VNX - Su Master Propulsion 2003

General Information
MECHANICAL SPECIFICATIONS FOR THE

VEHICLE
TOWING - LASHING
OIL CHANGE
ENGINE AND TRANSMISSION ASSEMBLY
VALUES AND ADJUSTMENT
AXLE ASSEMBLIES VALUES AND
ADJUSTMENT
XHXB - XHXE - XHXF - XHXG
77 11 320 002
"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer
in the production of the various component units and accessories from which his
vehicles are constructed.
FEBRUARY 2003
All copyrights reserved by Renault.
EDITION ANGLAISE
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of Renault.
RENAULT 2002
vnx.su
General
Information
Contents
Page
01A
03A
MECHANICAL SPECIFICATIONS
FOR THE VEHICLE
Engine - Clutch - Gearbox 01A-1
TOWING - LASHING
All types 03A-1
Page
05A
07A
07B
OIL CHANGE
Engine 05A-1
Gearbox 05A-2
Power assisted steering 05A-3
ENGINE AND TRANSMISSION
ASSEMBLY VALUES AND
ADJUSTMENT
Dimensions 07A-1
Capacity - Grade 07A-4
Alternator belt tension 07A-6
Cylinder head tightening 07A-7
AXLE ASSEMBLIES VALUES AND
ADJUSTMENT
Wheels and tyres 07B-1
Brakes 07B-2
Front axle geometry checking values 07B-3
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SPECIFICATIONS
Engine- Clutch - Gearbox
01A
01A-1
101A
SPECIFICATIONS
Vehicle type Engine Gearbox type
Type Cubic capacity (cm
3
)
XHXE S9W206 2800 ZF S5.200
ZF S6.300
XHXF S9W208 2800
ZF S6.300
XHXG S9W212 2800
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SPECIFICATIONS
01A
01A-2
A Vehicle type
a = Engine family
b = Vehicle type
B Engine serial number
Table of comparison of engine codes:
RENAULT code IVECO code
S9W206 8140.43B
S9W208 8140.43S
S9W212 8140.43N
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TOWING - LASHING
All types
03A
03A-1
103A
TOWING - LASHING
All types
WARNING:
Observe the national regulations concerning towing for
each country.
Never use the driveshafts as an attachment point.
The towing points may only be used for towing the
vehicle on the road.
Never use the towing points for removing the vehicle
from a ditch or to lift the vehicle, either directly or
indirectly.
The vehicle is towed using the tow hitch (1).
Over a maximum distance of 60 miles (100 km): the
gearbox must be in neutral and the maximum
authorised towing speed is 37 mph (60 km/h).
Over a distance above 60 miles (100 km) or if the
gearbox is damaged: the longitudinal driveshaft must
be disconnected at the final drive.
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FLUID CHANGE AND REFILLING
Engine
05A
05A-1
105A
Engine
DRAINING
1 Plug
2 Oil filter
FILLING
3 Gauge
4 Plug
Essential equipment
Sump plug spanner
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Gearbox
05A
05A-2
Gearbox
S5.200 gearbox
S6.300 gearbox
1 Fuel filler and level cap
2 Drain plug
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Power assisted steering
05A
05A-3
Power assisted steering
CHECKING THE LEVEL
Use STARMATIC 3 oil for topping up or refilling
The level, when correct, should be visible between the
MIN and MAX marks on the reservoir (2).
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ENGINE AND GEARBOX ASSEMBLY VALUES AND ADJUSTMENT
Dimensions
07A
07A-1
107A
Dimensions
Cab chassis
Dimensions in metres:
L1 L2 L3 L4
A 3.130 3.630 4.130 4.630
B 0.949
C 0.950 0.950 1.242 1.807
D 5.029 5.529 6.321 7.386
E 1.678
F (unloaded) 2.277 2.275 2.271 2.268
G 1.600
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Dimensions
07A
07A-2
Cab chassis
L2 L3 L4
A 3.630 4.130 4.630
B 0.949
C 0.950 1.578 2.282
D 5.529 6.657 7.861
E 1.678
F (unloaded) 2.279 2.274 2.270
G 1.600
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Dimensions
07A
07A-3
VAN
L2 L3
A 3.630 4.130
B 0.949
C 1.398
D 5.977 6.477
E 1.678
F (unloaded) 2.753 2.751
G 1.600
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Capacities - grades
07A
07A-4
Capacities - grades
NOTE: never go past the MAX mark on the oil gauge.
Brake fluids must be approved by the Technical Department.
Engine
Average capacity (adjust with gauge) (1)
Draining Draining with oil filter replacement
S9W 5.2 6.3
Gearbox Final drive
S5.200 S6.300 569 669
Capacity 2.2 2.7 4.2 5.5
Brake circuit Capacity in litres Grade
Normal bleed 1
SAE J 1703 and DOT 4
Bleeding the regulation circuit 1
Components Capacity in litres Grade
Fuel tank
75, 100, 140
depending on vehicle
Diesel
Power assisted steering 1.5
ELF RENAULT MATIC D2 or
MOBIL ATF 220
Cooling circuit 12
GLACEOL RX (type D)
Add coolant only
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Capacities - grades
07A
07A-5
REMOVAL
Place the vehicle on axle stands.
Disconnect the battery.
Remove:
the air filter unit,
the engine undertray,
cooling assembly (see Section 19A Cooling,
Cooling assembly).
Loosen the bolts (1) and the lock nut (2) on the tension
wheel.
Slacken the belt by loosening the bolt (3).
Remove the belt.
REFITTING
Refit the air conditioning compressor.
Proceed in the reverse order to removal.
Note:
Never refit a belt once it has been removed, always
replace it.
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Alternator belt tension
07A
07A-6
Alternator belt tension
REMOVAL
Remove:
the cooling assembly (see Section 19A Cooling,
Cooling assembly).
the air conditioning belt (see Section 07A Values
and settings of the engine and transmission
assembly, Air conditioning belt tension) if the
vehicle is fitted with air conditioning.
To remove the belt, pivot the automatic belt tensioner
in the direction shown below using a 15 mm angled
ring spanner.
Remove the alternator belt.
REFITTING
Note:
Never refit a belt once removed, always replace it.
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Tightening the cylinder head
07A
07A-7
Tightening the cylinder head
CYLINDER HEAD
Always replace bolts with a thread diameter of less
than 11.5 mm.
Cylinder head tightening procedures
Lubricate the thread of the cylinder head bolt and the
washers beneath the head with engine oil.
Tighten all the bolts in order and to torque (6 daNm).
Check that all the bolts are correctly tightened to
6 daNm then, bolt by bolt, tighten to an angle of
180 10.
Do not retighten the cylinder head bolts after
performing this procedure.
Note:
In order to ensure that the bolts are correctly
tightened, use a syringe to remove any oil which may
be in the cylinder head mounting holes.
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VALUES AND SETTINGS OF AXLE ASSEMBLIES
Tyres and wheels
07B
07B-1
107B
Tyres and wheels
wheel nut tightening torque: 36 daNm.
Pressure values are given as guidelines. The values given are for a fully laden vehicle or for motorway driving. For
vehicles with a chassis to be fitted with equipment which is likely to alter the axle loads, refer to the manufacturer's
information relating to the type, brand and operation of the vehicle.
Tyre pressures must be checked when cold. The increase in temperature during driving increases the pressure by
0.2 to 0.3 bar.
If the pressure is checked when the tyres are warm, take this increase into account and never deflate the tyres.
Type of tyre Axle load in N for each assembly
Tyre inflation pressure
in Bar
185/75 R16 C
Single wheel Twin wheel
1300 2440 3.0
1480 2760 3.5
1800 3400 4.75
185/75 R16
1480 3760 3.5
1640 3080 4.0
1800 3400 4.75
195/65 R16 C
1440 2660 3.5
1600 3020 4.0
1745 3295 4.5
1800 3400 4.75
195/75 R16 C
1350 2565 3.0
1560 2965 3.5
1760 3345 4.0
1950 3700 4.75
205/75 R16 C
1520 2850 3.0
1820 3420 3.75
2120 4000 4.75
205/80 R15 P 1600 3000 7.25
215/75 R16 C
(6 tonne vehicle)
1660 3080 3.0
1880 3520 3.5
2300 4360 4.75
215/75 R16 C
(6.5 tonne vehicle)
2040 3920 4.0
2300 4360 4.5
2500 4720 5.25
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Brakes
07B
07B-2
Brakes
Vehicle
Disc thickness (in mm) Disc thickness (in mm)
Maximum disc
run-out (in mm)
Front Rear
Standard Minimum Standard Minimum
3.5 to 5 T 22 19
22 19 0.02
5.5 to 6.5 T 26 23
Vehicle
Lining thickness (in mm) (mounting included)
Brake fluid Front Rear
New Minimum New Maximum
ALL TYPES 20 7 20 7 SAE J 1703
DOT 4
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Front axle checking values
07B
07B-3
Front axle checking values
GEOMETRY VALUES POSITION
OF FRONT
AXLE (mm)
ADJUSTMENT
CASTOR
612' 20' Unladen Not adjustable
CAMBER
1 20' Unladen Not adjustable
PIVOT
645' 5' Unladen Not adjustable
WHEEL ALIGNMENT
-025' Unladen
Adjust by rotating the connecting
rod.
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Engine and peripherals
ENGINE AND PERIPHERALS
TOP AND FRONT OF ENGINE
DIESEL INJECTION
STARTING/CHARGING
COOLING SYSTEM
FUEL TANK
ENGINE MOUNTING
77 11 320 022
vehicles are constructed."
