring of the AT in questionin the event of a fault.Check the continuity with respect to earth of track 1 of the computer connector.Check the wiring on the automatic transmission computer and the 12 track connector.Carry out any necessary repairs.

None.NOTES

If the fault persists after these checks, replace solenoid valve S1.If the "solenoid valve S1 circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure for programming theno load and full load values using command G20* (refer to the "assistance" section).

Check the insulation with respect to earth of the connection between track 17 of the computer connector and track 1of the 12 track connector on the wiring side. Repair or replace the wiring of the AT in question in the event of a fault.Check the wiring on the automatic transmission computer and of the 12 track connector.Carry out any necessary repairs.

If the fault persists after these checks, replace solenoid valve S1.If the "solenoid valve S1 circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure for programming theno load and full load values using command G20* (refer to the "assistance" section).

23N7U/SU0 engine

23-65


Fiche n° 44Bargraph 7 RH illuminated (cc.1-2.dEF) or flashing (1.dEF)Convertor bridging solenoid valve circuitXR25 assistance: *27: cc.1 : Short circuit to 12 volts.

1.dEF : Short circuit to earth2.dEF : Open circuit.

7

None.

AFTER REPAIR

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measure the resistanceof the bridging solenoid valve coil between earth and track 8 on the solenoid valve side.If the resistance measured is not around 13 ± 2 ohms at 20°C, uncover and perform the same measurement directlyon the solenoid valve. If the resistance is not correct, replace the solenoid valve. If the resistance is correct, repair orreplace the wiring in question.

SUO541.0


cc.1

NOTES

None.NOTES

Check the insulation with respect to 12 volts of the connection between track 2 of the computer connector and track8 of the 12 track connector on the wiring side. Repair or replace the wiring of the AT in question in the event of afault.Check the wiring on the automatic transmission computer and of the 12 track connector.Carry out the necessary repairs.

1.dEF The fault is present if the bargraph which may be flashing illuminatesduring a road test at low load (vehicle speed > 80 km/h).NOTES

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measure the resistanceof the bridging solenoid valve coil between earth and track 8 on the solenoid valve side.If the resistance measured is not around 13 ± 2 ohms at 20°C, uncover and perform the same measurement directlyon the solenoid valve. If the resistance is not correct, replace the solenoid valve. If the resistance is correct, repair orreplace the wiring in question.

If the fault persists after these checks, replace the bridging solenoid valve.If the"bridging solenoid valve circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure for programming theno load and full load values using command G20* (refer to the "assistance" section).

Check the insulation with respect to earth of the connection between track 2 of the computer connector and track 8of the 12 track connector on the wiring side. Repair or replace the wiring of the AT in question in the event of a fault.Check the wiring on the automatic transmission computer and of the 12 track connector.Carry out the necessary repairs.

If the fault persists after these checks, replace the bridging solenoid valve.If the fault "bridging solenoid valve circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure for programming theno load and full load values using command G20* (refer to the "assistance" section).

23N7U/SU0 engine

23-66


Fiche n° 447

None.

AFTER REPAIR

NOTES

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the bridging solenoid valve coil between earth and track 8 on the solenoid valve side.If the resistance measured is not around 13 ± 2 ohms at 20°C, uncover and perform the samemeasurement directly on the solenoid valve. If the resistance is not correct, replace the solenoid valve. Ifthe resistance is correct, repair or replace the wiring in question.

Check the continuity of the connection between track 2 of the computer connector and track 8 of the 12track connector on the wiring side. Repair or replace the wiring of the AT in question in the event of afault.Check the wiring on the automatic transmission computer and the 12 track connector.Carry out the necessary repairs.

If the fault persists after these checks, replace the bridging solenoid valve.

If the fault "bridging solenoid valve circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure forprogramming the no load and full load values using command G20* (refer to the "assistance" section).

SUO541.0


2.dEF

Continued

23N7U/SU0 engine

23-67


Fiche n° 44Bargraph 8 LH illuminated (cc.0) or flashing (co.1)Sequence solenoid valve EVS2 circuitXR25 assistance: *08: co.1 : Open circuit or short circuit to 12 volts.

cc.0 : Short circuit to earth.

8

AFTER REPAIR


SUO541.0


co.1

None.NOTES


cc.0

The fault is present if the bargraph which may be flashing illuminateswhen moving the lever to position D and selecting low adherence mode(snow button).

NOTES

Check the continuity and the insulation with respect to 12 volts of the connection between track 31 of the computerconnector and track 7 of the 12 track connector on the wiring side. Repair or replace the wiring of the AT in questionin the event of a fault.Check the continuity with respect to earth of track 1 of the computer connector.Check the wiring on the automatic transmission computer and on the 12 track connector.Carry out the necessary repairs.

None.NOTES

If the fault persists after these operations, replace the solenoid valve S2.If the "solenoid valve S2 circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure for programming theno load and full load values using command G20* (refer to the "assistance" section).

Check the insulation with respect to earth of the connection between track 31 of the computer connector and track 7of the 12 track connector on the wiring side. Repair or replace the wiring of the AT in question in the event of a fault.Check the wiring on the automatic transmission computer and of the 12 track connector.Carry out the necessary repairs.

If the fault persists after these checks, replace the solenoid valve S2.

If the "solenoid valve S2 circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure for programming theno load and full load values using command G20* (refer to the "assistance" section).

23N7U/SU0 engine

23-68


Fiche n° 44Bargraph 8 RH illuminatedPressure modulation solenoid valve circuitXR25 assistance: *28: cc.1 : Short circuit to 12 volts.

co.0 : Open circuit or short circuit to earth.dEF : Solenoid valve short circuit

8

AFTER REPAIR

Check the insulation with respect to 12 volts of the connection between track 16 of the computerconnector and track 3 of the 12 track connector under the automatic transmission on the wiring side.Repair or replace the wiring of the AT in question in the event of a fault.

SUO541.0


cc.1

None.NOTES

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the pressure modulation solenoid valve coil between tracks 3 and 9 on the solenoid valveside.If the resistance measured is not around 4 ± 2 ohms at 20°C, uncover and perform the samemeasurement directly on the solenoid valve. If the resistance is not correct, replace the hydraulicdistributor. If the resistance is correct, repair or replace the wiring in question.

co.0

If the "modulation solenoid valve circuit" fault persists, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure forprogramming the no load and full load values using command G20* (refer to the "assistance" section).

None.NOTES

Check the continuity and the insulation with respect to earth of the following connections:- Between track 16 of the computer connector and track 3 of the 12 track connector on the wiring side.- Between track 4 of the computer connector and track 9 of the 12 track connector on the wiring side.Repair or replace the wiring of the AT in question in the event of a fault.Check the wiring on the automatic transmission computer and the 12 track connector.Carry out the necessary repairs.

