Special Features of the f5r 740 Engine(1)

"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 by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".

C RENAULT 1999

77 11 205 759 JULY 1999 Edition Anglaise

N.T. 3218A

DA03 - EA03

SPECIAL FEATURES OF THE

F5R 740 ENGINE

(including related assemblies)

For all parts not dealt with in this Technical Note refer to Workshop Repair Manual

MR 312.

Follow the instructions regarding cleanlinesswhen working on this vehicle.

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.

Contents

07-107-307-407-2107-2207-2307-2407-2507-2707-29

Pages

Capacities - GradesAccessories belt tensioningTiming belt tensioning procedureCylinder head tighteningTyres - wheelsBrakesBrake compensatorUnderbody heightFront axle angle checking valuesRear axle angle checking values

Timing beltCylinder head gasket

11-111-8

TOP AND FRONT OF ENGINE

VALUES AND SETTINGS

11

Pages

07

SpecificationsInlet manifoldExhaust manifold

12-112-412-6

SpecificationsSupply pumpSupply pressure / Pump outputHigh pressure pumpInjection rail / InjectorsPressure sensorAnti-percolation system

13-113-213-313-413-613-1113-13

FUEL SUPPLY13

FUEL MIXTURE

Oil vapours rebreathingExhaust gas recirculation E.G.R.Fuel vapours rebreathing

14-114-214-4

ANTI-POLLUTION14

12

IdentificationOil pressureEngine and transmission assemblySumpMulti-function support

10-110-210-310-810-11

ENGINE AND PERIPHERALSASSEMBLY

10

16

AlternatorStarter

16-116-4

STARTING - CHARGING

Filling - bleedingDiagramCoolant pumpCatalytic converter

19-119-219-319-4

COOLING19

GeneralCompressorCondenserConnecting pipes

62-162-262-362-5

AIR CONDITIONING62

Mechanical power steering pumpPower steering unit

36-136-3

STEERING ASSEMBLY36

Cover - DiscFlywheel

20-120-4

CLUTCH20

IdentificationGearsCapacities - LubricantsConsumablesParts which must always be repla-cedSpecial features

21-121-121-221-3

21-321-4

MANUAL GEARBOX21

Contents

Pages Pages

Static ignitionGeneralInstallationSpecial features of direct injectionCleanliness / SafetyOperationInjection fault warning lightEngine immobiliser functionInjection / AC strategyIdle speed correctionFuel pressure regulationMixture regulationAdaptive mixture correctionCentralised coolant temperaturemanagementComputerWiring diagram

17-117-217-317-517-617-917-1017-1117-1217-1317-1517-1617-17

17-1817-1917-22

IGNITION - INJECTION17

Brake hub / discHub / disc bearing

33-133-2

REAR BEARING ELEMENTS33

Master cylinderBrake servo

37-137-3

MECHANICAL COMPONENTCONTROLS37

* Adjust using a dipstick(1) Following replacement of the oil filter

VALUES AND SETTINGSCapacities - Grades 07

UnitsCapacityin litres

(approx.) *

Petrol engine(oil)

F5R

Grade

Whendraining

5.15.4 (1)

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

- 15 °C

ACEA A2/A3

ACEA A1*/A2/A3

ACEA A1*/A2/A3

ACEA A1*/A2/A3

+ 10 °C

ACEA A1-98 standard* Oil for fuel economy

15W40-15W50

10W30-10W40-10W50

0W30-5W30

0W40-5W40-5W50

European Union countries and Turkey

PETROL

Other CountriesIf the lubricants specified for the European Union countries are notavailable, the following specifications must be taken into account:

PETROL

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

- 15 °C

API SH/SJ

API SH/SJ

API SH/SJ

API SH/SJ

API SH/SJ

Oil for fuel economy:API SJ-IL SAC GF2 standard

15W40-15W50

10W40-10W50

10W30

5W30

5W40-5W50

07-1

VALUES AND SETTINGSCapacities - Grades 07

Units Capacityin litres

JC5gearbox

Grade Special features

3.1 All countries: TRANSELF TRX 75 W 80 W(API GL5 or MIL-L 2105 G or D standards)

F5Rcoolingcircuit

7 Glacéol RX(type D)

Protection to - 20 °C ± 2 °C for hot, temperate andcold climates.Protection to - 37 °C ± 2 °C for very cold climates.

07-2

VALUES AND SETTINGSAccessories belt tensioning 07

A CrankshaftB Air conditioning compressorC AlternatorD Power steering pumpE Coolant pumpF PulleyT Automatic tensioner

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

ALTERNATOR, POWER STEERING AND AIRCONDITIONING

To remove the belt, turn the belt’s automatic ten-sioner in the direction indicated below using a 13mm offset ring ended spanner. Clamp the tensio-ner using a 6 mm hexagonal wrench (1).

15579-1R1

15304R

15110R

WARNING: the accessories belt rests on the ridgedpart on the pulley (F).

07-3

VALUES AND SETTINGSTiming belt tensioning procedure 07

ESSENTIAL SPECIAL TOOLS

Mot. 799-01 Tool for immobilising pinions for

toothed timing belt

Mot. 1054 Top Dead Centre pin

Mot. 1368 Tool for tightening camshaft

pulleys

Mot. 1383 Pipe wrench for removing HP

pipes

Mot. 1448 Clip pliers for spring clips

Mot. 1453 Engine support tool

Mot. 1488 Tool for refitting camshaft

covers

Mot. 1512 Tool for fitting the camshaftseals

Mot. 1526 Tool for setting the camshafts

Mot. 1535 Tool for immobilising the

camshaft pulleys

There are two very distinct procedures for settingthe timing.

1st PROCEDURE

The first procedure is applied in the event of re-placement of any components in the timing facewhich do not require slackening of the camshaftpulley(s).

Follow the instructions regarding cleanliness andsafety when working on the fuel circuit.

ESSENTIAL EQUIPMENT

Angular tightening wrench

07-4


Setting the timing

WARNING: it is essential to de-grease the end of the cranks-haft, the crankshaft pinionbore and the crankshaft pulleycontact surfaces to prevent sli-ding between the timing andthe crankshaft which coulddestroy the engine.

Position the camshaft groovesusing Mot. 799-01 as indicatedin the diagram opposite.

It is essential that the groovesare horizontal and offsetdownwards.

15614S

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

16077R

07-5


Check that the crankshaft is at Top Dead Centreand not in the balancing hole.

Correct position

15163S

15163-1S

Incorrect position

07-6


The crankshaft groove (5) should be between the two marks on the en-gine block.

15577R

The exhaust camshaft pinion mark should be opposite the cylinder posi-tion sensor securing hole.

07-7


Fitting the belt

When the timing belt is changed, it is essential tochange the timing tensioners and pulleys.

Check that the tensioner lug (1) is correctly posi-tioned in the groove (2).

15578R

15201R

Refit:- the timing belt,- the pulleys (3) tightening

the mounting bolts to a tor-que of:• 5 daN.m for the M10 bolts• 2.5 daN.m for the M8 bolts

- the crankshaft accessoriespulley bringing the bolt intoposition without contactwith the pulley (clearancebetween bolt and pulley2 to 3 mm).

NOTE:- the crankshaft accessories

pulley bolt can be re-used ifthe length under the headdoes not exceed 49.1 mm(otherwise change it),

- do not coat a new bolt withoil. However, if the bolt isre-used, it is essential to coatit with oil.

07-8


Align marks (6) and (7) on the tensioner using a6 mm hexagonal wrench at (B).

15256R

Pre-tighten the tensioner nut to a torque of 0.7daN.m.

Tighten the crankshaft pulley bolt to a torque of2 daN.m (Top Dead Centre pin Mot. 1054 still inplace).

NOTE: do not turn the tensioner anti-clockwise.

07-9


15303S

Remove camshaft setting tool Mot. 1526 and TopDead Centre pin Mot. 1054.

Carry out angular tightening of the crankshaftpulley bolt to 115° ± 10°, while immobilising theengine flywheel using a screwdriver.

Make a mark (C) indicating theposition of the camshaft pul-leys in relation to the camshaftbearing cap castings.

15778-1R

07-10


15163-1S

Correct position

15163-2R

Turn the crankshaft two revolutions clockwise (ti-ming end). Before the end of the two revolutions(that is a half-tooth before alignment of themarks on the camshaft pulleys and the camshaftbearing cap castings), insert the Top Dead Centrepin Mot. 1054 to be between the balancing holeand the pinning hole, then bring the timing to itssetting point.

Incorrect position

15163S

Remove the Top Dead Centre pin Mot. 1054.

Check that the tensioner marks are aligned andrepeat the tensioning procedure if they are not.Then tighten the nut to a torque of 2.7 daN.m.

Checking the setting and the tension

Checking the tension

Turn the crankshaft two revolutions clockwise (ti-ming end), then pin the crankshaft just before theend of the two revolutions aligning the camshaftpulley and camshaft bearing cap casting marksmade previously.


Check that the tensioner marks are aligned andrepeat the tensioning procedure if they are not.

07-11


15614S

Checking the setting

Ensure that the tensionermarks are positioned correctlybefore checking the timing set-ting.

Fit the Top Dead Centre pinMot. 1054 checking the ali-gnment of the marks madepreviously.

Fit (without using force) cams-haft setting tool Mot. 1526(the camshaft grooves shouldbe horizontal and offset down-wards). If the tool does not en-gage, the timing setting andtensioning procedure must berepeated.

16077R

07-12


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

Setting the timing

WARNING: it is essential to degrease the end of the crankshaft and thecrankshaft pinion bore, the crankshaft pulley contact surfaces and theends of the camshafts (timing end) and the camshaft pulley bores toprevent sliding between the timing, the crankshaft and the camshaftpulleys which could destroy the engine.

15614S

Position the camshaft grooves horizontally, as indicated on the diagramabove, using tool Mot. 799-01.

It is essential that the grooves are directed downwards.

This operation can be made easier by fitting the camshaft pulleys usingthe old nuts, tightening them to a torque of 1.5 daN.m maximum.

07-13


Fit tool Mot. 1526 which is secured to the end ofthe camshafts.

15163S

Remove the old pulley nuts. It is essential to re-place them with new nuts.

Pre-tighten the nuts, without locking them, with aclearance of 0.5 to 1 mm between the nuts andthe pulleys.

Check that the crankshaft is pinned at Top DeadCentre and not in the balancing hole (crankshaftgroove (5) should be between the two marks (1)of the engine block).

Correct position

16077R

15163-1S

Incorrect position

15114-1R

07-14


When a timing belt is changed, it is essential tochange the timing tensioners and pulleys.

Position the exhaust camshaft pulley mark oppo-site the poition sensor thread.

NOTE: incorrect positioning of the exhaust cams-haft pulley prevents starting of the engine.

Ensure that the tensioner lug (1) is correctly posi-tioned in the groove (2).

15201R

Refit:- the timing belt,- the pulleys (3) tightening

the mounting bolts to a tor-que of 5 daN.m in the caseof the ∅ 10 mm bolts and2.5 daN.m in the case of the∅ 8 mm. bolts.

Fit the crankshaft accessories pulley, pre-tightening the bolt (without fully tightening the bolt, clearance of2 to 3 mm between the bolt and the pulley).

NOTE:- the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed

49.1 mm (otherwise change it),- do not coat the new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil.

15578R

07-15


Check that there is still a clearance of 0.5 to 1 mmbetween the camshaft nuts and pulleys.

Align tensioner marks (6) and (7) using a 6 mmhexagonal wrench at (B).

15256R

Pre-tighten the tensioner nut to a torque of 0.7daN.m.

Turn the timing face through six revolutions viathe exhaust camshaft pulley using tool Mot. 799-01.

NOTE: during this operation, ensure that the pul-leys do not come into contact with the nuts. Ifthey do, reposition them from time to time.

07-16


15578-1R

Check that the tensioner marks are aligned and repeat the tensioningprocedure if they are not. Then tighten the nut to a torque of 2.8 daN.m.

Turn the exhaust camshaft pulley to position the mark opposite the pha-sing sensor.

Tighten the crankshaft pulley bolt to a torque of 2 daN.m (Top DeadCentre pin still in place in the crankshaft).

Make a mark (C) to indicate the position of the camshaft pulleys in rela-tion to the camshaft bearing cap castings.