FEBRUARY 2003
All copyrights reserved by RENAULT.
EDITION ANGLAISE
reference numbering system is forbidden without the prior written authority of
RENAULT.
RENAULT 2003
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Engine
and peripherals
Contents
Page
10A
11A
13B
16A
ENGINE AND PERIPHERALS
Identification 10A-1
Oil consumption 10A-2
Oil pressure 10A-3
Engine and gearbox 10A-4
Timing belt 11A-1
Cylinder head gasket 11A-6
DIESEL INJECTION
Features 13B-1
Special notes 13B-3
Location of components 13B-5
Cleanliness 13B-8
Diesel prefilter 13B-9
High-pressure pump 13B-10
Injector 13B-12
Injector rail 13B-15
Pressure sensor 13B-18
Diesel temperature sensor 13B-19
Clogging gauge sensor 13B-20
Accelerator potentiometer 13B-21
Computer 13B-22
Injection warning light 13B-23
Computer track allocation 13B-24
STARTING - CHARGING
Alternator 16A-1
Starter 16A-2
Page
19A
19C
19D
COOLING SYSTEM
Specifications 19A-1
Filling - Bleeding 19A-2
Check 19A-3
Diagram 19A-4
Radiator 19A-5
Cooling system 19A-6
Water pump 19A-8
FUEL TANK
General information 19C-1
Fuel tank 19C-2
Filler neck 19C-3
Fuel gauge 19C-4
ENGINE MOUNTING
Suspended engine mounting 19D-1
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ENGINE ASSEMBLY AND PERIPHERALS
Identification
10A
10A-1
110A
Identification
Vehicle type Engine Gearbox Cubic
capacity (cm
3
)
Bore
(mm)
Stroke
(mm)
Compression
ratio
XHXE S9W206
ZF S5.200
ZF S6.300
2800 94.4 100 21.7:1
XHXF S9W208 ZF S6.300 2800 94.4 100 21.7:1
XHXG S9W212 ZF S6.300 2800 94.4 100 21.7:1
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Oil consumption
10A
10A-2
Oil consumption
OIL CONSUMPTION MEASUREMENT
PROCEDURE
a) Topping up to the maximum level
The operation must be performed with a warm
engine (after the cooling fan has cut in) and after
a stabilisation period of 15 minutes so that the oil
flows into the sump completely.
Check using the dipstick.
Top up to the MAX mark.
Seal the drain plug (with a paint mark on both the
filler plug and the sump drain plug) in order to be
able to check later that it has not been removed.
b) Customer driving
Ask the customer to drive for approximately
1 200 miles (2 000 km) or wait until the MIN level
is reached.
c) Topping up to the MAX level
The operation must be performed with a warm
engine (after the cooling fan has cut in) and after
a stabilisation period of 15 minutes.
Check using the dipstick.
Top up to the MAX level.
Note the quantity of oil used and mileage driven
since the last top up to MAX level.
d) Measurement of oil consumption
OIL CONSUMPTION =
Additional oil quantity (in litres)
miles (in thousands)
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Oil pressure
10A
10A-3
Oil pressure
CHECKING
The pressure check must be made when the engine is
warm (cooling fan in operation).
Contents of the kit (Mot. 836-05).
USE
MEASURE WITH TOOL (MOT. 836-05)
Remove the oil pressure sensor located behind the
alternator and fit tool (Mot. 836-05).
Special tooling required
Mot. 836-05 Oil pressure measuring kit
Engine speed in rpm Pressure in bar
750 0.8
4000 3.5
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Engine and gearbox
10A
10A-4
Engine and gearbox
REMOVAL
Remove the side sills.
Remove the engine and gearbox undertrays.
Remove:
the battery,
the indicators,
the lamp units,
the radiator grille,
the air filter,
the upper cross member (1),
the bumper (2).
Mot. 1202-01
Pliers for large hose clips
Mot. 1202-02
Mot. 1448 Remote operation pliers for cooling
system hose clips
Mot. 1390 Adjustable engine support tool
Mot. 1709 Addition for engine support
Tightening torques
longitudinal driveshaft mounting bolt 10 daNm
suspended mounting mounting bolt 5.2 daNm
gearbox support mounting bolt 2.8 daNm
wheel bolt 36 daNm
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Engine and gearbox
10A
10A-5
Remove the front cross members (3) and (4).
Drain:
the cooling circuit using the charge station (if fitted to
the vehicle),
the cooling system through the radiator bottom hose
the gearbox and engine if necessary.
Remove the mounting bolt (5) from the expansion
valve air conditioning pipes flange.
Remove the mounting bolt (6) from the expansion
valve air conditioning pipes.
Remove:
the bolt (7) from the air conditioning pipes flange on
the condenser,
the mounting bolts (8) from the condenser pipes.
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Engine and gearbox
10A
10A-6
Disconnect:
the air hoses on the intercooler,
the cooling hoses.
Remove:
the fan assembly bellows clamp,
the cooling assembly mounting bolts.
Remove the cooling assembly.
Remove:
the diesel filter connectors,
the diesel filter.
Disconnect the inlet pipe from the diesel filter.
Disconnect:
the return pipe on the high-pressure pump,
the computer connectors.
Remove:
the expansion chamber and its support,
the battery tray,
the engine / battery separation plate.
Drain the power assisted steering circuit via the oil
inlet hose on the pump.
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Engine and gearbox
10A
10A-7
Remove:
the power steering reservoir,
the power steering reservoir mounting,
the power steering pump union.
Disconnect the connectors from the engine
interconnection unit.
Unclip fuse holders (9).
Disconnect:
the vacuum pump pipe,
the heating hoses using tool (Mot. 1448),
the earthing braids on the chassis.
Remove:
the clutch slave cylinder,
the exhaust downpipe,
the gearbox control cables.
Disconnect the gearbox connectors.
Position the engine support beneath the engine.
Remove:
the engine / gearbox separation plate,
the left and right-hand suspended mountings
mounting bolt.
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Engine and gearbox
10A
10A-8
Remove the gearbox support mounting bolt.
Lift the engine / gearbox assembly using the engine
mounting and addition (Mot 1709) to remove the
engine mountings.
Pull out the trolley until it is in contact with the axle.
Fit the load positioner.
Remove the engine/gearbox assembly.
REFITTING
Position the engine / gearbox assembly following the
same method as for removal.
Refit:
the right-hand suspended engine mounting,
the left-hand suspended engine mounting,
the gearbox support.
For information on tightening torques, see
Section 19D, Suspended mounting.
Perform the following operations:
fill the gearbox with oil,
fill the engine with oil, if necessary,
fill and bleed the cooling circuit (see Section 19A,
Filling and bleeding),
fill and bleed the power assisted steering circuit,
fill the cooling circuit with the filling station (if fitted to
the vehicle).
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Timing belt
11A
11A-1
111A
Timing belt
REMOVAL
Remove:
the air filter unit.
Drain:
the cooling circuit through the radiator bottom hose,
the refrigerant circuit using the filling station.
Remove the cooling assembly (see Section 19A,
Cooling assembly).
Remove:
the four mounting bolts (1) from the ventilator fan,
the three mounting bolts (2).
Remove the air conditioning compressor belt (see
Section 07A, Power unit values and adjustment, Air
conditioning compressor belt).
Mot. 910 High-pressure pump adjustment
gauge rod
Mot. 1054 TDC setting pin
Tightening torques
Crankshaft pulley bolt 20 daNm
Tension wheel nut 4.1 daNm
Tension wheel support bolt 2.7 daNm
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Timing belt
11A
11A-2
Remove the alternator belt (see Section 07A, Power
unit values and adjustment, Alternator belt).
Remove:
the air exchanger / inlet manifold pipe,
the lifting lug (on the intake air heater side),
the injector access flap.
Disconnect the injector connectors (3).
Remove the upper timing cover.
FITTING
Turn the crankshaft so that the camshaft pulley
mark (4) aligns with the cylinder head cover mark (5)
and the crankshaft pulley mark (6) aligns with the
cylinder housing (7).
IMPORTANT
Never turn the engine anti-clockwise while the
tension wheel is loosened. The belt could come off.
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Timing belt
11A
11A-3
Remove the exhaust downpipe.
Insert the Top Dead Centre gauge rod (Mot. 1054) in
the adjustment hole (8).
Insert gauge rod (Mot. 910) (9) into the High-Pressure
pump pulley.
Remove:
the accessories crankshaft pulley,
the lower timing cover.
Compress the timing tension wheel with a
screwdriver (10) and fit a nut cut into the shape of a
calliper behind the push rod to slacken the tension
wheel.
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Timing belt
11A
11A-4
Remove:
the tension wheel mounting bolts (11),
the tension wheel support (12),
the timing belt.
REFITTING
Check that the gauge rods (Mot. 910) and (Mot. 1054)
are in place.
Align the mark on the camshaft pulley with the mark on
the cylinder head cover.
Check that the key groove is vertical (13).
Fit the belt in the order shown.
WARNING
Check that the reels do not have any play or stiff
points when they are rotated by hand. If they do,
replace them.
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Timing belt
11A
11A-5
Apply LOCTITE 542 to the tension wheel support
bolts.
Refit the tension wheel mounting bolt to a torque of
2.7 daNm.
Release the timing tensioner.
Remove the gauge rod from the High-Pressure pump
pulley (Mot. 910) and the Top Dead Centre gauge rod
(Mot. 1054).
Provisionally refit the crankshaft pulley.
Turn the crankshaft twice in the direction of engine
rotation and check that the belt is fitted.
Remove the crankshaft pulley.