If the fault persists after these checks, replace the hydraulic distributor.

If the "modulation solenoid valve circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure forprogramming the no load and full load values using command G20* (refer to the "assistance" section).

None.NOTES

23N7U/SU0 engine

23-69


Fiche n° 448

AFTER REPAIR

SUO541.0


dEF

Turn off the ignition, disconnect the 12 track connector under the automatic transmission and measurethe resistance of the pressure modulation solenoid valve coil between tracks 3 and 9 on the solenoid valveside.If the resistance measured is not around 4 ± 2 ohms at 20°C, uncover and perform the samemeasurement directly on the solenoid valve. If the resistance is not correct, replace the hydraulicdistributor. If the resistance is correct, repair or replace the wiring of the AT in question.

.NOTES

If the fault persists after these checks, replace the hydraulic distributor.

If the "modulation solenoid valve circuit" fault reappears, replace the computer.Erase the fault memory of the new computer at the end of the operation. Apply the procedure forprogramming the no load and full load values using command G20* (refer to the "assistance" section).

None.NOTES

23

Continued

Check the insulation between the following two connections:- Between track 16 of the computer connector and track 3 of the 12 track connector on the wiring side.- Between track 4 of the computer connector and track 9 of the 12 track connector on the wiring side.Repair or replace the wiring in question in the event of a fault.

N7U/SU0 engine

23-70


Fiche n° 44

Bargraph 9 LH illuminated or flashing

Selector lever position information

9

AFTER REPAIR

SUO541.0

The fault is present if the bargraph which may be flashing illuminates whenmoving the selector lever from position P to position L (keeping the lever locked ineach position for 5 seconds ).

NOTES

Check the assembly of the multifunction switch on the automatic transmission and its adjustment (referto checking method).


Ignition off, disconnect the 10 track connector under the automatic transmission and for each selectorlever locked position, carry out continuity and insulation checks (see table below).

Lever locked position Continuities ensured Insulations ensured

P Tracks 1 and 4 / Track 8Track 16 / Track 10

Tracks 2 and 3 / Track 8Track 7 / Track 9

R Tracks 1 and 2 / Track 8Track 7 / Track 9


N Tracks 4 and 2 / Track 8Track 6 / Track 10


D Tracks 2 and 3 / Track 8Tracks 1 and 4 / Track 8

Track 6 / Track 10Track 7 / Track 9

3 Tracks 1, 2, 3 and 4 / Track 8 Tracks 6 / Track 10Track 7 / Track 9

L Tracks 1 and 3 / Track 8Tracks 2 and 4 / Track 8

Track 6 / Track 10Track 7 / Track 9

If one of the insulations or one of the continuities is not ensured, replace the multifunction switch (referto replacement method).

If the multifunction switch is not faulty, ensure the continuity and the insulation with respect to earth ofthe following connections:- Between track 27 of the computer connector and track 1 of the 10 track connector on the wiring side.- Between track 41 of the computer connector and track 2 of the 10 track connector on the wiring side.- Between track 26 of the computer connector and track 3 of the 10 track connector on the wiring side.- Between track 13 of the computer connector and track 4 of the 10 track connector on the wiring side.Also ensure the insulation between all these connections.

23N7U/SU0 engine

23-71


Fiche n° 44Bargraph 9 RH flashing

Speed measurement (comparison between vehicle speed andgearbox input when changing gear).

9

AFTER REPAIR

SUO541.0

Deal with any other illuminated bargraph first.The speed measurement fault is present if the bargraph illuminates during a roadtest (whilst changing up and down through all gears).

NOTES

- Check the conformity of the automatic transmission computer using command G70*.Correct computers: N7U engine: 77 00 874 433 - N7Q engine: 77 00 874 432


- Check the vehicle speed sensor:* Measure the resistance of the sensor between tracks 6 and 12 of the 12 track connector under the

automatic transmission.Replace the sensor if its resistance is not around 430 ohms.

* Check the mounting of the sensor on the automatic transmission housing.* Check the routing of the wiring of the sensor and its condition.

- Check the gearbox speed sensor:* Measure the resistance of the sensor between tracks 5 and 11 of the 12 track connector under the

automatic transmission.Replace the sensor if its resistance is not around 430 ohms.

* Check the mounting of the sensor on the automatic transmission housing.* Check the routing of the wiring of the sensor and its condition.

Check the wiring on the automatic transmission computer and the 12 track connector.Carry out the necessary repairs.

Erase the memory of the computer (G0**), turn off the ignition then perform a road test to determineduring which gear change the fault occurs (ensure that all gears are selected both changing up anddown).

If the fault fault reappears, check the coherence and the stability of the vehicle speed information on #05and the gearbox speed information on #07 under the fault consideration conditions.- if the speeds are not stable (abnormal fluctuation in the value), try and remove this interference.- if the fault reappears, and the speeds are stable although the fault is taken into account, replace the

hydraulic distributor and the solenoid valves.- if the fault fault reappears, replace the automatic transmission (internal AT problem).

23N7U/SU0 engine

23-72


Fiche n° 44


No load or full load not programmed

10

AFTER REPAIR

SUO541.0

- Apply the following procedure:* Put the selector lever in position P or N but do not start the engine.* Enter code G20* on the keypad of the XR25.* Press the accelerator when the display shows "PF" flashing.

The display then shows "bon" then "PL" flashing.* Release the accelerator pedal and start the engine.

Then following the displays "bon", "Fin" then "4.tA3" when the procedure occurs correctly. Thebargraph 10 LH should extinguish.

* Turn off the ignition.


Deal with bargraph 5 LH first if this is also illuminated.NOTES

Failure to program signifies a load value outside the allowable range or that the kickdown switch is notworking when validating the full load position.

If the procedure has not occurred correctly, what position causes the programming problem?

Also check the conformity of the AT computer on G70*NOTESFull load

Accelerate fully and check the status of bargraph 13 LH ("kickdown active").If the bargraph 13 LH does not illuminate in the full load position, check the operation and the assemblyof the kickdown switch (contact closed). Ensure the continuity of the switch circuit with the front RH pillarearth and with track 18 of the computer connector.

Check the full load value on #40.If is not greater than 186 on N7U engines and 189 on N7Q engines at full load, programming cannotoccur:- Check the accelerator control and the cable adjustment.- Check the conformity of the injection potentiometer (injection fault finding).Try and program the no load and full load values again using command G20*.

Also check the conformity of the AT computer on G70*NOTESNo load

Check the no load value on #40.If is not less than 36 on N7U engines and 46 on N7Q engines in the no load position, programming cannotoccur:- Check the accelerator control and the cable adjustment.- Check the conformity of the injection potentiometer (injection fault finding).Try and program the no load and full load values again using command G20*.