07-17


Remove the Top Dead Centre pin.

Carry out angular tightening of the crankshaftpulley bolt to 115° ± 10°, while immobilising theengine flywheel using a screwdriver.

15163-1S

15303S

Pin the crankshaft aligning the camshaft pulleyand camshaft bearing cap casting marks madepreviously to ensure that the pin is correctly posi-tioned in the pin hole and not in the crankshaftbalancing hole.

Correct position

15163S

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

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

Incorrect position

16078R

07-18


Remove camshaft setting tool Mot. 1526, cams-haft pulley immobilising tool Mot. 1535 and TopDead Centre pin Mot. 1054.

Checking the setting and tension

Checking the tension

Turn the crankshaft two revolutions clockwise (ti-ming side), then pin the crankshaft just before theend of the two revolution aligning the camshaftpulley and camshaft bearing cap casting marks.


Check that the tensioner marks are aligned andrepeat the tensioning procedure if they are not.

Tighten the exhaust camshaft pulley nut to a tor-que of 3 daN.m, then turn it through an angle of45° then a second angle of 45° using tool Mot.1368.

16218S

07-19


Checking the setting

Ensure that the tensionermarks are positioned correctlybefore checking the timing set-ting.

Fit the Top Dead Centre pinMot. 1054 checking that themarks made previously are ali-gned.

Fit (without using force) cams-haft setting tool Mot. 1526(the camshaft grooves shouldbe horizontal and offset down-wards). If the tool does not en-gage, the timing setting andtensioning procedure must berepeated.

16077R

15614S

07-20

VALUES AND SETTINGSCylinder head tightening 07

CYLINDER HEAD TIGHTENING PROCEDURE

The bolts can be re-used if the length under the head does not exceed137.7 mm (otherwise change all the bolts).

REMINDER: to obtain correct tightening of the bolts, remove any oilfrom the cylinder head securing holes using a syringe.

Do not coat new bolts with oil. However, if the bolts are re-used, it is es-sential to coat them with oil.

Tighten all the bolts to 2 daN.m in the order indicated below.

15659R

Check that all the bolts are correctly tightened to 2 daN.m then carry outangular tightening (bolt by bolt) of 195° ± 6° in the order of tightening.

The cylinder head bolts are not re-tightened following application ofthis procedure.

07-21

VALUES AND SETTINGSTyres - Wheels 07

Vehicle Rim Tyres

Tyre pressurewhen cold (in bar) (1)

Front Rear

DA0 3 6.5 J 16 195/50 R 16 V 2.4 2.2

EA0 3 6.5 J 16 195/50 R 16 V 2.4 2.3

(1) During motorway use with full load.

Wheel nut tightening torque: 9 daN.m

Rim run-out: 1.2 mm

07-22

VALUES AND SETTINGSBrakes 07

Vehicle

At the front

Disc thickness (in mm)

Maximum Minimum

At the rear

Disc thickness (in mm)

Maximum Minimum

Drum diameter (in mm)

Maximum (1) Minimum

DA0 3EA0 3 24 21.8 8 6.3 - -

(1) Drum: maximum wear diameter (where applicable).

The disc run-out is 0.07 maximum

Vehicle

Lining thickness (in mm)

Front (including support)

New Minimum

Rear

New Minimum

Brake fluid

DA0 3EA0 3 18.3 6 11 5 SAE J1703

DOT 4

07-23

VALUES AND SETTINGSBrake compensator 07

VehicleFuel level status

(driver in vehicle)

Check pressure (1) (in bar)

Front Rear

DA0 3EA0 3 140 49

BRAKING PRESSURE

+ 180

90966S

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

07-24

VALUES AND SETTINGSUnderbody height 07

VehicleAt the front

H1 - H2 = ... mmAt the rear

H4 - H5 = ... mmDimension X (in mm)

D and G

DA0 3 116 51 471

EA0 3 116 38 488

Tolerance: ± 7.5 mm

The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not ex-ceed 5 mm, the driver’s side always being the highest.

Any alteration to the underbody height also requires adjustment of the brake compensator (if fitted) and ofthe headlights.

07-25

VALUES AND SETTINGSUnderbody height 07

16102R

H1 : radius of tyre under loadH2 : height measured between the lower surface of the sub-frame and the ground in line with the centre-

line of the wheelH4 : radius of rear tyre under loadH5 : height measured between the centreline of the rear axle joint and the ground

MEASURING POINTS

88636-4R

07-26

DA03

H1-H2 = 116 mmH1-H2 = 124 mmH1-H2 = 130 mm

H5-H2 = 71 mmH5-H2 = 51 mmH5-H2 = 31 mm

10°36’10°42’10°49’

Maximum right /left difference= 1°

4°03’4°33’5°03’


H1-H2 = 116 mmH1-H2 = 124 mmH1-H2 = 130 mm

81603S1

93011-1S

93014-1S

93013-1S

93012-1S

VALUES AND SETTINGSFront axle angle checking values 07

UNLADEN

CANNOT BEADJUSTED

CAMBER

VALUES

CASTOR

- 0°12’- 0°11’- 0°08’


SETTINGPOSITION OF THE

FRONT AXLE

KINGPIN INCLINATION

PARALLELISM

POSITION FOR TIGHTENING RUBBER BUSHES

Adjusted byrotating track

rod sleeves1 turn = 30’

(3 mm)

(For 2 wheels)

toe out

+ 0°10’ ± 10’

+ 1 mm ± 1 mm

ANGLES

UNLADEN- -

±30’

±30’

±30’CANNOT BE

ADJUSTED

CANNOT BEADJUSTED

07-27

EA03

H1-H2 = 116 mmH1-H2 = 125 mmH1-H2 = 133 mm

H5-H2 = 83 mmH5-H2 = 63 mmH5-H2 = 43 mm

10°36’10°44’10°52’


3°47’4°17’4°47’


H1-H2 = 116 mmH1-H2 = 125 mmH1-H2 = 133 mm

81603S1

93011-1S

93014-1S

93013-1S

93012-1S

VALUES AND SETTINGSFront axle angle checking values 07

UNLADEN

CAMBER

VALUES

CASTOR

- 0°12’- 0°10’- 0°06’


SETTINGPOSITION OF THE

FRONT AXLE

KINGPIN INCLINATION

PARALLELISM

POSITION FOR TIGHTENING RUBBER BUSHES

Adjusted byrotating track

rod sleeves1 turn= 30’

(3 mm)

(For 2 wheels)

toe out

+ 0°10’ ± 10’

+ 1 mm ± 1 mm

ANGLES

UNLADEN- -

±30’

±30’

±30’

CANNOT BEADJUSTED

CANNOT BEADJUSTED

CANNOT BEADJUSTED

07-28

(For 2 wheels)

Toe-in

- 0° 30’ ± 20’

- 3 mm ± 2 mm

- 0°50’ ± 15’

93013-2S

93011-2S

81603S1

VALUES AND SETTINGSRear axle angles checking values 07

UNLADEN

CAMBER

VALUES4 BAR AXLE

PARALLELISM

ANGLES

UNLADEN

UNLADEN- -

POSITION FOR TIGHTENINGRUBBER BUSHES

POSITION OF THE

REAR AXLESETTING

CANNOT BEADJUSTED

CANNOT BEADJUSTED

07-29

ENGINE AND PERIPHERALS ASSEMBLYIdentification 10

Type ofvehicle

Engine GearboxCubic

capacity(cm3)

Bore(mm)

Stroke(mm)

Compressionratio

DA03EA03 F5R 740 JC5 1998 82.7 93 11.5/1

Manual to be consulted: Mot. F5R.

10-1

87363R1

ENGINE AND PERIPHERALS ASSEMBLYOil pressure 10


Mot. 836 -05 Boxed kit for measuring oil

pressure

Douille longue ou clé à tube de 22 mm

CHECK

The oil pressure check must be carried out whilethe engine is warm (approximately 80 °C).

Contents of boxed kit Mot. 836-05.

USE

B + F

Connect the pressure gauge in place of the oilpressure switch.

Oil pressureIdle 1 bar (minimum)3,000 rpm 3 bars (minimum)

22 mm long socket or tube wrench

ESSENTIAL EQUIPMENT

10-2

ENGINE AND PERIPHERALS ASSEMBLYEngine and transmission assembly 10

Sub-frame front mounting bolt 6.2

Sub-frame rear mounting bolt 10.5

Front right suspended engine mountingcover to engine mounting bolt 6.2

Front right suspended engine mountingcover mounting nut 4.4

Rubber engine mounting to front left sidemember support mounting nut 6.2

Shock absorber base mounting bolts 18

Brake caliper mounting bolt 4

Steering shaft yoke mounting bolt 3

Wheel bolt 10

Three point clamp nuts 2

Sub-frame - side member tie-rod bolts 3

TIGHTENING TORQUES (In daN.m)


Mot. 1040-01 Dummy mounting forremoving/refitting engine andtransmission assembly

Mot. 1159 Tool for retaining the engine onthe sub-frame

Mot. 1233-01 Threaded rods for lowering thesub-frame


Mot. 1453 Tool for supporting the engine

REMOVAL

Place the vehicle on a two post lift.

Disconnect the battery.

Remove the engine undertray.

Drain:- the cooling circuit via the lower radiator hose,- the gearbox and the engine (if necessary),- the refrigerant circuit using filling equipment.


10-3


15961R

- the horns,- the two power steering pipe fasteners on the

sub-frame on the right-hand side,- the steering shaft yoke nut and eccentric bolt

after pushing back the protector.

Remove:- the front wheels and the mud shields,- the sub-frame - body tie-rods,- the steering ball joints,- the brake calipers (and the ABS sensors) and at-

tach them to the suspension springs,- the shock absorber base bolts,- the heat shield (A) and the gearbox control ca-

ble,- the protective plate (1) and unclip the fuel

pipes,- the fuel supply and return pipes. Fit plugs to

maintain cleanness,- the tie-rod (2) mountings,- the catalytic converter clamp (3) and attach it to

the body.

SPECIAL FEATURES OF VEHICLES FITTED WITH ADRIVER’S AIR BAG

WARNING

To prevent any risk of destruction of the rotaryswitch under the steering wheel, follow the in-structions below:• Before the steering column and the rack are

uncoupled, it is ESSENTIAL that the steeringwheel is immobilised with the wheels straightusing a "steering wheel immobiliser" tool forthe entire duration of the operation.

• If there is any doubt about the correct centringof the rotary switch, the steering wheel mustbe removed and the centring procedure descri-bed in the "Air bag" section must be applied.

REMINDER: in this case, only qualified, trainedpersonnel must carry out the procedure.

Remove:- the front bumper,- the air filter unit and its support,- the accelerator and clutch cables,- the brake servo vacuum pipe (manifold end).

Remove the computer fasteners and fold back theassembly on the engine.

10-4


98756R

Remove:- the heating radiator hose using tool Mot. 1448,- the expansion bottle fasteners and move it

aside,- the relay board and the electrical connector of

the engine connection unit,

- the earth strap on the bulkhead,- the air conditioning pipe fasteners on the

pressure relief valve,- the starter supply wire.

NOTE: it is essential to fit plugs on the pipes andthe pressure relief valve to prevent theintroduction of moisture into the circuit and onthe fuel pipes to keep them clean.

Fit engine retaining tool Mot. 1453 ensuring thatthe strap is positioned correctly.

Remove the suspended engine mountings coverand the engine tie-bar.

Place a shim between the gearbox and the sub-frame.

Remove nut (1), then, using a copper hammer, tapto detach the stud from the suspended enginemountings fastener.

98754R

15959R1

10-5


Fit the two tools Mot. 1159 as indicated below.

99024R2

15960R

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

98755R1

Lower the lift until the tool comes into contactwith the ground.

Remove the sub-frame mounting bolts and re-move the engine and transmission assembly by lif-ting the body.

When starting to lift the body, be sure to removethe catalytic converter and to extract the radiatorfrom its upper fasteners (then place it on the sub-frame again).

NOTE: in the case of an operation which requiresseparation of the engine/gearbox/sub-frame as-sembly, take care to mark the position of the toolsMot. 1159 on the sub-frame.

10-6


REFITTING

The alignment of the sub-frame with the bodywill be made easier by positioning two threadedrods Mot. 1233-01 in the two front fasteners ofthe body sub-frame.