Refit the lower timing cover.
Insert the tension wheel nut.
Turn the crankshaft twice.
Loosen the tension wheel, then retighten to a torque of
4.1 daNm.
Checking the timing gear setting
Turn the crankshaft twice in the usual direction of
rotation and check the four adjustment points using
gauge rods (Mot. 910) and (Mot. 1054).
Tighten the crankshaft pulley bolts to torque
(20 daNm).
Refit:
the alternator belt,
the air conditioning compressor belt.
fill and bleed the cooling circuit (see Section 19A,
Filling/bleeding),
fill the refrigerant circuit using the filling equipment.
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Cylinder head gasket
11A
11A-6
REMOVAL
Remove:
the timing belt (see operation),
the air intake pipe,
the turbocharger air intake pipe,
the expansion bottle and its mounting,
the air filter mounting,
the turbocharging hoses,
the radiator lower and upper hoses (cylinder head
side).
Disconnect the various sensors and the air intake
heater.
Take out the air intake heater diesel pipes from the
inlet manifold.
Remove:
the lifting lug (engine flywheel side),
the oil decanter.
Remove:
the high-pressure pipes,
the diesel return pipes.
Disconnect the pressure sensor.
Mot. 910 High-pressure pump adjustment
gauge rod
Mot. 1054 TDC setting pin
Tightening torques
Crankshaft pulley bolt 20 daNm
Tension wheel nut 4.1 daNm
Tension wheel support bolt 2.7 daNm
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11A
11A-7
Remove the injectors.
Remove:
the stay between the exhaust manifold and the
cylinder cover,
the turbocharger oil return pipe,
the turbocharger oil intake pipe.
Remove the cylinder head cover.
Remove:
the cylinder head bolts,
the cylinder head.
Note:
Use a syringe to remove oil from inside the top of the
cylinder head to access the cylinder head bolts.
Note:
The cylinder head is centered on the cylinder cover
by two pins (A). Do not swivel the cylinder head, but
detach it by lifting it (no risk of causing the sleeves to
detach as they are force-fitted).
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11A
11A-8
Clean the cylinder head.
CHECKING THE GASKET FACE
Check that there is no gasket face bow.
Maximum bow: 0.05 mm.
Maximum rectification: 0.4 mm.
Test the cylinder head for possible leaks with the
cylinder head test kit (see Garage equipment
catalogue).
Position the pistons at mid-stroke to prevent any
contact with the valves when the camshafts are being
refitted.
Position the cylinder head gasket then the cylinder
head.
Check the bolts, then tighten the cylinder head (see
Section 07A Engine and transmission assembly
values and settings, Cylinder head tightening).
REFITTING
Refitting the timing belt (see Section 11A Top and
Front of Engine: Timing Belt).
Fill and bleed the cooling system, (see Section 19A
Cooling, Filling and Bleeding).
fill the refrigerant circuit using the filling equipment.
Note:
During this operation, make sure that foreign bodies
do not enter the pipes leading to oil under pressure.
WARNING
Do not scratch the aluminium gasket faces.
Wear gloves during this operation.
Clean the gasket faces with DECAPJOINT cleaning
product to dissolve the part of the gasket which is
stuck to the sump and cylinder cover.
Apply the product to the part to be cleaned, wait
approximately 10 minutes, then remove residue
using a wooden spatula.
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DIESEL INJECTION
Specifications
13B
13B-1
113B
DIESEL INJECTION
Specifications
Vehicles Gearbox
Engine
Type Index
Bore
(mm)
Stroke
(mm)
Cubic
capacity
(cc
3
)
Compression
ratio
Depollution
standard
XHXE ZF
S5.200 S9W 206 94.4 100 2800 21.7 Euro 3
XHXF ZF
S6.300 S9W 208 94.4 100 2800 21.7 Euro 3
XHXG ZF
S6.300 S9W 212 94.4 100 2800 21.7 Euro 3
ENGINE
ENGINE SPEED (rpm) FUME OPACITY
Idle speed No load maximum
Homologation
value
Legal maximum
S9W 206 780 25 4200 25 0.96 m
-1
(32 %) 3 m
-1
(70 %)
S9W 208 780 25 4200 25 1.12 m
-1
(32 %) 3 m
-1
(70 %)
S9W 212 780 25 4200 25 0.95 m
-1
(32 %) 3 m
-1
(70 %)
DESCRIPTION MANUFACTURER/TYPE SPECIAL NOTES
High-pressure pump BOSCH 4C - VGT Pressure from 300 to 1350 bar
Booster pump (low-pressure) Pressure from 1.5 to 3 bar
Diesel pressure sensor
BOSCH
Screwed onto the rail
Tightening torque: 3.5 0.5 daNm
Injectors
BOSCH
Solenoid injector
Resistance: 0.33 at 20 C
Maximum operating pressure: 1350 bar
Pressure regulator Screwed onto the high-pressure pump
Resistance: 2.4 at 20 C
Tightening torque: 0.6 daNm
Injection computer BOSCH 86-track computer
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DIESEL INJECTION
Specifications
13B
13B-2
DESCRIPTION MANUFACTURER/TYPE SPECIAL NOTES
Accelerator potentiometer HELLA Dual track potentiometer
Resistance across tracks 2 and 3
Pedal in rest position: 1134
Pedal depressed: 2010
Resistance across tracks 5 and 6
Pedal in rest position: infinite
Pedal depressed: 1004
Diesel temperature sensor BOSCH Resistance: 2115 58 at 25 C
Engine coolant temperature
sensor
BOSCH Resistance: 2115 58 at 25 C
Engine speed sensor BOSCH Resistance: 774 to 946 to 20 C
Camshaft sensor BOSCH Resistance: 774 to 946 to 20 C
"Flamstart" solenoid valve BERU Resistance: 7.5 to 8.5 at 20 C
"Flamstart" spark plug BERU Resistance: 0.3 at 20 C
Turbocharging pressure
sensor
BOSCH Resistance: 5300 2900 at 20 C
Output voltage, ignition on, engine off (across
tracks 1 and 4):
0.4 V for an atmospheric pressure of 200 mbar
4.65 V for an atmospheric pressure of 2500 mbar
Turbocharging air
temperature sensor
BOSCH Resistance between 97 and 58 k
Atmospheric pressure sensor - Incorporated into the computer
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DIESEL INJECTION
Special notes
13B
13B-3
Special notes
The high-pressure direct injection system is intended
to deliver a specific quantity of diesel to the engine at a
specific time.
DESCRIPTION
BOSCH 86-track computer controlling the injection
system.
The system consists of:
a fuel pre-filter,
a low-pressure pump,
a fuel filter,
a high-pressure pump,
a pressure regulator mounted on the pump,
an injector rail fitted with a diesel pressure sensor,
four solenoid injectors,
an engine speed sensor,
a camshaft sensor,
a turbocharger air temperature and pressure sensor,
a coolant temperature sensor,
a diesel temperature sensor,
an accelerator pedal potentiometer,
a declutchable engine cooling fan control.
The common rail direct high-pressure injection
system works sequentially (based on the operation of
multipoint injection for petrol engines).
This new injection system reduces operating noise,
reduces the volume of pollutant gases and particles
and produces high engine torque at low engine
speeds thanks to a pre-injection procedure.
The high-pressure pump generates the high-
pressure sent to the injector rail. The pressure
regulator located on the pump controls the pressure
according to the requirement determined by the
computer. The rail supplies each injector through a
steel pipe.
The injection computer receives information from
various sensors. It calculates the injection
characteristics (advance, pre-injection, injection
time) and controls the opening of the injectors.
The computer:
determines the value of injection pressure necessary
for the engine to operate correctly and then controls
the pressure regulator. It checks that the pressure
value is correct by analysing the value transmitted by
the pressure sensor located on the rail,
determines the injection time necessary to deliver the
right quantity of diesel and the moment when
injection should start,
controls each injector electrically and individually
after determining these two values.
The high-pressure pump consists:
three pumping pistons,
a pressure regulator which controls the output
pressure,
a piston cut-off solenoid valve which modulates the
pressure in accordance with the computer.
The computer controls:
the idle speed regulation,
the fuel supply (advance, flow and rail pressure),
the fan assembly control,
the authorisation to engage the air conditioning
compressor clutch,
the control of the intake air heater.
Injection computer switches on the engine cooling
fan and the coolant temperature warning light on the
instrument panel.
vnx.su
DIESEL INJECTION
Special notes
13B
13B-4
CHECKING SEALING AFTER REPAIR
Re-prime the circuit. To do this, start the low-pressure
pump by switching on the ignition several times.
The system injects the diesel fuel into the engine at a
pressure of up to 1350 bar. Check that the injector
rail is depressurised before any work.
It is absolutely vital that you observe the tightening
torque:
of the high-pressure pipes,
of the injector flange,
of the pressure sensor and pressure regulator.
When the high-pressure pump, injectors, supply
and return unions are removed, the ports should
be fitted with new and appropriate blanking pieces
to prevent contaminants from entering.
Dismantling the interior of the high-pressure pump
is prohibited.
The fuel return pipe fitted to the injectors must be
replaced when it is removed.
Loosening a high-pressure pipe connection when
the engine is running is prohibited.
You must respect the cleaning and safety advice
specified in this document when working on the
high-pressure injection system.
After any operation, check that there are no
diesel leaks. Run the engine at idle speed until
the engine cooling fan starts up, then accelerate
several times with no load.
WARNING
The engine must not run with diesel containing more
than 10% diester.