23N7U/SU0 engine

23-73


Fiche n° 44Bargraph 10 RH flashingP/N information outputXR25 assistance: *30: co.o : Open circuit or short circuit to earth.

cc.1 : Short circuit to 12 volts.

10

AFTER REPAIR

- Ensure the continuity and the insulation with respect to earth of the connection between track 11 ofthe AT computer connector and the connector of the injection computer (track 7 on N7Q engines and81 on N7U engines).

- Check the wiring on the injection computer and on the automatic transmission computer.

SUO541.0


co.o

None.NOTES

- Ensure the insulation with respect to 12 volts of the connection between track 11 of the AT computerconnector and the connector of the injection computer (track 7 on N7Q engines and 81 on N7Uengines).

cc.1

The fault is present if the flashing bargraph illuminates when moving the selectorlevel from position P to position R (or from N to D).NOTES

None.NOTES

23N7U/SU0 engine

23-74


Fiche n° 44

Bargraph 11 LH

ECO/PERF switch (bargraph illuminated in sport position)

11

AFTER REPAIR

SUO541.0

- Check the operation of the switch contact.- Ensure the presence of earth on track A2 of the switch connector.- Check the condition of the wiring on the switch, the computer and the intermediate connections R150

(passenger compartment / LH front wing) and R149 (engine / LH front wing).- Ensure the continuity between track A1 of the ECO/PERF switch connector and track 6 of the computer

connector.

Ensure the coherence of the bargraph operation.

None.NOTES

Bargraph 11 LH extinguished for all switch positions.

- Disconnect the switch connector.

If bargraph 11 LH remains illuminated: ensure the insulation with respect to earth of the connectionbetween track 6 of the computer connector and track A1 of the switch connector on the one hand andits warning light on the other.

If bargraph 11 LH extinguishes: replace the ECO/PERF switch (contact permanently closed).

Bargraph 11 LH illuminated for all switch positions.

23N7U/SU0 engine

23-75


Fiche n° 44

Bargraph 12 LH

Stop switch (bargraph illuminated with brake pedal pressed)

12

AFTER REPAIR

SUO541.0

- Check the adjustment of the stop switch and its operation (continuity between tracks 1 and 2, pedalnot pressed).

- Check and ensure the presence of + after ignition on track 1 of the switch connector.- Check the condition of the wiring on all the connections of the "stop information" line.- Ensure the continuity of the connection between track 2 of the switch connector and track 5 of the

computer connector. Intermediate connections: R150 (passenger compartment / front LH wing) andR149 (engine / front LH wing).


None.NOTES

Bargraph 12 LH illuminated permanently.

- Disconnect the connector of the stop switch.

If bargraph 12 LH does not illuminate: ensure the insulation with respect to 12 volts of the connectionbetween track 5 of the computer connector and track 2 of the stop switch connector.

If bargraph 12 LH illuminates: check the assembly, the adjustment and the operation of the stop switch(contact open between terminals 1 and 2). Replace it if faulty.

Bargraph 12 LH extinguished when braking.

23N7U/SU0 engine

23-76


Fiche n° 44

Bargraph 13 LH

Kickdown (bargraph illuminated in full load position)

13

AFTER REPAIR

SUO541.0

- Disconnect the switch connector.

If bargraph 13 LH remains illuminated: ensure the insulation with respect to earth of the connectionbetween track 18 of the computer connector and the switch connector.

If bargraph 13 LH extinguishes: check the assembly, the adjustment and the operation of the kickdownswitch and replace it if faulty (contact permanently closed).


Deal with bargraph 3 LH ("kickdown fault") first if it is illuminated.NOTES

Bargraph 13 LH illuminated in the no load position.

- Check the adjustment of the accelerator cable (cable too taut).- Check the operation of the switch contact (replace the switch if necessary).- Ensure the presence of earth on the switch connector on the wiring side.- Check the condition of the wiring on the switch, the computer and the intermediate connections R150

(passenger compartment / front LH wing) and R149 (engine / front LH wing).- Ensure the continuity between the switch connector and track 18 of the computer connector.

Bargraph 13 LH extinguished in the full load position.

23N7U/SU0 engine

23-77


Fiche n° 44

Bargraph 14 LH

Engine speed information (bargraph illuminated engine notrunning)

14

AFTER REPAIR

SUO541.0

If this bargraph presents an operating incoherence (still illuminated engine running), bargraph 6 LH("engine speed and torque information fault") is illuminated, and therefore should be dealt with first.


Deal with bargraph 6 LH ("engine speed and torque information fault") first if it isilluminated.NOTES

23N7U/SU0 engine

23-78


Fiche n° 44

Bargraph 15 LH

Low adherence switch (bargraph illuminated button pressed)

15

AFTER REPAIR

SUO541.0

- Check the operation of the switch contact.- Ensure the presence of earth on track A1 of the switch connector.- Check the condition of the wiring on the switch, the computer and the intermediate connections R150

(passenger compartment / front LH wing) and R149 (engine / front LH wing).- Ensure the continuity between track B5 of the mode switch connector and track 33 of the computer

connector.


The low adherence switch is a one-touch button (does not lock).Activation of this operating mode is displayed on the instrument panel.NOTES

Bargraph 15 LH always extinguished.

Bargraph 4 RH ("low adherence switch fault") should be illuminated, and therefore should be dealt withfirst.

Bargraph 15 LH always illuminated.

23N7U/SU0 engine

23-79


Fiche n° 44

Bargraphs 18 RH and LH and 19 LH

Solenoid valve controls

18

AFTER REPAIR

SUO541.0

These bargraphs are used to display the control of the various solenoid valves:

- Solenoid valve EVS1.- Solenoid valve EVS2.- Converter bridging solenoid valve


NoneNOTES

19

23N7U/SU0 engine

23-80

Order ofoperations


Action Bargraph Display and Notes

1 Computer conformity G70*N7Q engine: 77 00 874 432

N7U engine: 77 00 874 433

2 Recognition ofselector lever positions #01

Check on the XR25 display or onthe instrument panel that all thelocked positions of the selectorlever are correctly recognised.

- Check starting authorisation inP and N.

- Check the operation of thereversing lights in R.

3 Eco/Perf operatingmode

Press selectorswitch

The instrument panel displays"S" in Sport mode.

4 Stop switch Press brakepedal

5 Kickdown

Pressacceleratorpedal fully

down

6 Low adherenceoperating mode

Press lowadherence

switch

Bargraph 15 LH is illuminated when pressing the

switch.The instrument panel

displays this mode by the symbol"neige" (snow).