Be sure to reposition the catalytic converter on lo-wering the body onto the engine and transmis-sion assembly.

Tighten the sub-frame mounting bolts to a torqueof:- 6.2 daN.m at the front,- 10.5 daN.m at the rear.

Refit in the reverse order to removal.

Fit the heat shields correctly.

Fit the caliper mounting bolts with LoctiteFRENBLOC and tighten them to the specified tor-que.

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

Carry out the following operations:- fill the engine and gearbox with oil (if necessa-

ry),- fill and bleed the cooling circuit (see section 19

"Filling - Bleeding").

Fill the refrigerant circuit using the filling equip-ment.

10-7

ENGINE AND PERIPHERALS ASSEMBLYSump 10

REMOVAL



Remove the steering shaft yoke nut.

97390-1R2


T.Av. 1233-01 Tool for working on the sub-frame - axle

Pre-tightening of sump bolts 0.8

Tightening of sump bolts 1.35 ± 0.15

TIGHTENING TORQUES (in daN.m)

10-8


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

13507R2

Drain and remove the sump.

10-9


REFITTING

Apply a spot of RHODORSEAL 5661 at (A) on ei-ther side of bearing n° 1, and at (B) at the intersec-tion of the crankshaft closing plate and the cylin-der block.

15159-2R

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

15195R

10-10

ENGINE AND PERIPHERALS ASSEMBLYMulti-function support 10

REMOVAL



Remove:- the alternator (see section 16 "Alternator").- the air conditioning compressor fasteners and

attach it to the upper crossmember,- the multi-function support removing the stud

(A).

REFITTING

Refit the support tightening the bolts and thestud to a torque of 4.4 daN.m.

Refer to section 07 "Accessories belt tensioning"for the tensioning procedure.


15576R

Multi-function support bolts and stud 4.4 ± 0.4

TIGHTENING TORQUE (in daN.m)

10-11

Angular tightening wrench

TOP AND FRONT OF ENGINETiming belt 11


Wheel bolt 10

Pulley bolt:

- M10: 5

- M8: 2.5

Tensioner nut 2.8

Crankshaft pulley bolt 2 + 115° ± 10°

Mounting bolt on suspended mounting 6.2

Intermediate timing cover bolt 2

High pressure pump mounting bolt 1

High pressure pipe union 2.5

Mot. 799-01 Tool for immobilising pinionsfor toothed timing belt

Mot. 1054 Top dead centre pin

Mot. 1368 Tool for tightening camshaftpulleys

Mot. 1383 Pipe wrench for removing HPpipes

Mot. 1453 Engine support

Mot. 1488 Tool for refitting camshaft co-vers



Mot. 1535 Tool for immobilising camshaftpulleys

TIGHTENING TORQUES (in daN.m or/and °) REMOVAL



Remove:- the front right wheel,- the front right wheel arch and the engine un-

dertray.

Fit the engine support Mot. 1453.

98750R2

ESSENTIAL EQUIPMENT


11-1


Remove:- the Top Dead Centre pin plug,

15102-1S

Remove :- the suspended engine mountings cover and

movement limiter assembly,- the bolt (A) and slacken engine tie-bar bolt (B).

Raise the engine.

15424R3

Lock the accessories belt tensioner. To do this,turn the tensioner towards the right and immobi-lise it using a 6 mm hexagonal wrench (see section07 "Accessories belt tensioning").

15579-1S

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

15617R

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

11-2


- the exhaust camshaft sealing plug (4),- the high pressure fuel pipe using tool Mot.

1383 (5). For this operation, support the unionsusing open wrenches.

Fit blanking pieces to maintain cleanness.

Remove:- the high pressure fuel pump (6),- the timing cover mounting bolts then remove

the covers (7).

15578-3R

15615R2

11-3


Setting the timing

Position the exhaust camshaft pulley mark (1) onetooth before the phase sensor fastener (2). Thecamshaft grooves must be towards the bottomand almost horizontal as indicated below.

15614-1S

15740-1R

11-4


Insert pin Mot. 1054 to be between the balancinghole and the setting groove of the crankshaft.

15163-2S

Turn the engine slightly, in the same direction, en-gaging pin Mot. 1054 at the setting point.

Incorrect position

15163S

Correct position

15163-1S

11-5


Remove the timing pulley immobilising the en-gine flywheel using a screwdriver.

15303S

Slacken the timing belt usingthe tensioner.

Remove the belt and the pul-ley.

Take care not to let the cranks-haft pinion fall as it does nothave a key.

WARNING: it is essential to de-grease the end of the cranks-haft, the crankshaft pinionbore and the contact surfacesof the crankshaft pulley to pre-vent sliding between the ti-ming and the crankshaft whichcould destroy the engine.

15578S

11-6


REFITTING

When the timing belt is changed, it is essential tochange the timing tensioners and pulleys.

Refit:- the timing belt (it is essential to follow the pro-

cedure described in section 07 "Timing belt ten-sioning procedure"),

- the accessories belt (see section 07 "Accessoriesbelt tensioning procedure"),

- the Top Dead Centre pin plug applying a spotof RHODORSEAL 5661 to the thread,

- the new exhaust camshaft sealing plug usingtool Mot. 1488,

- the high pressure fuel pump and pipe (refer tothe procedure described in section 13 "Highpressure pump"),

Replace the shim (1),

16127R

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

15617S

15615S

- the air resonator and air intake pipe,- the right-hand suspended engine mounting

tightening the bolts to the specified torque.

11-7

Cylinder head testing equipmentAngular tightening wrench

TOP AND FRONT OF ENGINECylinder head gasket 11

ESSENTIAL SPECIAL EQUIPMENT

Mot. 1054 Top Dead Centre pin


Mot. 1368 Tool for tightening camshaftpulleys

Mot. 1383 Pipe wrench for removing HPpipes



Mot. 1488 Tool for refitting camshaft co-vers



Mot. 1530 Tool for removing injectors

Mot. 1532 Tool for removing the highpressure rail

Mot. 1533 Tool for fitting injector seals

Mot. 1535 Tool for immobilising camshaftpulleys

ESSENTIAL EQUIPMENT

TIGHTENING TORQUES (in daN.m or/and °)

Wheel bolt 10

Pulley bolt:

- M10: 5

- M8: 2.5

Tensioner nut 2.8

Crankshaft pulley bolt 2 + 115° ± 10°

Mounting bolt on suspended mounting 6.2

Intermediate timing cover bolt 2

Camshaft bearing cap casting bolt 1.2

Oil separator bolt 1.3

Injection rail mounting bolt 1.5




11-8


Remove:- the air intake pipe and resonator,- the ignition coil and harness,- the inlet manifold (see section 12 "Inlet mani-

fold"),- the high pressure fuel pipe using tool Mot.

1383 supporting the unions using openwrenches.


Remove:- the high pressure fuel pipe (see section 13

"High pressure pump"),- the suspended engine mountings,- the exhaust camshaft sealing plug,- the accessories belt (see section 11 "Accessories

belt").

Position the engine at Top Dead Centre using thepin Mot. 1054.

Remove the timing belt (see section 11 "Timingbelt").

Fit tool Mot. 1535 positioning the timing coverbolt in hole (1), and remove the camshaft pulleys.

REMOVAL



Remove:- the front right wheel,- the front right wheel arch and the engine un-

dertray.

Drain the cooling circuit (via the lower radiatorhose).

Fit the engine support tool Mot. 1159.

99024R2

16078R2

15960R

11-9


Remove:- the clips between the injectors and the rail,- the injectors using tool Mot. 1530. To do this,

turn the injector slightly to break the carbondeposit.

Extract the injector and position the plugs tomaintain cleanness.

16635R

Remove the injection rail mounting bolts (fit thesealing plugs).

Fit the injection rail extraction tool Mot. 1532 (thedowels and the threaded rods).

16126R

Extract the injection rail. The injector retainingclips remain in place and may allow the injectionrail to escape on removal.


11-10


Remove:- the oil separator,

15612S

- the EGR valve/manifoldconnecting pipe,

- the EGR valve support,- the camshaft bearing cap

bolts.

15612-3S

11-11


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

15660-1R

Remove:- the camshafts,

15656S

11-12


- the earth strap,- the catalytic converter/ ma-

nifold connecting bolts,- the exhaust manifold strut,- the harness supports,- the coolant pipes on the ple-

num chamber,- the tabs and the hydraulic

stops,

15657S

- the aluminium timing cover (1).

15574R

11-13


Remove the cylinder head.

15659S

CHECKING THE MATING SURFACE

Check whether the mating surface is deformedusing a ruler and a set of feeler gauges.

Maximum deformation 0.05 mm

Grinding of the cylinder head is prohibited.

Test the cylinder head to detect any cracks.

Cleaning

It is very important that the mating surfaces ofthe aluminium parts are not scratched.

Use the product Décapjoint to dissolve the part ofthe gasket which remains attached.

Apply the product to the section to be cleaned;wait approximately ten minutes, then remove itusing a wooden spatula.

It is advisable to wear gloves during this opera-tion.

Do not allow the product to fall onto the paint-work.

Your attention is drawn to the care which mustbe taken when carrying out this operation to pre-vent the introduction of foreign bodies into thepressurised oil feed pipes leading to the cams-hafts (pipes located both in the cylinder block andin the cylinder head).

11-14


REFITTING

When removing-refitting the cylinder head,observe the following points:

- It is essential to reprime the hydraulic stops asthey risk becoming empty after a veryprolonged time.To check whether it is necessary to reprimethem, press the top of the stop at (A) with thethumb. If the stop piston lowers, immerse it ina container full of diesel.

15658R

Refit:- the tabs,- the camshaft lubricating the bearings.

WARNING: do not apply oil to the cylinder headcover mating surface.

NOTE: the camshafts are identified by a mark (A).

Details of mark (A) :- mark B is only used by the supplier,- mark C identifies the camshafts:

A = Inlet,E = Exhaust,

- mark D indicates the type of engineFor example:

F5RE616 330 11 38

BCD

15653-2R

11-15

15614S


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

NOTE: the mating surfaces must be clean, dry andnot greasy (avoid finger prints).

Using a roller (uneven) apply Loctite 518 to thecamshaft bearing cap casting mating surface untilit is reddish.

15641S

11-16

15656S


Refit:- the camshafts.

15612-2R

- the camshaft bearing capcastings. Tighten them to atorque of 1.2 daN.m follo-wing the order and the pro-cedure indicated.

11-17

15612R


Tighten the oil separator to atorque of 1.3 daN.m in the or-der indicated.

- the EGR valve support,- the oil separator.

Using a roller (uneven) apply Loctite 518 to themating surfaces until they are reddish.

15643S

11-18


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

15644R

- the coolant pipes on the plenum chamber,- the harness supports,- the earth strap,- the catalytic converter/manifold connecting

bolts,- the exhaust manifold strut,- the EGR valve/manifold connecting pipes,- the EGR valve support.

11-19


Refit the injector seals using tool Mot. 1533 (refer to the procedure described in section 13 "Injectionrail/injectors").

Refit the injectors and the clips on the rail observing their positions.

16125S

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

11-20


Setting the timing

WARNING: it is essential to degrease the end ofthe crankshaft, the crankshaft pinion bore andthe contact surfaces of the crankshaft pulley toprevent sliding between the timing and thecrankshaft which could destroy the engine.

Refit:- the timing belt (it is essential to follow the

procedure described in section 07 "Timing belttensioning procedure",

- the high pressure pump refitting the shim (1)(see section 13 "High pressure pump"),

16127R

- the exhaust camshaft sealing plug using toolMot. 1488,

- the inlet manifold (see section 12 "Inletmanifold"),

- the accessories belt (refer to the proceduredescribed in section 07 "Accessories belt"),

- the right-hand suspended engine mountingand the engine tie-bar.

Before starting the engine, switch on the ignitionseveral times to run the petrol pump and primethe fuel circuit.

IMPORTANT: if the exhaust manifold fasteningstuds have been removed, change them and sealusing "LOCTITE FRENBLOC BLEUE".