WARNING
ALL PIPES REMOVED MUST BE REPLACED.
vnx.su
DIESEL INJECTION
Location of components
13B
13B-5
5
17
18
High-pressure pump
Variable geometry turbocharger solenoid valve
Computer
vnx.su
DIESEL INJECTION
13B
13B-6
1 Injector
2 Injector diesel return pipe
3 Pressure sensor
4 Common injection rail
5 High-pressure pump
6 Pressure regulator
7 High-pressure pump/rail fuel supply pipe
8 Diesel filter
9 Diesel heater
10 Water present indicator
11 Diesel fuel temperature sensor
12 Diesel filter clogging indicator
13 Declutchable engine cooling fan connector
14 Coolant temperature sensor
15 Coolant temperature probe
vnx.su
DIESEL INJECTION
13B
13B-7
16 Engine speed sensor
17 Variable geometry turbocharger solenoid valve
18 Computer
19 Diesel pre-filter
20 Low-pressure pump
vnx.su
DIESEL INJECTION
Cleanliness
13B
13B-8
Cleanliness
INSTRUCTIONS TO BE FOLLOWED BEFORE
OPENING THE FUEL CIRCUIT
Use new thinner for each operation (used thinner
contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush in good
condition (the brush must not shed its bristles).
Use a brush and thinners to clean the connections to
be opened.
Blow compressed air over the cleaned parts (tools,
cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain
adhering.
Wash your hands before and during the operation if
necessary.
When wearing leather protective gloves, cover them
with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE
OPERATION
As soon as the circuit is open, all openings must be
plugged to prevent impurities from entering the
system. The plugs to be used are available from the
Parts Stores. They must not, under any
circumstances, be reused .
Close the resealable bag, even if it has to be
reopened shortly afterwards. The ambient
atmosphere carries impurities.
All components removed from the injection system
must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
The use of a brush, thinner, bellows, sponge or
normal cloth is strictly prohibited once the circuit has
been opened. In fact, these tools are liable to cause
dirt to enter the system.
If a component is being replaced, the new
component must not be removed from its packaging
until it is ready to be fitted to the vehicle.
vnx.su
FUEL SUPPLY
Diesel pre-filter
13A
13A-9
2113A
FUEL SUPPLY
Diesel pre-filter
The cartridge is located under the engine.
REMOVAL
Disconnect:
the pipes (1) coming from the tank,
the engine supply (2) pipes.
Unclip the pre-filter.
REFITTING
Be careful not to squeeze or damage the pipes.
FOLLOW THE CLEANLINESS INSTRUCTIONS
CLOSELY
WARNING
Be careful of the diesel fuel in the pipes.
vnx.su
DIESEL INJECTION
High-pressure pump
13B
13B-10
2213B
DIESEL INJECTION
High-pressure pump
DISMANTLING THE INTERIOR OF THE HIGH-
PRESSURE PUMP IS PROHIBITED
REMOVAL
Remove the air filter unit.
Disconnect the oil vapour rebreathing pipe (1) on the
filler neck.
Disconnect:
the solenoid valve connector (2) for deactivating a
component,
fuel supply pipe (3),
fuel return pipe (4) on the high-pressure pump,
the pressure regulator connector (5).
Remove:
the pump - rail pipe (6),
the return unit (7),
the three mounting nuts (8) from the high-pressure
pump,
the high-pressure pump,
the seals on the pump.
Tightening torques
high-pressure pump nuts 2.7 daNm
pump - rail pipe 2.2 daNm
WARNING
Before any operation, connect the After-Sales
diagnostic tool, establish dialogue with the injection
computer and check that the injection rail is no
longer pressurized.
Wait until the fuel temperature drops.
Order the special high-pressure injection circuit plug
kit.
YOU SHOULD FOLLOW THE CLEANLINESS
INSTRUCTIONS CLOSELY
vnx.su
DIESEL INJECTION
High-pressure pump
13B
13B-11
Clean the high-pressure pump.
REFITTING
Fit the pump with new seals.
Finger-tighten the high-pressure mounting nuts.
Fit the injection pipe between the high-pressure pump
and the rail and pretighten by hand until it touches.
Tighten the injection pipe to a torque of 2.2 daNm.
Torque tighten the high-pressure pump mounting
nuts (2.7 daNm).
Before starting the engine, reprime the fuel circuit.
Start the low-pressure pump by switching on the
ignition several times.
Start the engine.
Check that there are no stored faults using the
diagnostic tool. Clear them if necessary.
WARNING
Clean the gasket faces with DECAPJOINT
compound to dissolve any pieces of gasket which
are still attached.
Apply the product to the part to be cleaned, wait
approximately 10 minutes, then remove residue
using a wooden spatula.
After any operation, check that there are no leaks in
the diesel circuit.
Proceed as follows:
run the engine at idle speed until the fan starts up,
accelerate several times under no load,
carry out a road test,
switch the ignition off and check that there is no
leakage of diesel.
vnx.su
DIESEL INJECTION
Injector
13B
13B-12
Injector
DISMANTLING THE INTERNAL COMPONENTS OF
AN INJECTOR IS PROHIBITED
REMOVAL
Remove:
the lifting bracket,
the engine cover.
Disconnect:
the injectors (1),
the pressure sensor (2).
Tightening torques
high-pressure pipe unions 2.2 daNm
injector flange bolt 4.4 daNm
WARNING
longer pressurized.
kit.
YOU SHOULD FOLLOW THE CLEANLINESS
INSTRUCTIONS CLOSELY
Note:
injectors may be replaced individually.
all high-pressure pipes which are removed must
always be replaced.
vnx.su
DIESEL INJECTION
Injector
13B
13B-13
Remove:
the diesel return pipes (3),
the injection pipes (4).
Remove:
the injector flanges,
the injectors.
Fit anti-pollution plugs.
CLEANING
It is strictly forbidden to use the following when
cleaning the injector:
a wire brush,
an emery cloth,
an ultrasound cleaner.
To clean the nose of the injector, let it soak in
degreaser, then wipe it with a lint-free cloth.
REFITTING
Refit:
the injectors
the injector brackets.
Tighten to torque:
the injector flange bolts to 4.4 daNm,
the injection pipes to 2.2 daNm.
Note:
Remove the blanking plugs at the last moment.
vnx.su
DIESEL INJECTION
Injector
13B
13B-14
Refit the fuel return pipe to the injectors.
Throw away the bag of used plugs after the operation.
Use the diagnostic tool to clear any faults which may
be stored by the computer before restarting the
engine.
After any intervention, check that there are no leaks
in the diesel circuit.
Proceed as follows:
leakage of diesel.
vnx.su
DIESEL INJECTION
Injector rail
13B
13B-15
Injector rail
REMOVAL
Remove:
the engine cover,
the lifting bracket.
Remove the bolts (1) from the oil decanter.
Remove:
the lifting bracket (2),
the bolts (3) from the rail protector,
the rail protector.
Tightening torques
injection pipe union 2.2 daNm
injection rail mounting bolt 2.7 daNm
WARNING
longer under pressure.
Make a note of the fuel temperature.
kit.
CLOSELY
vnx.su
DIESEL INJECTION
Injector rail
13B
13B-16
Disconnect the pressure sensor and the injector
wiring.
Remove the injection pipe (4) between the high-
pressure pump and the rail.
Remove pipes (5) from the injectors.
Remove the three nuts (6) from the injector rail.
Fit plugs to maintain cleanliness.
vnx.su
DIESEL INJECTION
Injector rail
13B
13B-17
REFITTING
Fit the injector rail.
Finger tighten the rail mounting bolts 6).
Fit and hand tighten:
the pipe between the pump and the rail,
the pipes between the rail and the injectors.
Tighten to torque:
the three injector rail mounting bolts (2.7 daNm),
the injection pipe unions on the rail and the high-
pressure pump (2.2 daNm).
Refit the rail protector and tighten the bolts to torque
(2.7 daNm).
Tighten to torque:
the oil circuit metal tube,
the lifting bracket nuts,
the oil decanter bolts,
the injection pipe unions on the rail and injectors
(2.2 daNm).
Continue the refitting procedure in the reverse order to
removal.
Throw away the bag of plugs used during the
operation.
Use the diagnostic tool to clear any faults which may
be stored by the injection computer before restarting
the engine.
Before starting the engine, reprime the fuel circuit.
Start the low-pressure pump by switching on the
ignition several times.
Start the engine.
Note:
Leave removal of the anti-pollution plugs from any
component until last.
After any intervention, check that there are no
leaks in the diesel circuit.
Proceed as follows:
leakage of diesel.
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DIESEL INJECTION
Pressure sensor
13B
13B-18
Pressure sensor
REMOVAL
Remove the access flap on the engine cover.
Disconnect the pressure sensor.
Unscrew the pressure sensor using tool (Mot. 1495).
Remove the pressure sensor.
Fit anti-pollution plugs.
REFITTING
Replace the pressure sensor seal.
Remove blanking plugs.
Screw in the sensor then tighten it to torque.
Connect the sensor connector.
Refit the access flap.
Tightening torque
pressure sensor 3.5 0.5 daNm
WARNING
Make a note of the fuel temperature.
kit.
CLOSELY
After any intervention, check that there are no
leaks in the diesel circuit.
Proceed as follows:
leakage of diesel.
vnx.su
DIESEL INJECTION
Diesel fuel temperature sensor
13B
13B-19
Diesel fuel temperature sensor
1 Diesel fuel temperature sensor
Tightening torque
diesel fuel temperature sensor 1.8 daNm
WARNING
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DIESEL INJECTION
Clogging gauge sensor
13B
13B-20
Clogging gauge sensor
1 Clogging gauge sensor
Tightening torque
clogging gauge sensor 3 daNm
WARNING
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DIESEL INJECTION
Accelerator potentiometer
13B
13B-21
REMOVAL
Disconnect:
the battery,
the accelerator pedal connector (1).