7 Accelerator cableCheck

position ofclip

If the cable adjustment ismodified, reprogram the no load

and full load positions usingcommand G20* (refer to the

"assistance" section).

AUTOMATIC TRANSMISSIONFault finding - Checking conformity

SUO541.0

Only perform this conformity check after having carried out a complete checkusing the XR25 (no faults).NOTES

BG11

BG12

BG13

BG15

23N7U/SU0 engine

23-81

AUTOMATIC TRANSMISSIONFault finding - Assistance

SUO541.0

Replacing the computer / Procedure for programming the no load and full load positions of theaccelerator pedal:

When replacing the automatic transmission computer the no load and full load positions of the acceleratorpedal will have to be programmed using the following procedure:* Put the selector lever in position P or N but do not start the engine.* Enter code G20* on the keypad of the XR25.* Press the accelerator pedal when the display shows "PF" flashing.

The display then shows "bon" then "PL" flashing.* Release the pedal and start the engine.

Then follow the displays "bon", "Fin" then "4.tA3" when the procedure occurs correctly.Bargraph 10 LH should extinguish.

* Turn off the ignition.

Reminder of the gears possible depending on the selector lever position and the operating mode active:

DRIVE 3 L

ECO 1 - 2 - 3 - 4 1 - 2 - 3 1(= 1st gear hold)

SPORT 1 - 2 - 3 - 4 1 - 2 - 3 1 - 2(= 2nd gear hold)

NEIGE/SNOW

3 - 4Start in 3rd

1 - 2 possible withkickdown active.

2 - 3 - 4Start in 2nd

1 possible with kickdownactive

1

23N7U/SU0 engine

23-82

AUTOMATIC TRANSMISSIONFault finding - Assistance (continued)

SUO541.0

Information provided on the display of the XR25 on #01:

The letter or figure on the right indicates the position of the selector lever.The figure to the left of the point represents the gear engaged.

Selector leverposition

Ignition onengine not running

Ignition onengine running

Vehicle moving Comments

p P.P P.P

R r.r r.r r.r

N n.n n.n n.n

D 1.d

1.dor

3.d in low adherencemode

1.d2.d3.d4.dH.d

For converterbridging

3 1.3

1.3or

2.3 in low adherencemode

1.32.33.3H.3

For converterbridging

L 1.L 1.L 1.L2.L 2.L in sport mode

The display X.F indicates a fault in the multifunction switch.

23N7U/SU0 engine

23-83

AUTOMATIC TRANSMISSIONFault finding - Customer complaints

SUO541.0

Only refer to this customer complaint after having performed a complete test withthe XR25 and a conformity check.NOTES

PROBLEMS ON THE INSTRUMENT PANEL

Automatic transmission fault warning light illuminated with no indicationon the XR25.

Chart 1

No indication on the automatic transmission display on the instrumentpanel (lever position, sport and snow operating mode).

Chart 2

No vehicle speed indication on the instrument panel Chart 3

The speedometer indicates a speed of approximately 45 km/h when the ignition is turned on.

Chart 4

PROBLEMS WHEN STARTING THE ENGINE

The starter motor does not engage with the selector lever in position P and/or N.

Chart 5

The starter motor operates, the engine does not start and the warning lightson the instrument panel become dim, lever in N.

Chart 6

The starter motor engages with the selector lever in a position otherthan P or N.

Chart 7

The vehicle moves forwards or backwards with the selector lever inposition N (not within the creeping phenomenon below 60°C).

Chart 8

PROBLEMS CHANGING GEAR

Gears change at the wrong times Chart 9

No kickdown in the full load position. Chart 10

23N7U/SU0 engine

23-84

AUTOMATIC TRANSMISSIONFault finding - Customer complaints (continued)

SUO541.0

AUTOMATIC TRANSMISSION OPERATING PROBLEMS

No drive in forward and/or reverse gear.

Chart 11

Delay engaging and engine races following a jerk when starting

The vehicle moves forward slowly when starting

One or several gears missing

OTHER PROBLEMS

No communication between the computer and the XR25. Chart 12

Oil under the vehicle Chart 14

Vibrations, engine slips or races when changing gear

...............................................................

Reversing lights do not operate Chart 13

Cannot change gear, vehicle stuck in one gear.

23N7U/SU0 engine

23-85


SUO541.0


AUTOMATIC TRANSMISSION FAULT WARNING LIGHTILLUMINATED WITH NO INDICATION ON THE XR25.Chart 1

Search for a short circuit to earth of the connection between track 12 of the AT computer connector andtrack 25 of the instrument panel connector (AT display connection on the instrument panel).This fault also leads to the lever position and operating mode (sport and snow) not being displayed.

AFTER REPAIR Perform a road test then a check with the XR25.

23N7U/SU0 engine

23-86


SUO541.0


NO INDICATION ON THE AUTOMATIC TRANSMISSIONDISPLAY ON THE INSTRUMENT PANEL

(lever position - sport and snow operating mode)Chart 2

Ensure the continuity and the insulation of the connection between track 12 of the AT computer connectorand track 25 of the instrument panel connector (AT display connection on the instrument panel).A short circuit to earth of this connection will also lead to the illumination of the automatic transmissionfault warning light.


23N7U/SU0 engine

23-87


SUO541.0


NO VEHICLE SPEED INFORMATION ON THE INSTRUMENTPANEL

Chart 3

Ensure the continuity and the insulation with respect to earth of the connection between track 24 of theAT computer connector and track 19 of the instrument panel connector (connection for the vehicle speedinformation on the instrument panel).


THE SPEEDOMETER INDICATES A VEHICLE SPEED OFAPPROXIMATELY 45 KM/H WHEN THE IGNITION IS

SWITCHED ON

Chart 4

Ensure the insulation with respect to 12 volts of the connection between track 24 of the AT computerconnector and track 19 of the instrument panel connector (connection for the vehicle speed informationon the instrument panel).


23N7U/SU0 engine

23-88

no

yes


SUO541.0


THE STARTER MOTOR DOES NOT ENGAGE WITH THESELECTOR LEVER IN POSITION P AND/OR N

Chart 5

Connect the XR25.On #01 , check the coherence between the display on theXR25 and the locked position of the selector lever (ignitionon and engine off)

Is coherence ensured?

Turn off the ignition, disconnect the 10 track connectorunder the automatic transmission.When the starter motor is operating, check for 12 volts ontrack 6 of the connector on the vehicle wiring side.

Is there 12 volts on track 6 ?

Turn off the ignition and check the continuity betweentracks 6 and 10 of the connector on the gearbox side, leverin position P and N.If continuity is not ensured, replace the multifunctionswitchIf the continuity is correct, ensure the continuity betweentrack 10 of the connector on the vehicle wiring side and thestarter motor.