11-21

FUEL MIXTURESpecifications 12

VehicleGear-box

Engine

Type IndexBore(mm)

Stroke(mm)

Cubiccapacity

(cm3)

Compressionratio

Catalyticconverter

Emissioncontrol

standard

Type ofinjection

DA0 3EA0 3 JC5 F5R 740 82.7 93 1998 11.5/1 ◊ C110

◊ C77 EU 96

Multipointdirect

Staticignition

Temperature in °C - 10 25 50 80 110

Air sensorNTC type resistance in Ohms

8525 to10450 1880 to 2120 760 to 860 - -

Coolant sensorNTC type resistance in Ohms - 2140 to 2360 770 to 850 275 to 290 112 to 117

CO (%) (1) C02 (%) HC (ppm) Lambda (λ)

750 ± 50 0.5 maximum 14.5 minimum 100 maximum 0.97 < λ < 1.03 Super unleaded(IO 95)

Checks carried out at idle *

Emissions of pollutants**Idle speed (rpm)

Fuel ***(minimum

octane rating)

(1) at 2,500 rpm the CO should be 0.3 maximum.* At a coolant temperature greater than 80 °C and after a constant engine speed of 2,500 rpm for

approximately 30 seconds.** For the legislative values, refer to the specifications for the country concerned.*** Compatible IO 91 unleaded.

12-1


DESCRIPTION BRAND/TYPE SPECIAL NOTES

Injection and ignition computerInjectors control computer

SIEMENS "SIRIUS 3H"SIEMENS "Driver"

90 tracks55 tracks

Injection - Direct multipoint sequential

Ignition - Static with monobloc coil

Idle stepper motor PHILIPS Resistance : 53 ± 5 Ω at 25 °C

Throttle potentiometer CTS - MAGNETIMARELLI

Incorporated in the throttle housingResistance of track : 1,200 ± 240 ΩResistance of cursor < 1,050 Ω

Magnetic sensor(TDC and engine speed) ELECTRIFIL

Variable reluctance typeResistance = 200 to 270 Ω

Camshaft position sensor SAGEM Hall Effect sensor

Canister solenoid valve SAGEM Incorporated in the canisterResistance : 26 ± 4 Ω to 23 °C

EGR solenoid valve SIEMENS

Resistance of sensor track≈ 5 KΩResistance of valve ≈ 6 KΩTrack 1 : sensor signalTrack 2 : sensor earthTrack 3 : sensor supplyTrack 4 : valve earthTrack 6 : valve supply

Injector SIEMENSResistance 1.78 ± 5 °COperation under high pressure

Fuel pressure sensor SIEMENS Resistance ≈ 3,8 Ω

Fuel pressure regulator SIEMENS Resistance between tracks 2 and 3 ≈ 2,084 Ω

Manifold pressure sensor DELCO Resistance ≈ 50 KΩ

Knock sensor SAGEM Piezo-electric type.Tightening to 2 daN.m

1 2 3

4 6

12-2


DESCRIPTION BRAND/TYPE SPECIAL NOTES

Upstream oxygen sensor BOSCHHeating resistance: 9 ± 1 Ω at 23 °CRich mixture > 750 ± 240 mVLean mixture < 150 ± 50 mV

Downstream oxygen sensor BOSCHHeating resistance : 3.4 ± 0.7 Ω at 23 °CRich mixture > 750 ± 70 mVLean mixture < 150 ± 50 mV

Ignition coils SAGEM

Monobloc coil with four outputsPrimary resistance≈ 0.5 ΩSecondary resistance : 11 ± 1 KΩ

A : cylinder 1 and 4 coil supplyB : cylinders 2 and 3 coil supplyC : supplyD : common wire

Spark plugs CHAMPIONREC 14 PYC

WARNING: long threadTightening : 2.5 to 3 daN.m

Idle manifold pressure - 310 ± 40 mbars

Exhaust counter-pressure

upstream of the pre-catalyticconverter

1,500 rpm 593,000 rpm 1764,500 rpm 4095,500 rpm 520

Scavenge pump BOSCH Pressure : 4.5 ± 0.06 bars

A B C D

12-3

FUEL MIXTUREInlet manifold 12

Inlet manifold ∅ 8 mounting bolt 2.5Inlet manifold ∅ 6 mounting bolt 1Side mounting bolt 2.5Throttle housing bolt 1


REMOVAL


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

15618R

15616R1

- the pressure sensor (2) and air temperature sen-sor (3) connectors,

- the ignition coil,- the ignition harness,

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

12-4

FUEL MIXTUREInlet manifold 12

REFITTING

Replace the manifold seal and the EGR valve.

Refit:- the inlet manifold replacing the seals and ob-

serving the tightening torque of the ∅ 6 mmand ∅ 8 mm bolts and nuts.

15617R1

- the manifold side bolt,- the coil (3) and the ignition harness (4),- the air resonator and air intake pipe.

In the case of removal of the throttle housing, re-fer to the procedure described in section 12"Throttle housing").

12-5

FUEL MIXTUREExhaust manifold 12

Catalytic converter/manifold connecting nuts 1.2

Exhaust manifold mounting nuts 1.8

Engine tie-bar 6.2

Oxygen sensor 4.5

Shock absorber lower bolts 17

Lower ball joint 6


- the front right wheel,- the front right mud shield,- the ABS sensor connector,- the front right brake caliper,- the right lower ball joint mounting bolt,- the lower shock absorber mounting bolts,- the front right driveshaft,- the oxygen sensor (3) using tool Mot. 1495,


Mot. 1495 Tool for removing the oxygen

sensor

REMOVAL



Remove:- the idle regulation solenoid valve (1),- the EGR pipe (2),

16080R

12-6

FUEL MIXTUREExhaust manifold 12

15619R

- the exhaust strut (1),- the manifold heat shields,- the engine tie-bar,- the manifold to catalytic

converter connection moun-ting bolts.

Slacken the catalytic converter/ exhaust line connectionclamp to move the catalyticconverter back a few centime-tres.

Remove the exhaust manifoldnuts.

Tilt the engine and detach themanifold from underneath.

REFITTING

Replace all the seals removed and the EGR pipeclamps.

It is essential to tighten all the bolts to the speci-fied torque.

Refit the heat shield.

IMPORTANT: in the case of removal of the ex-haust manifold mounting studs, replace them andseal using "LOCTITE FRENETANCH BLEUE".

16079S

12-7

FUEL SUPPLYSpecifications 13

The fuel supply circuit is composed of:- the low pressure supply pump (placed in the gauge/pump assembly in the tank (1),- a fuel filter located at the front of the tank (2),- a high pressure mechanical pump located at the end of the camshaft (3),- an injection rail (high pressure) fitted with the pressure sensor and regulator (which cannot be remo-

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

Removal of the interior of the high pressure pump and the injectors is prohibited. The pressure regulatorcannot be separated from the injection rail, it is essential to replace the assembly.

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

16310R

13-1

FUEL SUPPLYSupply pump 13

The low pressure supply pump is immersed in thefuel tank.

It is installed on the pump/gauge assembly andhas a low pressure regulator (4).

15754R

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

13-2

FUEL SUPPLYSupply pressure / Pump output 13

SUPPLY PRESSURE CHECK

Disconnect the fuel supply union (1) on the highpressure pump and fit in its place a "T" union fit-ted with the checking pressure gauge Mot. 1311.

Start the engine to run the low pressure fuelpump.

Pressure measured: 4.5 ± 0.06 barsMaximum pressure: 6 bars

SUPPLY PUMP OUTPUT CHECK

Disconnect the supply union (R) located after thefuel filter and place it in the graduated receptacle.

Run the supply pump shunting the control relay orusing the diagnostic equipment.

Minimum output measured: 165 litres/hour.


Mot. 1311 Fuel pressure checking kit withpressure gauge and adapters

ESSENTIAL EQUIPMENT

2,000 ml graduated receptacle

15615R

WARNING: THE PRESSURE READ UNDER THE"FUEL PRESSURE" PARAMETER ON THEDIAGNOSTIC EQUIPMENT CANNOT BE MEASUREDUSING A PRESSURE GAUGE. NO ATTEMPT MUST BE MADE TO READ IT IN ANYCIRCUMSTANCES.

15755R1

13-3

FUEL SUPPLYHigh pressure pump 13

The high pressure pump is a mechanical pump lo-cated at the end of the inlet camshaft.Removal of the interior of the high pressure pumpis prohibited, it is sold complete.

WARNING: when removing the injectors, the railor the high or low pressure pumps, be aware ofthe quantity of the fuel in the unions. Protectareas susceptible to damage.

REMOVAL

Disconnect the low pressure fuel supply and re-turn unions (1). Fit appropriate plugs to maintaincleanness.

Remove:- the inlet manifold (refer to the procedure des-

cribed in section 12 "Inlet manifold"),

ESSENTIAL SPECIAL EQUIPMENT

Mot. 1383 Tool for removing high pressureunions

WARNING:Before carrying out any work, connect the aftersales service diagnostic equipment, enter into dia-logue with the injection computer and check thatthe pressure in the rail is below 5 bars. Be awareof the fuel temperature.






THE RULES REGARDING CLEANLINESS MUST BEOBSERVED STRICTLY.

- the high pressure pipe (2) using tool Mot. 1383.To do this, support the pump’s intermediatesteel union during slackening (3) and the railunion (4),

- the pump mounting bolts (5),- the intermediate shim between the pump and

the cylinder head and clean its mating surface.

15615R3

13-4

FUEL SUPPLYHigh pressure pump 13

Fit:- the pump on its support and tighten the bolts

to the specified torque,- the pipe and tighten the unions to the specified

torque using tool Mot. 1383. To do this, sup-port the intermediate steel unions of the pumpand the rail.

REFITTING

Replace the intermediate shim between the pumpand the cylinder head.

16127S

WARNING:After all work, check that there are no leaks onthe fuel circuit. Run the engine at idle until the co-oling fan assembly cuts in, then accelerate severaltimes while stationary. Check that there are noleaks.

13-5

FUEL SUPPLYInjection rail / Injectors 13

NOTE: removal of the intermediate union locatedbetween the rail and the high pressure pipe andremoval of the pressure regulator is prohibited. Inthis case, replace the injection rail.

The injectors are secured to the injection rail bymeans of clips. They open directly into the cylin-der head combustion chamber.


Mot. 1383 Tool for removing high pressureunions

Mot. 1530 Tool for extracting injectors

Mot. 1532 Tool for removing the injectionrail

Mot. 1533 Tool for replacing injector seals

Rail mounting bolt 1.5 ± 0.2

High pressure pipe union 2.5 ± 0.3

Pressure sensor 2 ± 0.2


13-6


Disconnect the injection railand injector connectors.

Remove the inlet manifold (seesection 12 "Inlet manifold").

WARNING: when removingthe injectors, the rail or thehigh or low pressure pumps,be aware of the quantity ofthe fuel in the unions.Protect areas susceptible todamage.

15613S

REMOVAL

WARNING:Before carrying out any work, connect the aftersales service diagnostic equipment, enter into dia-logue with the injection computer and check thatthe pressure in the rail is below 5 bars. Beware ofthe fuel temperature.



13-7


Remove the high pressure union using tool Mot.1383 supporting the unions on the rail and on thepump (1).


Remove the fuel return pipe (low pressure).


Remove the rail mounting bolts.

Extract the rail using tool Mot. 1532.

NOTE: the injectors are secured to the rail by re-taining clips. It is not necessary to remove them toextract the injection rail.

Remove the injector clips


Fit extraction tool Mot. 1530.

Rotate to break the carbon deposit on the injectornozzle.

16126R

16635R

Remove the injectors.


15615R4

13-8

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


REPLACEMENT OF THE INJECTOR NOZZLE SEAL

It is essential to replace the Teflon injector seals.

To do this:- clean the injector soaking it in a suitable, clean

thinner. The use of a metal brush, sandpaper,or an ultrasound cleaner is prohibited,

- wipe the injector nozzle using a lint-free wipe,- cut the seal carefully using circlip pliers taking

care not to mark the injector, clean the injectoragain.

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

16373S

16375S

- remove the cone and retract the seal from theinjector using the body of tool Mot. 1533 pus-hing it to its limit.

16376R

16374R

13-9


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

Refit the connectors.

REFITTING

Change:- the O-rings,- the clips,- the injector Teflon seals.

Position the injectors on the injection rail.

Fit the injector retaining clips taking care to position them correctly.