Remove:
the three pedal mounting bolts (2),
the pedal.
REFITTING
CONNECTION
Track Description
1 Not used
2 Track 1 earth
3 Track 1 signal
4 Track 1 feed
5 Track 2 feed
6 Signal: track 2
Pedal
position
Resistance
(in ) of track 1
across tracks 2
and 3
Resistance
(in ) of track 2
across tracks 5
and 6
Released 1134 infinite
Depressed 2010 1004
Note:
A fault on the accelerator position potentiometer
causes changes in the idle speed or engine
operation.
vnx.su
DIESEL INJECTION
Computer
13B
13B-22
Computer
REMOVAL
Remove:
the battery,
the computer nuts (1),
the computer and disconnect it.
REFITTING
Program the immobiliser code following the procedure
described in Section 82A, Engine immobiliser.
If necessary repair the faults that appear then clear
them.
Check that the vehicle is operating correctly.
vnx.su
DIESEL INJECTION
Injection warning light
13B
13B-23
Injection warning light
Vehicles with the high-pressure diesel injection system
have injection fault warning lights and a coolant
temperature warning light.
The preheating warning light is represented by an
orange coil along with the electronic fault symbol. The
coolant temperature warning light is represented by an
engine along with the message STOP.
PRINCIPLE FOR WARNING LIGHTS COMING ON
When the ignition is switched on, the preheating
warning light comes on during the preheating phase
then goes out (see Section 13, Preheating control).
When there is an injection fault (severity level 1), the
injection warning light comes on permanently (it is
necessary to contact a RENAULT Dealer). These
faults are:
turbocharging pressure sensor fault,
diesel temperature sensor fault,
coolant temperature sensor fault,
engine speed sensor fault,
camshaft sensor fault,
engine cooling fan control relay fault,
injector fault,
3
rd
high-pressure pump component cut-out
solenoid valve,
engine speed synchronisation fault,
battery voltage fault,
injection computer fault.
When there is a serious injection fault (severity level
2), the injection fault warning light comes on and
flashes, in this case the vehicle must be stopped
immediately. These faults are:
diesel pressure sensor fault,
sensor supply fault,
injector fault,
injector supply fault,
diesel pressure regulator fault,
booster pump relay fault,
injection computer fault,
accelerator potentiometer fault.
When the engine overheats, the coolant temperature
warning light comes on.
vnx.su
DIESEL INJECTION
Allocation of computer tracks
13B
13B-24
CONNECTOR A CONNECTOR B
A1
A2
A3
A6
A7
A8
A9
A10
A12
A13
A14
A15
A18
A19
A20
A21
A23
A24
A29
A30
A31
A32
A33
A34
A35
A37
A39
A40
A41
A42
A43
---
---
---
---
---
---
---
---
---
---
Coolant temperature sensor signal

Air temperature sensor signal
Turbocharging air temperature and
pressure sensor supply
Turbocharging temperature and
pressure sensor earth
Fuel pump relay control
Variable geometry turbocharger control
High-pressure flow regulation solenoid
valve supply
Injector no. 4 control
Pressure sensor supply
Engine immobiliser computer
connection
Diesel temperature sensor signal
Air temperature sensor signal
Turbocharging air temperature and
pressure sensor earth
High-pressure flow regulation solenoid
valve earth
High-pressure pump component cut-
out solenoid valve control
Speed sensor signal
Coolant and fuel temperature sensors
earth
Camshaft sensor earth
Diesel heater relay control
Pressure sensor signal
Turbocharging pressure sensor signal
Declutchable engine cooling fan supply
Engine speed sensor earth
Declutchable engine cooling fan relay
control
B2
B4
B6
B7
B9
B10
B11
B12
B14
B19
B20
B21
B22
B23
B24
B26
B27
B29
B30
B31
B35
B38
B40
B41
B42
B43
---
---
---
---
---
---
---
---
---
---
---
Potentiometer track no. 1 potentiometer
signal
Engine speed sensor signal
Air-conditioning relay control
Fault finding procedure
+ After ignition
+ After ignition
Air intake heater solenoid valve relay
control
Earth
Engine speed sensor earth
Fault finding procedure
+ After ignition
Preheating warning light
+ After ignition
High-pressure circuit warning light
Earth
Brake switch track no. 1 signal
Accelerator pedal potentiometer track
no. 1 earth
no. 2 signal
Power take-off signal
Brake switch track no. 2 signal
no. 1 supply
Clutch switch signal
Supply relay control
+ After ignition
Intake heater plug relay control
Earth
vnx.su
STARTING - CHARGING
Alternator
16A
16A-1
116A
STARTING - CHARGING
Alternator
REMOVAL
Remove the engine undertray.
Disconnect:
the battery,
the alternator electrical connections.
Remove:
the air conditioning compressor belt (see
Section 07A, Air conditioning compressor belt) if
fitted to the vehicle,
the alternator belt (see Section 07A, Alternator
belt),
the alternator mounting bolts, then remove it using a
screwdriver.
REFITTING
To facilitate fitting the alternator, compress rings (1)
using pliers or a vice.
Refit:
the air conditioning compressor belt,
the alternator belt.
vnx.su
STARTING - CHARGING
Starter
16A
16A-2
Starter
REMOVAL
Remove the shield from underneath the gearbox.
Disconnect the starter motor feed.
Remove the starter motor.
REFITTING
Check for the presence of the centring dowel.
vnx.su
COOLING SYSTEM
Specifications
19A
19A-1
119A
COOLING SYSTEM
Specifications
VOLUME AND GRADE OF COOLANT
THERMOSTAT
Engine Volume (in litres) Grade Special notes
S9W 206
12
GLACEOL RX Type D use
coolant only
Protection down to
- 20 C 2 for hot,
temperate and cold
countries.
Protection down to
- 37 C 2 for very cold
countries.
S9W 208
S9W 212
Engine Start of opening (in C) Fully open (in C)
S9W 206
76 86 S9W 208
S9W 212
vnx.su
COOLING SYSTEM
Filling - Bleeding
19A
19A-2
Filling - Bleeding
FILLING
Open the bleed screw on the radiator top hose.
Fill the circuit through the expansion bottle opening.
Close the bleed screw as soon as the fluid runs out in
a continuous jet.
Fill the bottle until the coolant overflows.
Refit the bottle cap and tighten it.
AUTOMATIC BLEED
Turn on the engine.
Let the engine run at 2500 rpm, until the engine
cooling fan has completed three operating cycles
(time required for automatic degassing).
If necessary, adjust the coolant level in the expansion
bottle.
Note:
The engine must be stopped and the air-conditioning
system off so that the engine cooling fan is not
running when you start.
WARNING
do not open the bleed screw while the engine is
running and hot,
do not open the expansion bottle while the engine
is hot (over 50C) or running,
top up if required,
retighten the expansion bottle cap while the
engine is hot,
using approved equipment, measure the degree
of coolant protection,
check for any possible leaks,
make sure the passenger compartment heating
works properly.
vnx.su
COOLING SYSTEM
Checking
19A
19A-3
Checking
1 - Checking sealing
Turn the heater matrix tap to the "heating" position.
Replace the expansion bottle valve with adapter
Ms. 554-01.
Warm up the engine then switch it off.
Pump to pressurise the circuit.
Put the circuit under a maximum pressure of 0.9 bar.
The pressure should not drop; if it does, look for the
leak.
Slowly unscrew the union of tool M.S. 554-07 to
depressurise the cooling circuit, then remove tool
M.S. 554-01 and refit the expansion bottle valve
complete with a new seal.
2 - Checking the valve rating
If liquid passes through the expansion bottle valve, the
valve must be replaced.
Adapt tool Ms. 554-06 on pump Ms. 554-07, and fit the
valve to be checked onto it.
Increase the pressure, which should stabilise at the
valve rating pressure with a test tolerance of 0.1 bar.
Valve rating: 0.8 bar.
Essential special tooling
Ms. 554-01 Adapter for Ms. 554-07
Ms. 554-06 Adapter for Ms. 554-07
Ms. 554-07 Kit for testing cooling circuit sealing
vnx.su
COOLING SYSTEM
Diagram
19A
19A-4
Diagram
1 Engine
2 Radiator
3 "Hot" bottle with permanent degassing
4 Coolant pump
5 Thermostat
6 Temperature switch
vnx.su
COOLING SYSTEM
Radiator
19A
19A-5
Radiator
REMOVAL
Remove:
the direction indicators,
the bumper (2).
Disconnect the radiator temperature sensor connector.
Remove the radiator top and bottom hoses.
Remove the radiator mounting bolts.
REFITTING
Fill and bleed the cooling system (see Filling and
bleeding).
vnx.su
COOLING SYSTEM
Cooling system
19A
19A-6
Cooling system
REMOVAL
Drain:
the cooling circuit through the top hose,
the refrigerant circuit using the filling station.
Remove:
the engine oil filler neck mounting bolt.
Remove:
the direction indicators,
the bumper (2).
Disconnect the fan assembly connectors.
Remove:
the intercooler hoses,
the radiator coolant hoses.
vnx.su
COOLING SYSTEM
Cooling system
19A
19A-7
Cooling system
Remove bracket (5) from the pressure relief valve
connecting pipes.
Remove mounting (6) from the pressure relief valve
connecting pipes.