Keep operating the starter motor and move the selectorlever with the brakes on.

Does the engine start?

Check the mounting of the multifunction switch, thetightness of the 2 lock screws of the control cable on thegearbox then adjust the control.

Replace the multifunction switch if the fault persists.

Ensure the continuity of the connectionbetween track 6 of the connector and theignition switch.Ensure the ignition switch works correctly.

Adjust the automatic transmission controlfollowing the method described in theWorkshop Repair Manual.


no yes

yes

no

23N7U/SU0 engine

23-89

no


SUO541.0


THE STARTER MOTOR OPERATES, THE ENGINE DOES NOT

START AND THE WARNING LIGHTSON THE INSTRUMENT PANEL BECOME DIM, LEVER IN N.

Chart 6

With the handbrake released, does the engine turn overwhen the starter motor is operated?

Check the condition of the oil (colour, smell...).Replace the automatic transmission if the condition of theoil signifies an internal fault.

Check the battery charge as well as theoperation of the charging circuit.


yes

Only refer to this complaint after performing a check with the XR25.NOTES

THE STARTER MOTOR ENGAGES WITH THE SELECTOR

LEVER IN A POSITION OTHER THAN P OR N.Chart 7

On #01 or using the display on the instrument panel, check the coherence between the display and the lockedpositions of the selector lever (ignition on and engine off).If coherence is not ensure, adjust the control of the automatic transmission.If coherence is ensured, replace the multifunction switch (P/N contact faulty).

The adjustment and replacement methods are described in the Workshop Repair Manual .

23N7U/SU0 engine

23-90

yes

no


SUO541.0


THE VEHICLE MOVES FORWARDS OR BACKWARDS WITH

THE SELECTOR LEVER IN POSITION N (not within the

creeping phenomenon below 60°C).

Chart 8

On #01 on the XR25 or using the display on the instrumentpanel, check the coherence between the display and thelocked positions of the selector lever (ignition on andengine off).


.Check the condition of the oil (colour, smell...).

Does the condition of the oil signify a fault inside theautomatic transmission ?

Adjust the control following therecommendations given in the WorkshopRepair Manual.Replace the multifunction switch if necessary.

The symptom has probably be wronglyselected.


yes

Replace the automatic transmission.

no

23N7U/SU0 engine

23-91

no

no

Connect the XR25.Use function #01 during a road test, selector lever inposition D.

Can the customer complaint be reproduced?

yes

yes


SUO541.0


GEARS CHANGE AT THE WRONG TIMEChart 9

Monitor the readings given on the display during a roadtest in D and "Eco" mode.

Does the display indicate a modification in the operationmode (change to "Sport" or "Snow" mode) when the faultappears?

Refer to the fault finding defined forincorrect operation of bargraphs 11 LH or 15LH (interpretation of bargraphs section).

Adjust the brake switch and check theoperation of the pedal return spring.


no

yes

no

Does the status of bargraph 12 LH change when the faultappears without operating the brake pedal ?

no

Does the display of the selector lever position changewhen the fault appears?(loss of position D)

yes

Check the adjustment of the external control.Replace the multifunction switch if the fault persists.

B

B

yesRefer to the fault finding associated to thelack of illumination of bargraph 1 RH(interpretation of bargraphs section).

Are communications lost when the fault appears?(appearance of horizontal lines).

23N7U/SU0 engine

23-92

no

Check load information, engine off.Accelerate gently and check the change in load on #02.

Does the load change uniformly?

no


SUO541.0

Chart 9continued

Check the routing of the automatic transmission wiring(high voltage interference...).Modify if necessary.

Check the operation of the injection.Apply the checks defined in the associated fault finding inthe event of a fault.

Switch to injection fault finding and check theoperation of the load potentiometer.

Switch to injection fault finding and check theoperation of the TDC sensor.Check inter-computer connection if necessary.


yes

Check the engine speed information on #06 during a roadtest at a steady speed.

Is the value of engine speed constant?

yes

The symptom has probably been wrongly selected.

B

23N7U/SU0 engine

23-93

no

no

no

Check the conformity and the adjustment of theaccelerator control (refer to Workshop Repair Manual).

Does the accelerator control conform?

no


SUO541.0


NO KICKDOWN IN THE FULL LOAD POSITIONChart 10

Connect the XR25.Check the conformity of the automatic transmissioncomputer using command G70*:

N7Q engine: 77 00 874 432N7U engine: 77 00 874 433

Does the computer conform?

Check the load information, engine off:Accelerate gently and check the change in load on #02.

Does the load change uniformly?

Replace the automatic transmissioncomputer.Apply the procedure for programming the noload and full load values using commandG20* (refer to the "assistance" section).


yes

yes

yes

Check the operation of the kickdown switch: Check thestatus of bargraph 13 LH in the full load position.

Is bargraph 13 LH illuminated ?

yes

The symptom has probably been wrongly selected.

Readjust the accelerator control as shown inthe Workshop Repair Manual.Reprogram the no load and full load positionsusing command G20* (refer to the"assistance" section).

Switch to injection fault finding and check theload potentiometer.Also check the inter-computer connection.

Refer to the fault finding defined for dealingwith bargraph 13 LH (interpretation ofbargraphs section).

23N7U/SU0 engine

23-94


SUO541.0

23N7U/SU0 engine

yes

no


AUTOMATIC TRANSMISSION OPERATING PROBLEMSChart 11

On #01 on the XR25 or on the display on the instrument panel,check the coherence between the display and the lockedposition of the selector lever (ignition on and engine off),


Top up if necessary. Start the engine.Brakes applied, move the selector lever to position D and whilstaccelerating, monitor the vehicle speed on #05.

Does the vehicle speed information change?

yes

yes

Check the oil level and the condition of the oil (colour, smell...).

Does the condition of the oil signify a fault inside theautomatic transmission ? Replace the automatic transmission.

no

no

Adjust the control following therecommendations given in the WorkshopRepair Manual.


no

yes

Connect a pressure gauge and check the line pressure, engineidling and selector lever in position N.

Is the pressure zero?

no

Is the line pressure approximately 4 bar (3.5 - 4), engine idlingand selector lever in position N?


Check the control time of the modulatingsolenoid valve on #13 (engine idling and leverin position P or N).

- If the control time is not around 0.7 - 1 ms,replace the computer.

- If the control time is correct, replace thehydraulic distributor.A

yes

23-95


SUO541.0

Chart 11continued


23N7U/SU0 engine

no

no

no

yes

Refer to the procedure and the safety notes for adjusting thesetting point of the converter. Check this with the selector leverin position D then in R, noting the line pressure and the enginespeed .Theoretical values on line pressure at the setting point:

- 12 bar in D (10.6 - 13.6).- 18 bar in R (16.3 - 20.5)

Are the pressure values correct?