16125S

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

13-10

FUEL SUPPLYPressure sensor 13ESSENTIAL SPECIAL TOOLS

Mot. 997 -01 Socket for removing thepressure sensor

Injection rail pressure sensor 2 ± 0.2


REMOVAL

WARNING:Before carrying out any work, connect the aftersales service diagnostic equipment, enter into dia-logue with the injection computer and check thatthe pressure in the rail is below 5 bars. Be awareof the fuel temperature.



Disconnect the injection rail connectors.

WARNING: when removing the injectors, the railor the high or low pressure pumps, be aware ofthe quantity of the fuel in the unions. Protectareas susceptible to damage.

13-11

FUEL SUPPLYPressure sensor 13

Disconnect the pressure sensor(1) and unscrew it.

Fit a blanking piece to main-tain cleanness.

15613R

REFITTING

Change the seal.

Fit the sensor then tighten it to the specified tor-que.

Refit the connector.

WARNING:After all work, check that there are no leaks onthe fuel circuit. Run the engine at idle until the co-oling fan assembly cuts in, then accelerate severaltimes while stationary. Check that there are noleaks.

WARNING: removal of the fuel pressure regulatoris strictly prohibited.

13-12

FUEL SUPPLYAnti-percolation system 13

PRINCIPLE OF OPERATION

The anti-percolation system is controlled directlyby the injection computer.

The coolant temperature information is takenfrom the injection coolant temperature sensor(see section 17 "CCTM").

When the ignition is switched off, the injectioncomputer changes to monitoring mode. If the en-gine coolant temperature exceeds the thresholdof 100 °C during the two minutes which followswitching off of the engine, the fan low speed re-lay is supplied.

If the temperature again falls below 96 °C, the fanassembly relay is cut off (operation of the fan as-sembly cannot exceed a duration of 10 minutes).

13-13

ANTI-POLLUTIONOil vapours rebreathing 14

BASIC DIAGRAM OF THE CIRCUIT

13042R

1 Engine2 Oil separator3 Air filter housing4 Inlet manifold

15612S

CHECK

To ensure correct operation ofthe anti-pollution system, theoil vapours rebreathing circuitmust be kept clean and ingood condition.

14-1

ANTI-POLLUTIONExhaust gas recirculation E.G.R. 14

PRESENTATION OF CIRCUIT

16080R1

3 Inlet manifold4 Exhaust manifold5 EGR valve

14-2

ANTI-POLLUTIONExhaust gas recirculation E.G.R. 14

REFITTING

It is essential to change the valve seal.

PURPOSE OF THE EGR SYSTEM

The recirculation of the exhaust gas is used to re-duce the nitrogen oxide (NOx) content of the ex-haust gas.

Passage of the gas is authorised by the control ofan electromagnetic valve by the injection compu-ter.

Programming conditions:- engine speed 2,800 ± 100 rpm,- manifold pressure of 630 ± 150 mbars,- for a duration of approximately 30 seconds.

REMOVAL OF THE VALVE

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

EGR valve mounting bolt 2.7

EGR valve support 1

TIGHTENING TORQUES (in daN.m) PRINCIPLE OF OPERATION

The valve is controlled by an RCO signal emittedby the injection computer. The RCO signal permitsmodulation of the opening of the valve, andconsequently, the quantity of exhaust gas direc-ted back towards the inlet manifold.

The computer continuously carries out a test todetect the position of the EGR valve flap.

OPERATING CONDITIONS

The parameters which determine the activation ofthe EGR solenoid valve are as follows:- air temperature,- coolant temperature,- atmospheric pressure,- accelerator pedal position,- engine speed,- vehicle speed,- battery voltage.

EGR is authorised if:- the air temperature is greater than 10 °C,- the coolant temperature is greater than 70 °C,- the manifold pressure is between 300 and 650

mbars,- the engine speed is between 1,700 and 3,800

rpm,- a map (torque/engine speed/load potentiome-

ter) is above a given threshold.

The computer controls the EGR except in the follo-wing cases:- in the case of a fault on one of the following:

• coolant temperature sensor,• air temperature sensor,• pressure sensor,• vehicle speed information,• EGR valve.

15615R5

14-3

ANTI-POLLUTIONFuel vapours rebreathing 14

CANISTER PURGE CONDITION

The canister purge solenoid valve is controlled bytrack 4 of the computer when:- the coolant temperature is greater than 70 °C,- the air temperature is greater than 10 °C,- the throttle position potentiometer is not at

no-load and is outside idle regulation.

It is possible to display the canister purge solenoidvalve opening cyclic ratio using the diagnosticequipment by consulting the parameter "Canisterpurge solenoid valve RCO".

The solenoid valve is closed if the value is below1.5 % (minimum value).

CANISTER PURGE OPERATION CHECK

A system malfunction may result in an unstableidle or stalling of the engine.

Check the conformity of the circuit (refer to thebasic diagram) and the condition of the pipes tothe tank (refer to Workshop Repair ManualMR 312).

BASIC DIAGRAM OF THE CIRCUIT

97393-1R1

1 Inlet manifold2 Incorporated canister purge solenoid valve3 Fuel vapours absorber (canister) with solenoid

valve4 TankM Breather

14-4

STARTING - CHARGINGAlternator 16

IDENTIFICATION

Vehicle Engine Alternator Intensity

DA0 3EA0 3 F5R 740 BOSCH 14 V 53 98 A 100 A

CHECK

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

RPM 100 Amperes

2,000 63 A

3,000 86 A

4,000 95 A

16-1


REMOVAL



Remove:- the wiring and computer fasteners and fold it

back onto the engine,- the front right wheel,- the front right wheel arch.

98710S

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

15579-1S

15576-2S

Remove the power steering reservoir support fas-teners and unclip the power steering reservoir.

Move aside the power steering reservoir and sup-port assembly to allow access to the alternator.

Remove:- the power steering pump pulley,

16-2


- the power steering pump. REFITTING


NOTE: on refitting, use the upper alternator andpower steering support mounting bolt to positionthe alternator.

Take care not to crush the wiring between thecompressor and the power steering support.

Refer to section 07 "Accessories belt tensioning"for the tensioning procedure.

15576-4S

Disconnect the alternator.

Remove the alternator mounting bolts.

15576-3S

Remove the alternator from above.

16-3

STARTING - CHARGINGStarter 16

IDENTIFICATION

Vehicle Engine Starter

DA0 3EA0 3 F5R BOSCH 0001 106 012

REMOVAL



From below

Remove:- the manifold/catalytic converter connecting

rod,- the pre-catalytic converter lower heat shield,- the right-hand lower wishbone ball joint

mounting bolt,- the shock absorber strut upper bolt,- the starter supply wire.

Detach the ball joint and tilt the shock absorberstrut to uncouple the right-hand driveshaft.

Remove the air intake pipe and the resonator.

From above

Disconnect the starter energising connector.

Remove the starter mounting bolts.

16316S

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

REFITTING


15618S

16-4

IGNITIONStatic ignition 17

DESCRIPTION

The ignition system is of the static type supplied with signals from the engine speed and exhaust camshaft po-sition sensors.

The power module is incorporated in the injection computer.


Ignition coil bolts 1 to 1.5Spark plugs 2.5 to 3

16124S

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

17-1

INJECTIONGeneral 17

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

• SIEMENS "SIRIUS 3H" 90-way computer controlling the injection and the ignition. 55-way computercontrolling the opening of the injectors.

• Multipoint direct injection operating in sequential mode from the time the engine is started.

• Injection warning light on the instrument panel.

• Use of the engine overheating warning light in the event a major fault on the high pressure circuit.

• Special precautions relating to the engine immobiliser.Adoption of a 2nd generation type engine immobiliser making a special computer replacement procedurenecessary.

• High pressure fuel circuit with an electric scavenge pump (low pressure) and a mechanical high pressurepump.

• Idle speed- nominal idle when warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rpm

• Idle speeds corrected in line with:- air conditioning,- power steering,- coolant temperature,- electrical balance.

• Maximum engine speeds:- maximum engine speed when the coolant temperature is below 75 °C . . . . . . . . . . . . . . . . . . . . 5,900 rpm- maximum engine speed for T > 75 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,500 rpm

• Canister purge solenoid valve controlled by opening cyclic ratio (RCO).

• Electric exhaust gas recirculation (E.G.R.) valve controlled by opening cyclic ratio (RCO).

• Use of two oxygen sensors placed upstream and downstream of the catalytic converters.

• Automatic configuration for AC operation by exchange of signals between computers.

• Control of the fan assemblies and of the coolant temperature warning light on the instrument panel bythe injection computer (CCTM).

17-2

INJECTIONInstallation 17

1 Fuel vapours absorber with solenoid valve2 Injection computer3 Pressure regulator4 Manifold pressure sensor5 Fuel pressure sensor6 Idle stepper motor7 Electric E.G.R. valve8 Throttle position potentiometer9 High pressure pump

10 Engine speed sensor11 Ignition coil12 Air temperature sensor13 Knock sensor14 Power steering pressure switch15 Injectors control computer

16219

17-3

INJECTIONInstallation 17

3 Pressure regulator5 Fuel pressure sensor

16 High pressure injectionrail

17 Oil separator

4 Manifold pressure sensor6 Idle stepper motor9 High pressure pump

11 Ignition coil12 Air temperature sensor13 Knock sensor18 Coolant temperature sensor

15613R1

15617R2

7 Electric E.G.R. valve8 Throttle position potentiometer

19 Oxygen sensor (upstream)

16079R

17-4

INJECTIONSpecial features of direct injection 17

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

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

98406R1

The injection time is corrected in line with the fuel supply pressure.

IMPORTANT: IT IS ESSENTIAL TO FOLLOW THE INSTRUCTIONS REGARDING CLEANLINESS AND SAFETYDESCRIBED ON THE NEXT PAGE WHENEVER ANY WORK IS CARRIED OUT.

A 1 revolution of the crankshaftB 1 revolution of the camshaft

C Top dead centre 1 - 4D Top dead centre 2 - 3

1 Cylinder 1 intake2 Cylinder 2 intake3 Cylinder 3 intake4 Cylinder 4 intake

5 Long tooth6 84° or 14 teeth7 30 teeth

X Engine flywheel targetY Camshaft targetZ Voltage supplied by the cylinder position sensor

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

17-5

INJECTIONCleanliness / Safety 17

INSTRUCTIONS REGARDING CLEANLINESS WHICH IT IS ESSENTIAL TO FOLLOW WHEN WORKING ON THEHIGH PRESSURE DIRECT INJECTION SYSTEM

RISKS RELATING TO CONTAMINATION

The petrol direct injection system is very sensitive to contamination. The risks incurred by the introduction ofcontamination are:- damage to or destruction of the high pressure injection system,- seizing of a component or a component which is not sealed,- destruction of the engine (by continuous injection into the cylinder).

All after sales service operations must be carried out under extremely clean conditions. This means that no im-purities (particles a few microns in size) have penetrated into the high pressure injection system during remo-val or into the circuits via the fuel unions.

The principles of cleanness must be applied from the filter to the injectors.

WHICH ELEMENTS CAUSE CONTAMINATION?

The elements which cause contamination are:- metal or plastic splinters,- paint,- fibres:

• cardboard,• brush,• paper,• clothing,• cloth.

- foreign bodies such as hair,- ambient air,- etc...

WARNING: it is possible to clean the engine using a high pressure washer at the risk of damaging the connec-tions. Also, the moisture may stagnate in the connectors and cause electrical connection problems. The water may also be stored in the recesses of injectors and spark plugs opening directly into the cylinder.

17-6


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

• Ensure that the plugs for the unions which you wish to open are available (bag of plugs sold by the PartsDepartment).The plugs can be used only once. After use, they must be thrown away. (Cleaning is not sufficient to makethem reusable).

• Ensure that plastic bags which will hermetically seal several times are available for storing removed parts.There is less risk of parts stored in this way being subjected to impurities. The bags can be used only once.After use, they must be thrown away.

• Ensure that lint-free cleaning wipes are available (wipes with SODICAM part numbers). The use of conven-tional cloth or paper is prohibited. In fact, these create lint and may contaminate the system’s fuel circuit.Each wipe can be used only once.

CLEANING INSTRUCTIONS TO BE FOLLOWED BEFORE THE FUEL CIRCUIT IS OPENED

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

• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).

• Use a brush and thinner to clean the parts to be removed, the tools which will be used and the part of theworkbench used.