Remove:
bolts (7) mounting the connecting pipes on the
condenser,
bracket (8) from the connecting pipes,
the fan assembly gaiter clip,
the four cooling assembly mounting bolts.
Remove the cooling assembly.
REFITTING
bleeding).
It is vital to replace the seals and lubricate them with
refrigerant fluid.
Create a vacuum, then fill the refrigerant circuit using
the filling equipment.
vnx.su
COOLING SYSTEM
Coolant pump
19A
19A-8
Coolant pump
REMOVAL
Drain the cooling circuit through the radiator bottom
hose.
Remove:
the timing belt (see Section 11A Timing belt),
the tensioning roller,
the timing tensioner,
the coolant pump by disconnecting the thermostat
unit.
REFITTING
Clean the coolant pump.
Fit the new seal.
Pretighten mounting bolts (1) until they come into
contact with the coolant pump, then tighten them to a
torque of 5.5 daNm.
Refit the timing belt (see Section 11A Timing belt).
bleeding).
Tightening torques
coolant pump bolts 5.5 daNm
WARNING
Clean the gasket faces with DECAPJOINT product
to dissolve any pieces of gasket which are still
attached.
Apply the product to the part to be cleaned, wait 10
minutes, then remove residue using a wooden
spatula.
Note:
Apply a drop of LOCTITE FRENETANCH to the
coolant pump bolts.
vnx.su
TANK
General information
19C
19C-1
119C
TANK
General information
There are three types of tank for this vehicle:
95 litres,
100 litres,
140 litres.
The removal and refitting procedures are similar.
The tank is vented via a valve (1).
This valve also has the function of preventing fuel leaks if the vehicle rolls over.
vnx.su
TANK
Fuel tank
19C
19C-2
Fuel tank
REMOVAL
Drain the tank.
Remove the side sills.
Remove:
the spout sleeve (1),
the venting pipe (2).
Disconnect the supply pipe quick-release coupling
from the tank with tool (Mot. 1265-01).
Position two trolley jacks underneath the tank.
Remove the four tank mounting nuts.
Partially lower the tank and disconnect the gauge
connector.
Remove the fuel tank.
REFITTING
During refitting, take care to:
systematically replace the tightening clamps,
not restrict the pipes,
fit quick release couplings by hand and check that
they are correctly locked into place.
IMPORTANT
During this operation, it is essential to:
refrain from smoking or bringing hot objects close
to the work area,
use suitable protection against petrol splashes
caused by the residual pressure in the pipes,
protect sensitive areas from petrol.
vnx.su
TANK
Filler neck
19C
19C-3
Filler neck
REMOVAL
Tilt the part marked (1) of the plastic protector (2).
Remove screw (3) and then unclip the plastic protector
(2).
Remove:
the sleeve (4),
the venting pipe (5) on the fuel filler neck side.
Remove:
the four fuel filler neck mounting bolts,
the three mounting nuts from the fuel filler neck
mounting plate,
the filler neck.
REFITTING
During refitting, take care to:
systematically replace the tightening clamps,
not restrict the pipes.
vnx.su
TANK
Fuel gauge
19C
19C-4
Fuel gauge
REMOVAL
To remove the gauge, it is necessary to remove the
tank (see Section 19C, Tank, Tank).
Disconnect:
the quick release supply coupling (1) using tool
(Mot. 1265-01),
the venting pipe (2).
Remove the gauge mounting nut with tool (Mot. 1397).
Allow all the fuel in the gauge to flow out, then remove
it.
Mot. 1397 Fuel gauge dismounting nut
Mot. 1265-01 Pliers for quick release couplings
Tightening torque
gauge nut 6 daNm
IMPORTANT
During this operation, it is essential to:
refrain from smoking or bringing hot objects close
to the work area,
use suitable protection against petrol splashes
caused by the residual pressure in the pipes,
protect sensitive areas from petrol.
WARNING
Before any removal, check the flow of fuel (do not
restrict pipes as they risk being damaged).
vnx.su
TANK
Fuel gauge
19C
19C-5
REFITTING
Replace the O-ring seal.
Refit the gauge.
Position the nut and tighten it until the indexing points
on it correspond with the indexing points on the gauge.
Refit the tank (see Section 19C, Tank, Tank).
CONNECTION
Note:
If several hours will pass between removing and
refitting the pump / sender assembly, screw the nut
back onto the tank to avoid any damage.
Track Description
A1 Earth
A2 Minimum level warning light
B1 Sender unit information to instrument
panel
vnx.su
TANK
Fuel gauge
19C
19C-6
CHECKING THE GAUGE SENDER UNIT
Ensure that the resistance varies when the float is
moved.
Measuring height H
Place the removed sender unit on a flat surface.
H is the height measured between the float pin and the
seal contact surface (upper part of the gauge,
connection between the fuel tank and the gauge).
Indication Value between terminals A1 and B1
(in )
95 litres 100 litres 140 litres
4/4 7 7 20 4 7 7
3/4 54.5 7 40 6 54.5 7
1/2 98 10 68 10 98 10
1/4 155 16 109 15 155 16
Spare 275 15 137 15 275 15
Indication Height H (in mm)
4/4 0 0 0
3/4 94 99.65 87.6
1/2 141 160.40 150.6
1/4 196 224.45 199.9
Spare 235 254.45 254.9
Note:
All the above values are given merely as an
indication.
vnx.su
ENGINE MOUNTING
Suspended engine mounting
19D
19D-1
119D
ENGINE MOUNTING
Suspended engine mounting
Tightening torques
A 9.4 daNm
B 9 daNm
C 5.5 daNm
D 3.9 daNm
E 3.9 daNm
vnx.su
Engine and peripherals
DIESEL INJECTION
77 11 315 502
APRIL 2002
EDITION ANGLAISE
RENAULT 2002
vnx.su
Engine
and peripherals
Contents
Page
13B DIESEL INJECTION
Introduction 13B-1
Interpretation of faults 13B-2
Customer complaints 13B-97
Fault finding chart 13B-98
Components sheet 13B-111
Glossary 13B-115
vnx.su
DIESEL INJECTION
Fault finding - Introduction
13B
13B-1
113B
S9W BOSCH MS6.3
Electronic version: MS6.3
Engine type number: 140
DIESEL INJECTION
FAULT FINDING PROCEDURE:
Use one of the diagnostic tools to identify the system fitted to the vehicle (reading the computer family,
program No., Vdiag No., etc.).
Locate the Fault finding documents corresponding to the system identified.
Take note of information contained in the Introduction sections.
Read the faults in the computer memory and use the Interpretation of faults section of the documentation.
Reminder: Each fault is interpreted by a particular type of storage (fault present, fault stored in memory, fault
present or stored). The checks specified for dealing with each fault are therefore only to be carried out if the fault
shown by the diagnostic tool is described for its type of storage. The storage type should be considered when using
the diagnostic tool following ignition switch-off and switch-on.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the notes box.
If the conditions are not satisfied, use the fault finding strategy to check the circuit of the faulty part since the fault is
no longer present on the vehicle. Perform the same operation when a fault is declared as stored by the diagnostic
tool but is only interpreted in the documentation as a present fault.
Carry out the conformance check (appearance of possible faults not yet identified by the system's self-diagnostic
procedure) and implement the associated fault finding strategies according to the result.
Confirm the repair (customer complaint disappears).
Use the diagnostic procedure for each customer complaint according to the fault finding chart if the problem
persists.
TOOLING REQUIRED
To enter into dialogue with the injection computer: NXR and CLIP (Optima).
For miscellaneous electrical checks:
Optima 5800 with optional garage multimeter and temperature sensor.
Connector A carries the Engine harness wires.
Connector A carries the Passenger Compartment harness wires.
WARNING:
Any fault finding procedure requiring work to be carried out on the high pressure injection system requires
full understanding of the cleanliness and safety instructions in Section 13 of the Workshop Repair Manual
for the vehicle concerned.
This document introduces the generic fault finding procedure applicable to all:
Bosch MS6.3, Electronic version: MS6.3, Engine type number: 140 (bhp).
A Fault Finding Special Features Technical Note is available for every vehicle fitted with this computer.
It covers all the fault finding special features in this document for the vehicle concerned.
The following are required for carrying out fault finding on this system:
the fault finding special features Technical Note for the vehicle,
the wiring diagram of the function for the vehicle concerned,
the tools listed under the Special Tooling Required section.
vnx.su
DIESEL INJECTION
Fault finding - Interpretation of faults
13B
13B-2
S9W BOSCH MS6.3
DF075
ATMOSPHERIC PRESSURE SENSOR
DEF : Internal electronic fault
NOTES
The fault is detected if:
the computer detects a problem with the internal pressure sensor.
DEF
Clear the faults from memory and then start the engine.
If the fault is still there, contact the Techline.
AFTER REPAIR
Deal with any other possible faults.
Clear the fault memory.
Switch off the ignition.
Carry out a road test, then a check with the diagnostic tool.
vnx.su
DIESEL INJECTION
13B
13B-3
S9W BOSCH MS6.3
DF074
TURBOCHARGER PRESSURE SENSOR
CO.0 : Open circuit or short circuit to earth
CC.1 : Short circuit to + 12 V
1.DEF: Feed voltage too high
2.DEF: Feed voltage too low
3.DEF: Measured pressure too high
NOTES
The fault is detected:
if the manifold pressure sensor voltage is less than 0.25 V,
when the + after ignition is switched on.
CO.0
Disconnect the "inlet manifold pressure sensor/air temperature sensor" connector
and the injection computer connector.