Run the engine to obtain an oil temperature greater than 60°Con #04.Put the selector lever in position D, engine idling and brakesapplied.

Is the line pressure more than 0,2 bar less than that obtainedwith the lever in N ?

Theoretical values of engine speed at the setting point:- N7Q engine: 2450 150 rpm.- N7U engine: 2300 150 rpm.

Is the value of the setting point correct?

no

yes

yes

Perform a road test whilst monitoring the engine speed on theinstrument panel and the reading given by the XR25 on #01(refer to the "assistance" section).

Does the engine speed vary every time a gear changes?

yes

The checks carried out have not confirmed a fault and theautomatic transmission seems to be working correctly.If the vehicle still presents the customer complaint selected,perform the whole fault finding procedure again.


Replace the hydraulic distributor and thesolenoid valves.Replace the automatic transmission if thepressure remains low (pressure too low).

Replace the torque converter (a setting pointof more than 300 rpm above therecommended value requires the automatictransmission to be replaced).Replace the automatic transmission if thesetting point is still wrong.NOTE: A setting point which is too low canlead to a lack of engine power.

Replace the hydraulic distributor and thesolenoid valve.

A

23-96


SUO541.0

None.NOTES

NO DIALOGUE BETWEEN THE COMPUTER AND THE XR25Chart 12

Ensure the XR25 is not the cause of the fault by trying the communicate with a computer on anothervehicle.Check the ISO interface is in position S8 and that you are using the latest version of the XR25 cassette andthe correct access code (D14).Check the battery voltage and carry out any necessary repairs to obtain a correct voltage (U battery >10.5 volts).

AFTER REPAIR When the communication has been established, deal with any illuminated faultbargraphs.

Check whether the 5A fuse on the passenger compartment connection unit is not blown (if a replaced 5Afuse blows again when the ignition is turned on the next time, search as a matter of priority for a shortcircuit to 12 volts of the oil temperature sensor circuit on track 19).Check the connection and the condition of the wiring in the computer connector and the engine / frontLH wing (R149) + passenger compartment / front LH wing (R150) connections.Check that the computer is correctly fed:- Earth on tracks 1 and 15 of the computer connector.- + after ignition on track 29.

If a dialogue is still not established after these various tests, replace the computer and erase the faultmemory at the end of the operation (refer to the "assistance" section for programming the no load/fullload values).

23N7U/SU0 engine

Check that the diagnostic socket is correctly fed:- Earth on track 5 of the diagnostic socket (new 16 track socket).- + before ignition on track 16 of the diagnostic socket (new 16 track socket).Check and ensure the continuity and the insulation of the lines of the diagnostic socket / computerconnection:- Between track 35 of the computer connector and track 15 of the diagnostic socket (new socket).- Between track 21 of the computer connector and track 7 of the diagnostic socket (new socket).

23-97

no

Turn off the ignition and check the continuity between tracks 7and 9 of the connector on the gearbox side, lever in position R.If the continuity is not ensure, replace the multifunction switch.If the continuity is correct, ensure the continuity between track7 of the connector on the vehicle wiring side and the reversinglights.Also check the earth of the reversing lights.


SUO541.0

REVERSING LIGHTS DO NOT WORK

(Reverse gear works and the bulbs are good)Chart 13

Turn off the ignition, disconnect the 10 track connector underthe automatic transmission.Turn on the ignition again and check whether there is + afterignition on track 9 of the connector on the vehicle wiring side.

Is there + after ignition on track 9 ?

AFTER REPAIR When the communication has been established, deal with any illuminated faultbargraphs.

yes

Ensure the continuity of the connectionbetween track 9 of the 10 track connector andthe passenger compartment connection unit.


23N7U/SU0 engine

23-98


SUO541.0

OIL UNDER THE VEHICLEChart 14

Wash the automatic transmission, top up the oil and apply the method described in the Workshop RepairManual, apply talcum powder and locate the origin of the leak.

Deal with the origin of the leak and replace the faulty parts.

Check the oil level.


23N7U/SU0 engine

23-99

90130-3S

DRIVESHAFTSFront driveshaft

REMOVAL

Remove:

- the brake assembly (suspend it from thechassis so as not to damage the brake pipe),


Shock absorber base bolt 25.5Driveshaft nut 25Track rod end 4Gaiter mounting bolt on gearbox 2.5Brake caliper guide bolt 3.5Wheel bolt - 5 bolts 10Relay bearing pressure bolt 2

Rou. 604 -01 Tool for locking hub


T.Av. 1050-02 Hub puller

T.Av. 1380 Lever

29

TIGHTENING TORQUES (in daN.m) - the driveshaft nut using tool Rou. 604-01,

- the track rod end using tool T.Av. 476,

- the ABS sensor,- the ABS wiring mounting bracket.

REPLACEMENT

95234-1R

94338-1R

29-1

95413S

TRANSMISSIONSFront driveshaft

Remove the upper mounting bolt from the shockabsorber base.

Release, without removing, the lower bolt.

These vehicles are fitted with bonded driveshaftswhich have to be pushed back using tool T. Av.1050-02.

29

Remove the lower bolt from the shock absorberbase and tilt the stub axle carrier.

Remove the stub axle from the hub.

Left hand side:

Before removing the driveshaft, measure thedimension (X) between the driveshaft bowl andthe gearbox housing using a feeler gauge.

This dimension X should be the same when refit-ting and it should be checked to ensure the drives-haft is correctly clipped into the gearbox by thespring ring fitted on the end of the shaft.This dimension X can be measured using a set offeeler gauges and can be:3.6mm < X < 8.4 mm.

Remove the driveshaft from the gearbox using le-ver T. Av. 1380 (SU0 automatic transmission).

IMPORTANT: lever T. Av. 1380 cannot be used onSafrane with the N7U engine, with the manualgearbox VM1. There is not enough space to re-lease the driveshaft. Use a tyre lever, for example,instead.

99544R

10577R

29-2

TRANSMISSIONSFront driveshaft 29

By placing this between the gearbox housing andthe driveshaft bowl, and by levering on thegearbox housing, the driveshaft spring ring can beunclipped from the gearbox sunwheel.

WARNING

The driveshaft must be removed and replaced bymeans of the bowl so as to prevent the Triplanseal coming out of its housing .

Protect gaiters to prevent any damage.

Do not damage the seal in the gearbox.

10637R

Right hand side

Remove:

- the two mounting bolts (3) from the retainerplate of the relay bearing and remove it,

- the relay bearing cap pressure bolt (4),

- the driveshaft from the gearbox.

10560R

WARNINGTake the same precautions as when removing theleft hand driveshaft.