• Wash your hands before and during the operation if necessary.

• When using protective gloves, cover leather gloves with latex gloves (available from SODICAM).

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

• As soon as the circuit is opened, it is essential to plug the openings which could allow contamination to en-ter. The plugs to be used are available from the Parts Department. They must not be reused in any circum-stances.

• Reseal the bag hermetically, even if it has to be re-opened only a short time later. The ambient air carriescontaminants.

• All components of the injection system which are removed must, after being plugged, be stored in a her-metically sealed plastic bag.

• After opening the circuit, the use of a brush, thinner , a blower, a scraper, or a conventional cloth is strictlyprohibited. In fact, these elements are liable cause the entry of impurities into the system.

• If a component is replaced with a new one, do not remove this from its packaging until it is to be fitted onthe vehicle.

• When cleaning a mating surface, use lint-free absorbent paper. Start from the centre of the part and cleangradually towards the outside to push away any impurities.

17-7


DI1325

17-8

INJECTIONOperation 17

OPERATION OF THE DIRECT INJECTION

The low pressure pump (also called the scavenge pump) supplies the HP pump, via the filter, under a pressureof 4.5 bars.

The sole purpose of the HP pump is to supply the output which it directs towards the rail. The pressure regula-tor located on the rail modulates the high pressure values in line with the requirements of the computer andthe pressure sensor data. The fuel circulates in the rail to supply each injector.

The computers:- determine the pressure value necessary for correct operation of the engine, then control the pressure re-

gulator. They check that the pressure value is correct by analysing the value transmitted by the HP sensorlocated on the rail.

- determine the injection time necessary to supply the correct quantity of fuel, and the start of the injection.After determining these two values, they control each injector individually. The system can inject fuel intothe engine at a pressure between 50 to 100 bars,

- control the ignition.

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

16310R1

17-9

INJECTIONInjection fault warning light 17

Vehicles which operate with the multipoint direct injection system use two injection warning lights illumina-ted for a few seconds every time the ignition is switched on:- the injection warning light used in the event of a minor fault,- the coolant temperature warning light:

• illuminated if the coolant temperature is above 118 °C,• flashing in the event of a major injection fault making it necessary to stop the engine as soon as possi-

ble.

PRINCIPLE OF ILLUMINATION OF THE MINOR INJECTION FAULT WARNING LIGHT

In the event of a minor high pressure injection system fault, the warning light illuminates. These faults are:- injector failure,- low pressure operation fault,- inter-computer connection problem,- fuel pressure sensor fault,- excessive pressure.

If a fault is present when the ignition is switched on, the warning light illuminates for a few seconds, extin-guishes briefly then illuminates again depending on the fault.

PRINCIPLE OF ILLUMINATION OF THE COOLANT TEMPERATURE WARNING LIGHT

In the event of a major high pressure injection system fault, the engine overheating warning light flashes. Inthis case, it is essential to switch the engine off as soon as possible. These faults are:- fuel pressure regulator fault (pressure above 125 bars),- pressure sensor fault (pressure above 125 bars),- jamming of the EGR valve.

In this situation, the scavenge pump (low pressure), the ignition and the injection are cut off after a few se-conds.

17-10

INJECTIONEngine immobiliser function 17

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

REPLACEMENT OF AN INJECTION COMPUTER

The injection computers are supplied without a code but they can all be programmed with one.

When a computer is replaced, it must be programmed with the code of the vehicle and the correct operationof the engine immobiliser function must be checked.

To do this, simply switch on the ignition for a few seconds without starting the engine then switch it off. Withthe ignition off, the engine immobiliser function comes into operation after approximately 10 seconds (thered engine immobiliser warning light flashes).

WARNING:

In the case of this engine immobiliser system, the computer retains the engine immobiliser code for life.

Furthermore, this system does not have a security code.

Consequently, it is prohibited to carry out tests using computers borrowed from the warehouse or anothervehicle which must then be returned.

It will not be possible to erase the code.

17-11

INJECTIONInjection / AC strategy 17

THE COMPRESSOR IS OF THE VARIABLE CUBIC CAPACITY TYPE

INJECTION COMPUTER/AC COMPUTER CONNECTION

The injection computer is connected to the AC computer by two wires:- one wire from the injection computer to track 10 of the AC computer. The compressor operation authori-

sation or prohibition information is sent along this wire. - one wire from the AC computer to track 23 of the injection computer. This is for a power absorbed infor-

mation signal.

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

COMPRESSOR OPERATION STRATEGY

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

Engine starting strategy

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

Overheating protection strategy

The compressor is not engaged if the coolant temperature is above 110 °C.

17-12

INJECTIONIdle speed correction 17

IDLE SPEED CORRECTION IN LINE WITH THE TEMPERATURE

COOLANT (°C) Idle speed reference (rpm)

- 40 1,360

- 30 1,264

- 20 1,200

- 10 1,200

0 1,200

10 1,152

20 1,104

30 1,056

40 992

50 880

60 800

70 752

80 752

90 752

100 752

110 800

120 848

IDLE SPEED CORRECTION IN LINE WITH THE INLET MANIFOLD PRESSURE

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

17-13

INJECTIONIdle speed correction 17

POWER STEERING PRESSURE SWITCH - INJECTION COMPUTER CONNECTION

The injection computer receives information from the power steering pressure switch (which can be dis-played on the diagnostic equipment). This depends on the pressure in the hydraulic circuit and on the fluidityof the power steering fluid. The higher the pressure, the more energy is used by the power steering pump.

The injection computer alters the engine idle speed to a speed of 815 rpm.

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

The purpose of this correction is to compensate for the drop in voltage due to operation of a power consu-ming component while the battery is at low charge. To do this, the idle speed is increased, thus permittingthe rotation of the alternator to be increased and, consequently, the battery voltage.

The lower the voltage, the more significant the correction. Therefore the engine speed correction is variable.It begins when the voltage falls below 12.7 Volts. The idle speed may reach a maximum 910 rpm.

ADAPTIVE IDLE SPEED CORRECTION

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

PARAMETER F5R 740 engines

Nominal idle speed X = 750 rpm

Idle RCO 9 % ≤ X ≤ 15 %

Idle RCO adaptation value Limit:- minimum : - 6 %- maximum : +6 %

Every time the engine is switched off, the computer resets the stepper motor to its lower limit.

IMPORTANT: it is essential, after erasing the computer memory, to start the engine and then switch it off topermit resetting of the potentiometer. Start the engine again and let it run at idle so that the adaptive cor-rection can take place.

17-14

INJECTIONFuel pressure regulation 17

The fuel pressure is regulated by the computer by supplying a regulator (1) located on the injection rail. Thisregulator is controlled by a reference value which takes into account the variations and the age of the en-gine. This control reference value can be displayed by the diagnostic equipment in "parameters" mode.

The fuel pressure regulation takes into account the following components:- the injection rail pressure sensor,- the coolant temperature sensor (for the starting phase),- the engine speed sensor,- the throttle position potentiometer.

15613R2

The pressure read under the "fuel pressure" parameter should be between 45 and 100 bars (engine running)when the pressure regulation is active (Status: "Pressure regulation: CONFIRMED").The "Fuel regulation solenoid valve RCO" parameter should fluctuate between 20 and 30 %.

NOTE: a regulation error (Parameter: "Fuel pressure regulation error") results in illumination of the faultwarning light.

17-15

INJECTIONMixture regulation 17

OXYGEN SENSOR HEATING

The upstream oxygen sensor is heated by the in-jection computer from the time the engine is swit-ched on.

The downstream oxygen sensor is heated after agiven period determined in line with the coolanttemperature and the engine speed.

Heating of the upstream oxygen sensor is stop-ped:- if the vehicle speed is above 70 mph (140 km/h)

(value given for information),- in the event of high engine loads,- in the case of a significant engine speed.

The downstream sensor is heated continuously.

UPSTREAM SENSOR VOLTAGE

The value read on the diagnostic equipment un-der the parameter: "upstream sensor voltage" re-presents the voltage (expressed in millivolts) sup-plied to the computer by the oxygen sensor.When the engine is looped, the voltage shouldfluctuate rapidly between two values:- 150 ± 100 mV for a lean mixture,- 750 ± 100 mV for a rich value.

The smaller the gap between the maximum andminimum values, the less reliable is the informa-tion from the sensor (this gap is usually at least500 mV).

NOTE: in the case of a small gap, check the hea-ting of the sensor.

MIXTURE CORRECTION

The value read on the diagnostic equipment un-der the parameter: "mixture correction" repre-sents the average of the mixture corrections madeby the computer in line with the richness of thecarbonised mixture seen by the oxygen sensor.

The correction value has a mid-point of 128 and li-mits of 0 and 255 :- value below 128: leaner mixture required,- value above 128: richer mixture required.

ENTRY INTO THE MIXTURE REGULATION PHASE

Entry into the mixture regulation phase takes ef-fect after a given starting delay if the coolant tem-perature is above 20 °C and if the upstream sensoris ready (sufficiently warm).

The starting delay depends on the coolant tempe-rature (between 20 °C and 80 °C) and is between20 and 320 seconds.

Before entry into the mixture regulation phase,the value of the parameter is 128.

Unlooping phase

In the mixture regulation phase, the phases ofoperation during which the computer does nottake into account the value of the voltage sup-plied by the upstream sensor are:- at full-load if the engine speed is above 3,200

rpm,- during heavy acceleration,- during deceleration with the no-load informa-

tion,- in the event of failure of the oxygen sensor,- in the event of limitation of the engine speed

(excessive pressure, failure...).

DOWNGRADED MODE IN THE EVENT OF FAILUREOF THE OXYGEN SENSOR SENSOR

If the voltage supplied by the oxygen sensor is in-correct during the mixture regulation phase for aminimum duration of 10 seconds, the computerswitches to downgraded mode.

If a failure is detected and if the failure has alrea-dy been stored, the system goes straight into anopen loop (mixture correction value 128).

17-16

INJECTIONAdaptive mixture correction 17

PRINCIPLE

In the looping phase the mixture regulation corrects the injection time to obtain a dosage as close as possibleto mixture 1. The correction value is close to 128, with limits of 0 and 255.

The adaptive correction makes it possible to offset the injection map to realign the mixture regulationaround 128.

Therefore, it is necessary, following reinitialisation of the computer (return to 128 of the adaptive correc-tions), to carry out a special road test.

ROAD TEST

Conditions:- engine warm(coolant temperature > 75 °C),- do not exceed an engine speed of 3650 rpm.

Pressure zones which must be passed through during the test

Range n° 5(mbars)

Range n° 4(mbars)

Range n° 3(mbars)

Range n° 2(mbars)

Range n° 1(mbars)

221 321 421 521 621 780

Average 271 Average 371 Average 471 Average 571 Average 700F5R 740

Following this test, the corrections are operational.

The test must be followed by normal, smooth and varied driving for a distance of 3 to 6 miles (2 to 10 kilome-tres).

After the test, read the mixture adaptation values. Initially 128, they should have changed. If they have not,repeat the test taking care to observe the conditions strictly.

INTERPRETATION OF THE VALUES GATHERED FOLLOWING A ROAD TEST

In the case of a lack of fuel (injectors clogged, pressure and flow of fuel too low, ...), the mixture regulationincreases to obtain a mixture as close as possible to 1. The adaptive mixture correction increases until the mix-ture correction again fluctuates around 128.

In the event of an excessive amount of fuel the reasoning is reversed: the mixture regulation decreases andthe adaptive correction decreases as well to realign the mixture correction around 128.

PARAMETER F5R 740 engines

Operating mixture adaptationvalue

96 ≤ X ≤ 192

Idle mixture adaptive value 32 ≤ X ≤ 224

17-17

INJECTIONCentralised coolant temperature management 17

CCTM

244 Coolant temperature sensor (injection andcoolant temperature indication on the ins-trument panel).

Three-way sensor, two for the coolant tem-perature information and 1 for the indica-tion on the instrument panel.

This system is fitted with a single coolant tempera-ture sensor which is used by the injection, the fanassembly and the temperature warning light onthe instrument panel.

Operation

Sensor 244 enables:- the coolant temperature to be indicated on the

instrument panel,- the injection computer to be informed of the

engine coolant temperature.