Check the continuity and insulation of the pressure signal lines:
track 3 of the pressure sensor track A3 of the injection
computer
computer
Check the earth insulation on track A3 of the injection computer. It must be more
than 10 M .
Check the earth insulation on track A34 of the injection computer. It must be more
than 10 M .
Repair if necessary.
Reconnect the injection computer and check the presence of + 5 V on track 3 and
track 1 of the pressure sensor connector with + after ignition.
If the fault persists, contact your Techline.
If the fault persists, change the pressure sensor.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-4
S9W BOSCH MS6.3
DF074
CONTINUED 1
NOTES
if the manifold pressure sensor voltage is more than 4.75 V;
CC.1
Disconnect the "inlet manifold pressure sensor/air temperature sensor" connector
and the injection computer connector.
Check the continuity of the manifold pressure signal lines:
computer
computer
Check the insulation to + 12 V on tracks A34 and A19 of the injection computer.
Reconnect the injection computer and check the presence of + 5 V on track 3 and
track 1 of the pressure sensor connector with + after ignition.
If the fault persists, contact your Techline.
If the fault is still present, change the pressure sensor.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-5
S9W BOSCH MS6.3
DF074
CONTINUED 2
NOTES
if the measured voltage is more than 5.2 V,
1.DEF
YES
Check the condition and continuity of the computer's earth connections on
tracks B24, B43 and B12 or go to the next step.
NO
Measure the manifold pressure sensor feed voltage on track 4.
If it is more than 5.2 V, replace the manifold pressure sensor.
If not, contact your Techline.
Measure the "inlet manifold pressure sensor / air temperature sensor" connector feed
voltage on track 3.
Is the voltage more than 5.2 V?
AFTER REPAIR
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DIESEL INJECTION
13B
13B-6
S9W BOSCH MS6.3
DF074
CONTINUED 3
NOTES
if the measured voltage is less than 4.8 V,
2.DEF
YES
Disconnect the manifold pressure sensor and measure the voltage on track 3 again.
If the voltage is stable at 5 V, replace the pressure sensor.
NO Contact the Techline.
Measure the inlet manifold pressure sensor / air temperature sensor feed voltage on
track 3 with the sensor connected.
Is the voltage less than 4.8 V?
AFTER REPAIR
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DIESEL INJECTION
13B
13B-7
S9W BOSCH MS6.3
DF074
CONTINUED 4
NOTES
if the measured pressure is more than 2300 mbar,
3.DEF
The measured pressure is outside the manufacturer's specification. Check that the
turbocharger wastegate valve is operating correctly and check with a pressure
gauge that the turbocharging pressure never exceeds 2.2 bar.
Checking the inlet manifold pressure sensor / air temperature sensor:
The sensor delivers a voltage proportional to the manifold pressure:
2.5 bar absolute (1.5 bar relative) = 4.65 V
0.2 bar absolute (- 0.8 relative) = 0.4 V
Check first that the sensor is correctly fed with a voltage of + 5 V across tracks 1
and 3 with the sensor connected.
Use a vacuum pump connected to the sensor's vacuum coupling to check that the
signal corresponds to the graph. Disconnect track 4 linking the computer to the
sensor and connect the "+" lead of a multimeter (set at between 5 and 10 V) to
track 4 of the sensor and the "-" lead to track 1 of the sensor (sensor earth still
connected to the computer).
At atmospheric pressure, the voltage should be approximately equal to 1.7 V.
At a pressure close to 2.5 bar absolute, the voltage should be approximately equal
to 4.65 V.
At a pressure close to 0.2 bar absolute, the voltage should be approximately equal
to 0.4 V.
If the voltages do not correspond to the pressures, replace the sensor.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-8
S9W BOSCH MS6.3
DF128
INTAKE AIR TEMPERATURE SENSOR CIRCUIT
CC.0 : Short circuit to earth
CO : Open circuit
NOTES
the air temperature sensor voltage is less than 0.250 V,
the + after ignition is switched on.
CC.0
Disconnect the injection computer connector and the inlet manifold pressure
sensor / air temperature sensor connector.
Check the resistance of the air temperature sensor and its earth insulation (see
conformity check): the resistance should be 2400 at 20 C.
Check the continuity and insulation on the following tracks:
track 1 of the air temperature sensor track A19 of the
injection computer
injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-9
S9W BOSCH MS6.3
DF128
CONTINUED 1
NOTES
the air temperature sensor voltage is more than 4.75 V,
CC.1
Disconnect the injection computer connector and the inlet manifold pressure sensor
/ air temperature sensor connector.
Check the resistance of the air temperature sensor and its insulation to + 12 V (see
Check the continuity and insulation of the following tracks:
injection computer
injection computer
AFTER REPAIR
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DIESEL INJECTION
13B
13B-10
S9W BOSCH MS6.3
DF128
CONTINUED 2
NOTES
the air temperature sensor voltage is between 4.6 and 4.75 V,
CO
YES
Measure the voltage again on tracks A2 and A19 of the injection computer.
If the voltage is less than 4.6 V, contact the Techline.
Otherwise, check the continuity and insulation on the following tracks:
track 1 of the air temperature sensor track A19 of the injection
computer
computer
NO
Carry out a conformity check on the air temperature sensor.
Replace the inlet manifold pressure sensor / air temperature sensor if necessary.
Measure the inlet manifold pressure sensor / air temperature sensor voltage on tracks 1
and 2 with the sensor connected.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-11
S9W BOSCH MS6.3
DF002
COOLANT TEMPERATURE SENSOR CIRCUIT
CO : Open circuit
DEF : Voltage too high
NOTES
the coolant temperature sensor voltage is less than 0.250 V,
CC.0
Disconnect the injection computer connector and the coolant temperature sensor
connector.
Check the resistance of the coolant temperature sensor and its earth insulation
(see conformity check): the resistance should be 2575 at 20 C.
injection computer
injection computer
AFTER REPAIR
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DIESEL INJECTION
13B
13B-12
S9W BOSCH MS6.3
DF002
CONTINUED 1
NOTES
the coolant temperature sensor voltage is more than 4.75 V,
CC.1
connector.
Check the resistance of the coolant temperature sensor and its insulation to
+ 12 V (see conformity check): the resistance should be 2575 at 20 C.
injection computer
injection computer
AFTER REPAIR
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DIESEL INJECTION
13B
13B-13
S9W BOSCH MS6.3
DF002
CONTINUED 2
NOTES
the coolant temperature sensor voltage is between 4.6 and 4.75 V,
CO
YES
computer
computer
NO
Carry out a conformity check on the air temperature sensor.
Replace the temperature sensor if necessary.
Measure the air temperature sensor voltage on tracks 1 and 2 with the sensor
connected.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-14
S9W BOSCH MS6.3
DF002
CONTINUED 3
NOTES
the measured temperature is more than 130 C,
DEF
If there is a stored fault, check that the cooling system is operating correctly and that
the fan switches on.
If there is a present fault, check that the engine is not overheating, or treat the fault
as an open circuit.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-15
S9W BOSCH MS6.3
DF021
FUEL TEMPERATURE SENSOR CIRCUIT
CO : Open circuit
DEF : Voltage too high
NOTES
the fuel temperature sensor voltage is less than 0.250 V.
CC.0
Disconnect the injection computer connector and the fuel temperature sensor
connector.
Check the resistance of the fuel temperature sensor and its earth insulation (see
track 1 of the fuel temperature sensor track A15 of the injection
computer
computer
AFTER REPAIR
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DIESEL INJECTION
13B
13B-16
S9W BOSCH MS6.3
DF021
CONTINUED 1
NOTES
the coolant temperature sensor voltage is more than 4.75 V,
CC.1
connector.
Check the resistance of the coolant temperature sensor and its insulation to
+ 12 V (see conformity check): the resistance should be 2575 at 20 C.
computer
computer
AFTER REPAIR
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DIESEL INJECTION
13B
13B-17
S9W BOSCH MS6.3
DF021
CONTINUED 2
NOTES
the fuel temperature sensor voltage is between 4.6 and 4.75 V,
CO
YES
computer
computer
NO
Carry out a conformity check on the fuel temperature sensor.
Replace the temperature sensor if necessary.
Measure the fuel temperature sensor voltage on tracks 1 and 2 with the sensor
connected.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-18
S9W BOSCH MS6.3
DF021
CONTINUED 3
NOTES
the measured temperature is more than 130 C,
DEF
If there is a stored fault, check that the cooling system is operating correctly and that
the fan switches on.
If there is a present fault, check that the engine is not overheating, or treat the fault
as an open circuit.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-19
S9W BOSCH MS6.3
DF083
FUEL PRESSURE SOLENOID VALVE CIRCUIT
CO : Open circuit
NOTES
line fault on track A9,
with + after ignition switched on and engine running.
CC.0
Disconnect the injection computer connector and the fuel pressure solenoid valve
connector.
Check the resistance of the fuel pressure solenoid valve and its earth insulation
(see Glossary): the resistance should be 2.4 at 20 C.
Replace the fuel pressure solenoid valve if necessary.
Check the continuity and insulation on the following track:
track 1 of the fuel pressure solenoid valve track A9 of the
injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-20
S9W BOSCH MS6.3
DF083
CONTINUED 1
NOTES
line fault on track A9, detection of a line voltage not controlled by the ECU,
CC.1
Disconnect the injection computer connector.
Check the insulation to + 12 V on tracks A9 and A20 of the ECU connector.