Never allow a driveshaft to hang down under avehicle to avoid pinching the gaiter on thegearbox side.

29-3

DRIVESHAFTS

Front driveshafts 29REFITTING

Left hand side:

Check the condition of the spring ring (14) and re-place it if required.

Push the driveshaft in firmly on the gearbox side(holding it by the bowl) so that the spring ringlocks in the groove on the differential gear.

DI2916

Check the dimension X between the driveshaftbowl and the gearbox housing to ensure it iscorrectly clipped in.

Right hand side:

Position the driveshaft in the gearbox, taking carenot to damage the seal in the gearbox.Fit:

- the bearing retainer plate,- the two retainer plate mounting bolts,- the relay bearing pressure bolt and tighten it to

the correct torque

On both sides:Coat the splines of the stub axle with Loctite SCEL-BLOC 77 01 394 072

91749S

Insert the stub axle into the hub.

It should enter freely until the thread protrudes sothat the stub axle nut can be fitted.

Refitting is then the reverse of removal.

11758R

NOTE : check that the lug on the retainer plate forthe bearing is at the top.

29-4

91632R

91633S

TRANSMISSIONSFront driveshaft 29

Ensure the ABS wiring and the pad wear indicatorwire are correctly routed.

With the vehicle on the ground, remove the card-board protectors by tearing them off in accor-dance with the diagram.

Press the brake pedal several times in order tobring the piston into contact with the linings.

Never use a sharp tool which may damage thegaiter.

95295S

29-5

78616R1

DRIVESHAFTSWheel side gaiter 29


T.Av. 1256 Pliers for crimping OETIKER

clips

T.Av. 1168 Pliers for closing CAILLAU clips

UF 107 joint

A driveshaft can be partly repaired on the wheelside:

- replace a joint,- replace a gaiter.

SIX BALL JOINT ON WHEEL SIDE

1 Stub axle bowl2 Balls3 Ball cage4 Stop ring5 Driveshaft6 Gaiter7 Ball hubA ABS ring

REMOVAL

Cut the clips and the gaiters along their wholelength.

Remove as much grease as possible.

Separate the stop ring (4) and, simultaneously, hitthe front face of the ball hub (7) several timesusing a copper hammer.

Then remove the joint from the driveshaft.

REFITTING

Fit onto the shaft:

- the small clip,

- the gaiter (6).

Insert the ball joint (1) fitted with its stop ring(new) in the splines of the shaft up to the ring onthe shaft groove (B).

98824R

78615R3

29-6

DRIVESHAFTSWheel side gaiter 29

Distribute the amount of grease into the gaiterand the stub axle bowl.

NOTE: the amount of grease recommended in the"consumables" section must be complied with.

Position the lips of the gaiter in the grooves onthe bowl (1) and the driveshaft (5).

Fit the clips and tighten them with the tool corre-sponding to the type of clips supplied with the kit(CAILLAU click or OETIKER).

UF 107 joint

98824R

29-7

DRIVESHAFTSGearbox side gaiter 29

WARNING

The Triplan 2700 joint on the gearbox side mustnot be removed (difficult to replace due to thepresence of very complex parts).

Only the gaiter can be replaced after havingremoved joint UF 107 completely.

TB 2700 joint

29-8

FRONT AXLESpring and shock absorber assembly 31

IMPORTANTWhen removing and replacing a spring and shockabsorber assembly, in order to prevent the Triplanjoint on the gearbox side from coming out, do notpivot the stub axle carrier/disc assembly. Releasethe shock absorber base by pushing it towards thevehicle body.This operation should preferably be performedwith the wheels in the straight line position so asto limit the possibility of the joint coming out.

31-1

MECHANICAL ELEMENT CONTROLSGear selection control 37

EXPLODED VIEW

N7U engine

11820R

1 Gear lever knob

2 Gear grid

3 Housing

4 Control cable

5 Mounting on bulkhead

37-1

MECHANICAL ELEMENT CONTROLSGear selection control 37

IMPORTANT: the automatic transmission controllever is supplied by the Parts Department withoutthe gear selector knob.

If you need to repair this, carefully follow theinstructions enclosed with the replacement kit orelse refer to the following section "gear leverknob".

REMOVAL


Remove:- the gaiter (A),- the rear console,- the switch mounting (B) and disconnect the

switch,- the repeater (C) and remove the lighting sup-

port,- the switch mounting (D) and remove the

switch,- the ashtray - cigar lighter assembly,- the radio,

N7U engine

11793R

- the central console (a cut-out is provided to re-lease the handbrake lever),

- the rear heating duct,- the clips (E), (do not release the lock (G) - release the cable from the ball joint,- the nuts (F) and remove the control assembly.

- the five mounting bolts from the centralconsole,

95641R1

REFITTING

Refitting is the reverse of removal and ensure thatthe sleeve stop ring (G) is correctly locked.

37-2

MECHANICAL ELEMENT CONTROLSGear lever knob 37

REMOVALDisconnect the connector (A) and using a pair ofpliers, cut the two wires at (B).Remove the bolt (C) and pull the gear lever knobupwards in order to release it from the selectioncontrol.

N7U engine

95641-1R

REFITTING

Insert wires (1) and (2) into the lever sleeve.

WARNING: Three precautions should be taken soas not to trap the wires in the sleeve:

1 Insert the wires as shown on the diagram.

96476R

2 Ensure that the wires are not crossed (ensure thegear lever knob is fitted in the correct direction).

DI3714

3 Pull on the wires at the same time as insertingthem into the selector lever knob.

37-3

MECHANICAL ELEMENT CONTROLS

Gear lever knob 37

Secure the knob to the selection control (bolt C)and insert the wires into the protective sleeve (D).

N7U engine

Insert the two terminal connectors into theconnector (E) (no assembly direction).

Crimp the wires into the terminal connectors pro-vided in the kit.

DI3711

DI3712

DI3713R

37-4

MECHANICAL ELEMENT CONTROLS

Gear selection control cable 37REMOVAL


Passenger compartment side:The control cable can only be removed afterhaving removed the front and rear console (referto "removing the selection control" section).

Remove the clip (E).Release the cable from the ball joint.

N7U engine

95641R

Engine side:Remove:- the battery and its tray,- the support (B) - release the wiring channel,

11765R

- the control cable bolt (7) and clip (L),

11802R

11800R1

- the cable mounting bolt (2).

37-5

MECHANICAL ELEMENT CONTROLSGear selection control cable 37N7U engine

11792R

REFITTING / ADJUSTINGRefitting is the reverse of removal.

Adjusting the cable:

Put in position D.

Position the cable mounting.

Ensure that the automatic transmission is inposition D.