Depending on the coolant temperature, the injec-tion computer controls:- the injection system,- the fan assembly relays:

• the fan assembly is controlled at low speed ifthe coolant temperature exceeds 99 °C andstops when the temperature falls below96 °C,

• the fan assembly is controlled at high speedif the coolant temperature exceeds 102 °Cand stops when the temperature falls below99 °C,

• the fan assembly may be controlled for theAC and in the event of a temperature sensorfailure.

- the coolant temperature warning light.

In the event of failure of the coolant temperaturesensor, the fan assembly is controlled continuous-ly at low speed.

COOLANT TEMPERATURE WARNING LIGHT

The coolant temperature warning light is control-led by the injection computer if the coolant tem-perature exceeds 118 °C.When the ignition is switched on, the warninglight illuminates for a few seconds.

The engine overheating warning light flashes inthe event of a major HP injection system fault.

15615S

17-18

INJECTIONComputer 17

ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS

1 → IGNITION COIL 2-3 CONTROL

3 --- POWER EARTH

4 → CANISTER PURGE CONTROL

6 → FUEL PRESSURE REGULATOR CONTROL

8 → FAN ASSEMBLY 1 RELAY CONTROL

9 → COOLANT TEMPERATURE WARNING LIGHT

10 → AC COMPRESSOR CONTROL

11 → FUEL CONSUMPTION OUTPUT INFORMATION

12 → IDLE REGULATOR CONTROL (TRACK B)

13 ← COOLANT TEMPERATURE SENSOR INPUT

15 --- PRESSURE SENSOR EARTH

32 → IGNITION COIL 1-4 CONTROL

33 --- POWER EARTH

34 → OBD WARNING LIGHT CONTROL

37 → FAULT WARNING LIGHT CONTROL

38 → FAN ASSEMBLY 2 RELAY CONTROL

39 → ACTUATOR RELAY CONTROL

41 → IDLE REGULATOR CONTROL (TRACK A)

42 → IDLE REGULATOR CONTROL (TRACK C)

43 ← THROTTLE POTENTIOMETER SIGNAL

44 ← DOWNSTREAM OXYGEN SENSOR SIGNAL

45 ← UPSTREAM OXYGEN SENSOR SIGNAL

62 → EGR VALVE CONTROL

63 → UPSTREAM OXYGEN SENSOR HEATING CONTROL

65 → DOWNSTREAM OXYGEN SENSOR HEATING CONTROL

66 --- +AFTER IGNITION

68 → FUEL PUMP RELAY CONTROL

70 → TDC ENGINE SPEED INFORMATION

72 → IDLE REGULATOR CONTROL (TRACK D)

73 --- COOLANT TEMPERATURE SENSOR EARTH

74 --- THROTTLE POTENTIOMETER AND FUEL PRESSURESENSOR SUPPLY

75 --- THROTTLE POTENTIOMETER AND FUEL PRESSURESENSOR EARTH

PRO15097

17-19


ALLOCATION OF INJECTION COMPUTER INPUTS AND OUTPUTS (cont)

16 ← MANIFOLD PRESSURE SENSOR SIGNAL INPUT

18 ← EGR VALVE POSITION SIGNAL

19 --- KNOCK SENSOR SHIELDING

20 ← KNOCK SENSOR SIGNAL INPUT

23 ← AC COMPRESSOR POWER ABSORBED INFORMATION

24 ← ENGINE SPEED SENSOR SIGNAL INPUT

26 --- DIAGNOSTICS

27 --- INTER-COMPUTER CONNECTION

28 --- POWER EARTH

29 --- +AFTER IGNITION

30 --- +BEFORE IGNITION

46 ← CAMSHAFT SENSOR SIGNAL

49 ← AIR TEMPERATURE SENSOR INPUT

53 ← VEHICLE SPEED INPUT

54 ← ENGINE SPEED SENSOR SIGNAL INPUT

56 --- DIAGNOSTICS


58 ← ENGINE IMMOBILISER SYSTEM

59 → INJECTOR 1 CONTROL (TO CONTROL COMPUTER)


76 ← DOWNSTREAM OXYGEN SENSOR SIGNAL

77 --- AIR TEMPERATURE SENSOR EARTH

78 --- PRESSURE SENSOR SUPPLY

79 --- KNOCK SENSOR EARTH

80 --- UPSTREAM OXYGEN SENSOR EARTH

82 --- EGR VALVE EARTH

83 --- EGR VALVE SUPPLY

85 → POWER STEERING PRESSURE SWITCH INFORMATION


88 ← ELECTRIC HEATED WINDSCREEN SIGNAL



PRO15097

17-20


ALLOCATION OF INJECTOR CONTROL COMPUTER INPUTS AND OUTPUTS


2 ← INJECTOR 3 CONTROL INFORMATION (COMPUTER)


4 → TDC INFORMATION


22 --- POWER EARTH

23 --- POWER EARTH

25 --- + AFTER IGNITION







34 --- + BEFORE IGNITION

35 → INJECTOR 1 CONTROL








51 --- POWER EARTH

PRN15557

17-21

INJECTIONWiring diagram 17

16414G

17-22


16414D

17-23


PARTS LIST

104 Engine immobiliser system107 Battery120 Injection computer146 Knock sensor147 Air temperature sensor193, 194195, 196 Injectors199 Fuel gauge222 Throttle potentiometer224 Power steering pressure switch225 Diagnostic socket242 Oxygen sensor244 Coolant temperature sensor247 Instrument panel250 Speed sensor272 Air temperature sensor273 Speed threshold sensor371 Canister solenoid valve419 AC control unit565 Throttle housing597 Engine compartment fuse box and relays645 Passenger compartment ECU transponder777 Power fuse board778 Ignition coil927 Impact sensor

17-24

COOLINGFilling - Bleeding 19

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

FILLING

Open the bleed screw located on the plenumchamber.

Fill the circuit via the expansion bottle opening.

Close the bleed screw when the liquid starts toflow in a continuous stream.

Start the engine (2,500 rpm).

Adjust the level by overflow for approximately4 minutes.

Close the reservoir.

BLEEDING

Run the engine for 20 minutes at 2,500 rpm, untilthe fan(s) cut in (time required for automatic de-gassing).

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

DO NOT OPEN THE BLEED SCREW WHILE THEENGINE IS RUNNING.

RETIGHTEN THE EXPANSION BOTTLE PLUG WHILETHE ENGINE IS WARM.

Location of the bleed screw (1) on the plenumchamber

15615R6

19-1

COOLINGDiagram 19

1 Engine2 Radiator3 "Warm" reservoir with degassing in line with

thermostat4 Heater matrix5 Thermostat support6 ∅ 3 mm nozzle7 ∅ 8 mm nozzle

Coolant pump

Thermostat

Bleed screw

The expansion bottle valve calibration value is 1.6bar (brown).

14887-2R1

19-2

COOLINGCoolant pump 19

REMOVAL



Drain the cooling circuit via the lower engine ra-diator hose.

Remove:- the right-hand mud shield and the two engine

undertrays,- the accessories belt (see section 07 "Accessories

belt tensioning"),- the lower timing cover mounting bolt and

move it aside,- the coolant pump pulley,- the coolant pump.


Mot. 1202 Circlip pliers


Coolant pump bolt 1.7

Cleaning

It is very important that the mating surfaces arenot scratched.

Use the Décapjoint product to dissolve the part ofthe seal which remains attached.

Apply the product to the section to be cleaned,wait approximately ten minutes, then remove itusing a wooden spatula.

It is advisable to wear gloves during the opera-tion.

Do not allow any of the product to fall onto thepaintwork.

REFITTING

Refit:- the coolant pump (fitted with a new seal) tigh-

tening the bolts to a torque of 1.7 daN.m,- the accessories belt an tension it (see section 07

"Accessories belt tensioning").

Fill and bleed the cooling circuit (see section 19"Filling - Bleeding").

19-3

COOLINGCatalytic converter 19

REMOVAL



Remove the mounting nuts of the connection ofthe manifold and the catalytic converter.

Slacken the catalytic converter / exhaust lineconnecting clamp to move the catalytic converterback a few centimetres.

Remove:- the steering shaft yoke bolt,


T.Av. 1233 -01 Tools for working on the sub-frame - axle

- the sub-frame tie-rod mounting bolts and lo-wer the sub-frame by 40 mm at the front and90 mm at the rear,

97390-1S1

15870R

- the catalytic converter.

REFITTING

Change the catalytic converter/exhaust manifoldconnection seal and the exhaust clamp.

IMPORTANT: ensure that the steering shaft yokebolt is positioned correctly.

19-4

CLUTCHCover - Disc 20

VEHICLETYPE

ENGINETYPE

COVER DISC

DA0 3EA0 3

F5R 740

215 CPON 4400

26 splines VM : Moss GreenD = 215 mm V : GreenE = 6.8 mm BC : Capri Blue

BL : Light Blue

85873S

90693-2R1694990R1

Monodisc clutch operating dry, cable controlled.

Clutch stop in constant contact.

20-1


REMOVAL

Fit immobilising tool Mot. 582-01.

Remove the cover mounting bolts and remove theclutch disc.

Check and change any faulty parts.


Mot. 582 -01 Immobilising tool

TIGHTENING TORQUE (en daN.m)

Cover mounting bolt 2

REFITTING

Clean the clutch shaft splines and refit the assem-bly without any lubricant.

Fit the disc (hub offset gearbox side).

Align it.

REPLACEMENT (following removal of the gearbox)

95414S

Gradually screw in the bolts in a star formation,then tighten the cover mounting bolts to the spe-cified torque.

Remove immobilising tool Mot. 582-01.

Coat with MOLYKOTE BR2 grease:- the tube guide,- the fork pads.

99055R1

20-2


After refitting the gearbox, place the cable on theclutch fork and check the operation of the playcompensation system.

Check the clutch release travel.

The fork travel should be:

X = 25.4 to 25.9 mm

97758-1R

NOTE: in the event of an operation which doesnot require removal of the gearbox, or after fit-ting the gearbox, DO NOT LIFT the fork as it maycome free of the notch (A) of the stop.

99054R

20-3

CLUTCHFlywheel 20

REMOVAL

After removing the clutch disc, remove the engineflywheel mounting bolts (the bolts cannot be reu-sed).

Reworking of the clutch face is prohibited.

REFITTING

Clean the flywheel mounting bolt threads on thecrankshaft.

Degrease the contact surface of the flywheel withthe crankshaft.

Refit the flywheel immobilising it using toolMot. 582-01.

COMMENT: the flywheel mounting bolts must al-ways be replaced.


Mot. 582-01 Immobilising tool

Flywheel bolt 5.5


REPLACEMENT OF THE FLYWHEEL

20-4

MANUAL GEARBOXIdentification 21

"MEGANE" vehicles with F5R engines are fitted with JC5 manual gearboxes.

Workshop Repair Manual "B.V. JB/JC" deals with the complete repair of this component.

14834-1R

A mark (1), located on the gearbox casing, indi-cates:

A Type of gearboxB Gearbox indexC Manufacturing numberD Factory of manufacture

90775R

0 0 0JCX

X 0 0 0 0 0 0

B

C

A

D

Gears

JC5

Index VehicleStep down

ratio

Speedo-meter drive

gear1st 2nd 3rd 4th 5th Reverse

gear

106 DA0 3EA0 3

16--57

Withoutspeedo-meter

11-- 41

21--43

28--39

31--34

42-- 31

11--39

21-1

MANUAL GEARBOXCapacity - Lubricants

CAPACITY (in litres)

21

LEVEL CHECK

Fill to the level of the opening.

5-speed gearbox

JC5 3.1

Grade - Viscosity

TRX 75W 80W

92081S

21-2

Parts which must always be changed

MANUAL GEARBOXConsumables 21

TYPE PACKAGING

LOCTITE 518

LOCTITE FRENBLOC(locking and sealingresin)

24 ml syringe

100 g tube

24 cc vial

PART NUMBER

77 01 404 452

77 01 394 071

UNIT

77 01 421 162 Casing assembly surfaces

Threaded plugs and switchesBearing plugsEnds of the roll pins on the driveshafts

Input and output shaft nutsFixed gear and hub of 5th

Differential lock drive stud

Right-hand sun wheel splines

Fork pivotStop guideFork pads

MOLYKOTE BR2 77 01 421 1451 kg box Clutch

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

RHODORSEAL 5661

21-3

MANUAL GEARBOXSpecial features 21

The removal and refitting of the gearbox remainsidentical and does not present any difficulties inrelation to MEGANE vehicles fitted with a "JB"gearbox and "K4M and K4J" petrol engines.