Insert the ball joint onto the automatictransmission lever and the clip (L) and pre-tightenthe bolts (7).

11765R

Lock the sleeve stop ring on the control unit.

Ensure that all gears can be selected.

Using a ruler, measure the dimension (X). It shouldbe 139 mm (it is adjusted by moving the cable).

11820S1

37-6

AIR CONDITIONINGGeneral 62

91096-3R1

62-1

AIR CONDITIONINGGeneral

A Passenger compartmentB Engine compartmentC Air from outsideD To air mixing unitE BulkheadF Air from outside or recycled

Consumables:

- Compressor oilSANDEN SP 10: 135 CM3 ± 15

- RefrigerantR134a: 850 g ± 35

1 Variable displacement compressor2 Condenser3 Dehydration canister4 Pressure sensor5 High pressure valve6 Pressure relief valve7 Evaporator8 Low pressure valve9 Air conditioning fan unit10 Cooling fan unit11 Radiator12 High pressure fluid13 Low pressure vapour14 High pressure vapour

62

62-2

AIR CONDITIONINGGeneral 62

A Inlet for air from outsideB Windscreen demisting outletC Dashboard ventilator outletD Rear console ventilator outletE Rear footwell air outletF Front footwell air outlet

95003-1R

1 Heating radiator2 Left hand mixing motor3 Right hand mixing motor4 Evaporator temperature sensor5 Evaporator6 Fan7 Recycling motor8 External temperature sensor9 External air inlet flap10 Air distribution flap11 Engine coolant temperature sensor

(The demisting/deicing and air distributionmotors are not shown on the diagram)

62-3

AIR CONDITIONINGCondenser 62

REMOVAL

Put the vehicle on a lift.


Drain the R134a from the circuit using the fillingstation.

Remove the hoses from the condenser afterhaving removed the bolt (F).

95123R

Fit plugs so as to prevent moisture entering thehoses and the condenser.

Remove:- the label holder,- the external air inlet duct,- the air duct to the inlet manifold,- the degassing pipe,- the two mounting bolts of the power assisted

steering pipe.

Disconnect the coolant temperature sensorconnector.

Remove the four mounting bolts from the coolingradiator.

Move the radiator back as close as possible to theengine and secure it.

Remove the four mounting bolts from the dehy-dration canister cover.

N7U engine

95096R1

95093R1

62-4

AIR CONDITIONINGCondenser 62

Disconnect the pressure sensor.

Remove:- the four bolts from the condenser- the condenser union retaining bolt

- the two mounting bolts from the dehydrationcanister.

Remove the condenser with the dehydration ca-nister from the top.

REFITTING

- lubricate the seals and check their condition,

- replace the dehydration canister if the circuithas been left open to the air for more than 10minutes.

- if necessary blow dust off the cooling radiator.

IMPORTANT

When replacing the condenser, add 30 ml of SP 10oil in addition to the amount of oil retrieved usingthe filling station.

PRC62.1

N7U engine

62-5

AIR CONDITIONINGCompressor 62

The compressors fitted to the Safrane N7U en-gines are of type SD7V, variable displacementSANDEN compressors.

For all information on maintaining the compres-sors, refer to the "Air conditioning" section.

REMOVAL-REFITTING

Put the vehicle on a lift.


Drain the refrigerant circuit using the filling sta-tion.

Measure the quantities of refrigerant and oil re-trieved.

From underneath, disconnect:

- the hoses and blank the openings on thecompressor side and hoses with plugs or adhe-sive tape,

- the electrical feed wire of the compressor.

Slacken and remove the drive belt.

WARNING: refer to section 07 "Belt tension".

Remove the mounting bolts from the compressorand remove it.

Refitting should not present any problems.

Follow the recommendations in the "Air conditio-ning" section.

REMINDER: variable displacement compressorsonly operate with SP10 oil.

A Crankshaft pulleyB Air conditioning compressorC PulleyD AlternatorE Power assisted steering pulleyF Tension wheel

98580R

62-6

AIR CONDITIONINGDehydration canister 62

REMOVAL

This can only be replaced after having removedthe condenser.

Disconnect the condenser/dehydration canisterconnecting hoses.

When refitting, lubricate the threads withcompressor oil and replace the seals.

PRC62.2

62-7

95079S

AIR CONDITIONINGElectric control 62

Replacing the evaporator sensor

(version without Airbag)

Remove the glove compartment.

(version with Airbag)

This operation must only be performed by a fullytrained technician.

WARNING: pyrotechnic systems (airbags and pre-tensioners) must not be handled near heat sourcesor flames; they may be triggered.

Note: on these vehicles, the computer can belocked using the XR25 using command G80* (ISOselector on S8, code D49) during the operation.When this function is activated, all the ignitionlines are suspended and the Airbag warning lighton the instrument panel and bargraph 14 LH ofthe XR25 illuminate (new computers are deliveredin this condition).

Remove:- the rubber matting from the dashboard,- the blanking strip,- the adhesive "System tampering warning" strip

(yellow upon leaving factory and light blueafter Renault After-Sales operation).

Remove:- the cover from the module by means of its four

bolts (B) (tightening torque: 0.5 daN.m).

98659R

62-8


- the "glove compartment lock" blank (onebolt),

- the Airbag module by means of its five bolts(C).

Disconnect the two connectors from the passen-ger Airbag ignition module.

All types

Disconnect the connector from the evaporatorsensor.

Pull on the plastic end piece and remove the sen-sor.

98660R

95205R2

REFITTING


WARNING: the safety instructions for refitting orreplacing the passenger Airbag module MUST becomplied with. Failure to follow these instructionsmay cause the system not to operate correctly andmay even present a risk for the vehicle occupants.

IMPORTANT: proceed in the opposite manner toremoval applying the following procedure:- the mounting bolts of the module must be

tightened to a torque of 0.5 daN.m .

The "system tampering warning" label must besystematically replaced with a blue After Sales la-bel sold in sets for all types (Part Number 77 01204 944), after having cleaned the applicationarea beforehand with heptane (Part Number 7711 170 064). This precaution will ensure the totalefficiency of the system tampering label.

No foreign bodies (screws, clips, etc...) should beleft between the module and the passenger air-bag cover.

IMPORTANT When everything has been refitted:- using the XR25, check that there are no faults

on the system.- unlock the computer using command G81*.- check that the airbag warning light illuminates

for 3 seconds when the ignition is turned on,then extinguishes and remains extinguished.

62-9


Pressure sensor (411)

95093-1R

This is removed using a shortened 19 mm openwrench.

All operations on the pressure sensor can becarried out without draining the refrigerantcircuit since the mounting end piece of thepressostat is fitted with a SCRADER valve.

62-10

Documents

27240112-Basic-Manual-M-R-302 B54F TN