NOTE: when refitting the gearbox, it is preferableto support the clutch control fork using string (1)to prevent it from coming free from its ball joint(located on the clutch housing).


Drain plug 2.2Brake caliper bolt 3.5Driveshaft gaiter bolt 2.5Lower ball joint nut 6.5Shock absorber base bolt 17Gearbox surround and starter bolt 3Suspended engine mounting to gearbox bolt 6Wheel bolt 10

14834R

21-4

REAR BEARING ELEMENTSHub / Brake disc 33

99582S

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

Caliper mounting bolt 6Wheel bolt 10Stub axle bolt 17.5


REMOVAL

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

- the stub axle nut,

- the disc.

REFITTING

Fit the hub/disc and secure it using the stub axlenut.

Tighten the nut to the specified torque.

Coat the bolt with Loctite FRENBLOC.

Fit the caliper and tighten the bolts to the speci-fied torque.

Press the brake pedal several times to bring thepiston into contact with the linings.

99583-1R1

33-1

REAR BEARING ELEMENTSHub/disc bearing 33

16214R

Caliper mounting bolt 6Wheel bolt 10Stub axle nut 17.5



REMOVAL

Remove:- the brake/hub disc; to do this refer to the pro-

cedure described on the previous page,- the circlip.

By means of a press, remove the bearing usingtubes (A) and (B).

16215R

NOTE: ensure that the disc is positioned correctlyfor the removal of the bearing. The ABS crownwheel should be facing upwards.

REFITTING

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

IMPORTANT: ensure that the bearing is positio-ned correctly: the dust cover should be at the rear.

NOTE: the bearing dust cover plastic protectorshould be removed at the last moment.

Refit:- the circlip,- the hub/disc.

33-2

STEERING ASSEMBLYMechanical power steering pump


Mot. 453 -01 Hose clamps


REMOVAL


Remove the accessories belt (see section 07"Accessories belt tensioning procedure").

Fit a clamp Mot. 453-01 on the supply pipe.

Disconnect the high and low pressure pipes, beprepared for the flow of power steering fluid.

Remove:- the pulley (3 bolts),- the power steering pump (4 bolts).

36

REFITTING


Fill and bleed the circuit turning from lock to lockwith the engine running.

NOTE: the power steering pump cannot be repai-red. In the event of a fault, change it.

The power steering pump pressure should be bet-ween 86 and 93 bars.

16213S

36-1

STEERING ASSEMBLYMechanical power steering pump


Dir. 1083 -01 Tool for refitting the pulley

T.Ar. 1094 Tool for extracting differential

bearing

REPLACEMENT OF THE HUB

Place the pump on the workbench, in a vice.

Fit tool T.Ar. 1094 and extract the hub.

36

14837R

14836R

NOTE: insert a bolt (1) between the pump shaftand the push rod of tool T.Ar. 1094.

Position the hub (new) and fit it using tool Dir.1083-01. Coat it with multipurpose grease first tomake refitting easier.

NOTE: insert a shim (2) of approximately 25 mmbetween tool Dir. 1083-01 and the hub.

Observe the fitting dimension:X = 41.5 mm

2

1

X

1 Power steering pump2 Hub

36-2

STEERING ASSEMBLYPower steering unit


T.Av. 476 Tool for extracting ball joints

Mot. 453 -01 Hose clamps

36

16209S

Wheel bolt 10

Universal joint bolt 2.5

Engine tie-bar nut:- on gearbox 6.5- on sub-frame 7.5

Steering unit to sub-frame mounting nut 5

Steering ball joint nuts 3.5



REMOVAL


Remove:- the two wheels,- the engine undertray.

Disconnect the steering ball joints using tool T.Av.476.

In the engine compartment:

Fit hose clamps Mot. 453-01 onto the power stee-ring reservoir hoses.

Remove the air filter unit.

Disconnect the high and low pressure pipes on thesteering unit. Plug the pipes to prevent the entryof impurities.

Remove the universal joint bolt. To do this, directthe nut upwards and fit a steering wheel immobi-lising tool to retain the same position for refitting.

36-3

STEERING ASSEMBLYPower steering unit 36

16210S

Underneath the vehicle:

Remove the front engine tie-bar bolt.

Uncouple:- the exhaust downpipe from the exhaust assem-

bly,- the gearbox control lever.

Fit a shim to move the engine forwards.

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

16212S

16211S

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

Removal of the tie-rod makes it possible to re-move the steering unit easily.

Remove the steering unit from the left-handscuttle panel side by means of successive rotationsto detach the steering with its valve/ram pipes.

Never unscrew the steering rack axial ball jointsunless they are to be changed.

If a steering unit is to be changed, the steeringball joints must be retained.

36-4

STEERING ASSEMBLYPower steering unit 36

REFITTING

In the case of a new steering assembly

Fit the steering ball joints.

Refit in the reverse order to removal observingthe tightening torques.

Bleed the power steering circuit, turning fromlock to lock with the engine running.

NOTE: it is ESSENTIAL to observe the marking ofthe steering ball joints (one mark for the right-hand ball joint, two marks for the left-hand balljoint).

Adjust the parallelism if necessary.

36-5

MECHANICAL COMPONENT CONTROLSMaster cylinder 37

Pipes on master cylinder 1.7Mounting nuts on brake servo 2.3


REMOVAL



91101R

NOTE: these vehicles are fitted with a master cy-linder incorporated in the brake servo. The sealingof the brake servo is directly connected to themaster cylinder. When carrying out any work, anew seal (A) must be fitted.

Position the master cylinder in alignment with thebrake servo so that the push rod (P) correctly en-ters the master cylinder location.


DI3718

REFITTING


Check the length of the push rod.

Dimension X = 22.3 mm.

Adjustment according to model using rod (P).

16209S

Move aside the expansion bottle.

Disconnect the accelerator cable.

Drain the brake fluid reservoir and remove it.

Disconnect the pipes on the master cylinder mar-king their position.

Remove the two master cylinder mounting boltsand remove it.

37-1

MECHANICAL COMPONENT CONTROLSMaster cylinder 37

Fill the brake fluid reservoir and bleed the brakecircuit.

MASTER CYLINDER (REPLACEMENT)

The kit sold by the Parts Department consists of:- a master cylinder (four outlets or two outlets in

the case of ABS),- two plugs (A),- two mounting nuts (B).

DI3719

37-2

MECHANICAL COMPONENT CONTROLSBrake servo

TIGHTENING TORQUES (en daN.m)

Pipes on master cylinder 1.7Mounting nuts on brake servo 2.3Brake servo nuts on bulkhead 2

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

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

REMOVAL



37

Move aside the expansion bottle.

Disconnect the accelerator cable.

Remove:- the master cylinder (see previous page),

16209S

Unhook the clutch fork cable.

89204S

Disconnect the vacuum hose on the brake servo.

16208R

37-3


REFITTING

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

In the passenger compartment

Remove the pin (A) of the yoke connecting thebrake pedal to the push rod by acting on the clip,

37

91101R2

97860R


Before refitting the clutch pedal, coat the pin andthe grooved sector with grease.

Ensure that the clutch cable is positioned correctlyon the grooved sector.

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

PRG37.9

Remove the pin to detach the clutch and brakepedals.

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

It is necessary to remove the pedals to gain accessto the mounting nuts securing the brake servo tothe bulkhead.

Remove:- the four brake servo mounting nuts,- the brake servo.

37-4

MECHANICAL COMPONENT CONTROLSBrake servo 37

Refit the cable on the clutch fork.

Check that the assembly operates correctly.

With the pedal at rest, in the clutch engagedposition, pull the cable at the clutch fork on thegearbox.

The cable should have at least 2 cm "slack".

Check the fork travel.

It should be: X = 27.4 to 30.7 mm.

89204S

91830R1

Bleed the brake circuit.

37-5

The sealing of the brake servo must be checked onthe vehicle.

Fit Mot. 1311-01 between the brake servo and thevacuum source (inlet manifold).


SEALING CHECK

When checking the sealing of the brake servo, ensure that the sealing between the brake servo and the mas-ter cylinder is perfect. If there is a leak, change seal (A) (refer to the procedure described on page 37-1).

37

14287R

- assemble the pipes with the connecting "T",the vacuum pressure gauge and the assembly(1) (use union B from kit Mot. 1311-01 and aclamp with a worm screw (2)).

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

ving the clamp,


Mot. 1311-01 Pressure gauge and unions for

measuring pressure

14216R

14213R

- position the assembly connecting the valve onthe brake servo on one side and the manifoldoutlet pipe on the other.

NOTE: ensure that the closing valve is on the ma-nifold side.

Run the engine at idle for one minute.

Close the valve and switch off the engine.

The vacuum in the circuit is approximately613 mbar, if the vacuum falls to 33 mbar in 15 se-conds, there is a leak which may be located either:- at the check valve (change it),- at the push rod diaphragm (in this case, change

the brake servo).

37-6

AIR CONDITIONINGGeneral 62

CONSUMABLES

- DELPHI HARRISON V5 compressor oil:PLANETELF PAG 488 : 220 cm3 ± 15(to be ordered from ELF)

- Refrigerant:R134a : 750 g ± 30

- Compressor:DELPHI HARRISON V5

62-1

AIR CONDITIONINGCompressor 62

Pressure relief valve on evaporator bolt 0.6

Connecting pipes on pressure relief valvenut 0.8

Connecting pipes on dehydration canister

retaining bolt 0.8

Connecting pipes on condenserretaining bolt 0.8

Condenser connecting pipe on compressorretaining bolt 0.8

Pressure relief valve connecting pipe oncompressor retaining bolt 0.8

Compressor retaining bolt 2.1

Circuit pressure sensor 0.8

TIGHTENING TORQUES (In daN.m)

REMOVAL

Drain the R134a refrigerant circuit using the fil-ling equipment.


Remove:- the wheel arch protector,- the accessories belt.

Move aside the power steering reservoir.

Disconnect the compressor clutch.

15575R

REFITTING

Check the condition of the seals and coat themwith oil.

If the compressor is changed, it is supplied filledwith oil.


Create a vacuum, then fill the R134a refrigerantcircuit using the filling equipment.

IMPORTANT: when changing the compressor, it isessential to top up the oil correctly.

Remove the two R134a connecting pipes (B) onthe compressor.

Fit plugs to prevent the entry of moisture.

Remove:- the four fasteners (B) of the power steering

pump assembly with its support then move itaside on the engine,

- the compressor from above (3 bolts).

62-2

AIR CONDITIONINGCondenser 62

REMOVAL



Remove:- the air inlet on the upper crossmember,- the six upper crossmember mounting bolts,

- the mounting nut of the connecting pipes onthe condenser.

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

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

98838S


Remove the two cooling assembly upper faste-ners.

15975R

15901R1

62-3

AIR CONDITIONINGCondenser 62

REFITTING




IMPORTANT: when changing the compressor add30 ml of oil to the circuit.

62-4

AIR CONDITIONINGConnecting pipes 62

PRG62.2

LOW PRESSURE PIPE

REMOVAL



Remove:- the air filter unit,- the air filter unit support,- the connecting pipes on pressure relief valve

retaining bolt.

Move aside the power steering reservoir.

Remove the mounting bolt securing the low pres-sure pipe on the compressor.


Remove the pipe.

REFITTING




IMPORTANT: when changing a pipe, add 10 ml ofoil to the circuit or if a pipe bursts (rapid leak), add100 ml of oil.

HIGH PRESSURE PIPE BETWEEN THE PRESSURERELIEF VALVE AND THE DEHYDRATION CANISTER

REMOVAL



Remove:- the air filter unit,- the air filter unit support,- the connecting pipes on pressure relief valve re-

taining bolt.- the mounting bolt which secures the pipes on

the dehydration canister.


PRG62.4

Unclip the pipe from the body and remove it.

REFITTING




IMPORTANT: when changing a pipe, add 10 ml ofoil to the circuit or if a pipe bursts (rapid leak), add100 ml of oil.

62-5

Special Features of the f5r 740 Engine(1)

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Transcript of Special Features of the f5r 740 Engine(1)