Check the resistance of the fuel pressure solenoid valve and its insulation to
+ 12 V (see Glossary): the resistance should be 2.4 at 20 C.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-21
S9W BOSCH MS6.3
DF083
CONTINUED 2
NOTES
the solenoid valve control current is too low,
CO
Check the resistance and earth insulation of the fuel pressure solenoid valve (see
Glossary).
injection computer
injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-22
S9W BOSCH MS6.3
DF142
ENGINE SPEED SIGNAL
1.DEF : No engine running signal
2.DEF : Inconsistent signal
3.DEF : Engine speed signal interference, broken tooth on flywheel or engine speed
sensor internal fault
NOTES N.B. Detection of the fault changes to present after the engine has been started.
1.DEF
2.DEF
3.DEF
Measure the resistance of the sensor using a multimeter across tracks A37 and
A29.
The sensor resistance must be between 774 and 946 .
Check the earth insulation.
Check that the crankshaft position sensor is mounted correctly on the cylinder block.
Check the air gap which must be between 0.5 and 1.5 mm.
Replace the engine speed sensor if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-23
S9W BOSCH MS6.3
DF116
CYLINDER REFERENCE SENSOR CIRCUIT
1.DEF: Inconsistent camshaft signal
2.DEF: No signal
NOTES N.B. Detection of the fault changes to present after the engine has been started.
1.DEF
2.DEF
Measure the resistance of the sensor using a multimeter across tracks A31 and A4.
The sensor resistance must be between 774 and 946 .
Check the earth insulation.
Check that the camshaft position sensor is mounted correctly on the timing cover.
Check the air gap which must be between 0.5 and 1.5 mm.
Replace the camshaft position sensor if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-24
S9W BOSCH MS6.3
DF117
RAIL PRESSURE SENSOR CIRCUIT
1.DEF: Feed voltage too high
2.DEF: Feed voltage too low
NOTES
the voltage on the fuel pressure signal line is less than 0.2 V.
CO.0
Disconnect the fuel pressure sensor connector and injection computer connector
(A).
Check the continuity and insulation of the fuel pressure signal line:
fuel pressure sensor track 2 track A33 of the injection
computer
Check the continuity and insulation of the fuel pressure sensor earth connection:
fuel pressure sensor earth track 3 track A13 of the injection
computer
Reconnect the connectors.
If the fault is still there, replace the fuel pressure sensor.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-25
S9W BOSCH MS6.3
DF117
CONTINUED 1
NOTES
the voltage on the fuel pressure signal line is greater than 4.75 V.
CC.1
Disconnect the fuel pressure sensor connector and injection computer connector.
Check the earth insulation of the fuel pressure signal line:
fuel pressure sensor track 2 track A33 of the injection
computer
Check the continuity and insulation of the fuel pressure sensor feed:
fuel pressure sensor feed track 1 track A6 of the injection
computer
Reconnect the injection computer connector and check the presence of + 5 V
voltage across tracks A6 and A13 with the ignition switched on.
If no voltage, contact your Techline.
Carry out a conformity check on the fuel pressure sensor.
If the fault is still there, replace the fuel pressure sensor.
AFTER REPAIR
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DIESEL INJECTION
13B
13B-26
S9W BOSCH MS6.3
DF117
CONTINUED 2
NOTES
the feed voltage is higher than 5.2 V.
1.DEF
Check the + 12 V insulation on the fuel pressure sensor feed:
computer
If the voltage is higher, contact the Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-27
S9W BOSCH MS6.3
DF117
CONTINUED 3
NOTES
the measured voltage is less than 4.8 V.
2.DEF
Check the earth insulation of the fuel pressure sensor feed:
computer
If the voltage is lower, contact the Techline.
Reconnect the fuel pressure sensor. If the voltage on track 1 drops below 4.8 V,
replace the fuel pressure sensor.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-28
S9W BOSCH MS6.3
DF117
CONTINUED 4
NOTES
the pressure is higher than 1600 bar,
the engine speed is higher than 500 rpm,
Deal first with any rail pressure control valve fault.
3.DEF
Check condition of the high-pressure injection rail and make sure there is no
leakage.
Check the operation of the rail pressure control valve (e.g. jammed closed).
If the High Pressure pump is not faulty, replace the rail pressure sensor.
Clear the fault and start the engine.
If the fault is still present, contact the Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-29
S9W BOSCH MS6.3
DF182
EXCESSIVE ENGINE SPEED
DEF : Excessive engine speed detected
DEF
This fault is displayed when the maximum engine speed stored in the computer
memory is exceeded.
It may be caused by the engine racing accidentally or by a user fault on the part of
the driver.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-30
S9W BOSCH MS6.3
DF127
SUPPLY VOLTAGE SENSORS
NOTES
the computer detects a feed fault from the external sensors.
DEF
If the fault recurs after starting the engine, check the feed on all the engine sensors.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-31
S9W BOSCH MS6.3
DF150
TURBOCHARGER ACTIVATOR CIRCUIT
CO : Open circuit
NOTES
CC.0
Disconnect the injection computer connector and the wastegate solenoid valve
connector.
Check the resistance of the wastegate solenoid valve and its earth insulation (see
Glossary): the resistance should be 16 at 20 C.
Replace the wastegate solenoid valve if necessary.
wastegate solenoid valve track A track A36 of the injection
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-32
S9W BOSCH MS6.3
DF150
CONTINUED 1
NOTES
CC.1
Check the resistance of the wastegate solenoid valve and its insulation to + 12 V
(see Glossary): the resistance should be 16 at 20 C.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-33
S9W BOSCH MS6.3
DF150
CONTINUED 2
NOTES
the solenoid valve control current is too low,
CO
Check the resistance and earth insulation of the wastegate solenoid valve (see
Glossary).
wastegate solenoid valve track A track A36 of the injection
computer
wastegate solenoid valve track B track A8 of the injection
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-34
S9W BOSCH MS6.3
DF183
FAN UNIT
CO : Open circuit
NOTES
CC.0
Disconnect the injection computer connector and the fan relay connector.
Check the resistance of the fan relay and its earth insulation: the resistance should
be 6 at 20 C.
Replace the fan relay if necessary.
track 1 of the fan relay track A39 of the injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-35
S9W BOSCH MS6.3
DF183
CONTINUED 1
NOTES
CC.1
Check the insulation to +12 V of tracks A39 and A8 of the ECU connector.
Check the resistance of the fan relay and its earth insulation: the resistance should
be 6 at 20 C.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-36
S9W BOSCH MS6.3
DF183
CONTINUED 2
NOTES
the fan relay control current is too low,
CO
Check the resistance and earth insulation of the fan relay.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-37
S9W BOSCH MS6.3
DF099
CYLINDER 1 INJECTOR CIRCUIT
CO : Open circuit
NOTES
line fault on track A12 or A40,
CC.0
Disconnect the injection computer connector and injector No. 1 connector.
Check the resistance of injector No.1 and its earth insulation: the resistance
should be 0.33 at 20 C.
Replace injector No.1 if necessary.
track 1 of injector No.1 track A40 of the injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-38
S9W BOSCH MS6.3
DF099
CONTINUED 1
NOTES
line fault on track A40 or A12, detection of a line voltage not controlled by the ECU,
CC.1
Check the insulation to +12 V on tracks A40 and A12 of the ECU connector.
Check the resistance of injector No.1 and its insulation to + 12 V: the resistance
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-39
S9W BOSCH MS6.3
DF099
CONTINUED 2
NOTES
injector No.1 control current is too low,
CO
Check the resistance and earth insulation of injector No.1: the resistance should
be 0.33 at 20 C.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-40
S9W BOSCH MS6.3
DF099
CONTINUED 3
NOTES
the computer detects an internal electronic fault.
DEF
AFTER REPAIR
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DIESEL INJECTION
13B
13B-41
S9W BOSCH MS6.3
DF100
CO : Open circuit
NOTES
CC.0
Disconnect the injection computer connector and injector No. 2 connector.
Check the resistance of injector No.2 and its earth insulation: the resistance
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-42
S9W BOSCH MS6.3
DF100
CONTINUED 1
NOTES
CC.1
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-43
S9W BOSCH MS6.3
DF100
CONTINUED 2
NOTES
CO
Check the resistance and insulation to earth of injector No.2: the resistance
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-44
S9W BOSCH MS6.3
DF100
CONTINUED 3
NOTES
DEF
AFTER REPAIR
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DIESEL INJECTION
13B
13B-45
S9W BOSCH MS6.3
DF101
CO : Open circuit
NOTES
CC.0
Disconnect the injection computer connector and the injector No. 3 connector.
Check the resistance of injector No.3 and its insulation to earth: the resistance
Replace injector N3 if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-46
S9W BOSCH MS6.3
DF101
CONTINUED 1
NOTES
CC.1
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-47
S9W BOSCH MS6.3
DF101
CONTINUED 2
NOTES
CO
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-48
S9W BOSCH MS6.3
DF101
CONTINUED 3
NOTES
DEF
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-49
S9W BOSCH MS6.3
DF102
CO : Open circuit
NOTES
CC.0
Disconnect the injection computer connector and the injector No.4 connector.
Check the resistance of injector No.4 and its insulation to earth: the resistance
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-50
S9W BOSCH MS6.3
DF102
CONTINUED 1
NOTES
CC.1
Check the insulation to +12 V on tracks A43 and A10 of the ECU connector.
Check the resistance of injector No.4 and its insulation to +12 V: the resistance
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-51
S9W BOSCH MS6.3
DF102
CONTINUED 2
NOTES
CO
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-52
S9W BOSCH MS6.3
DF102
CONTINUED 3
NOTES
DEF
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-53
S9W BOSCH MS6.3
DF114
THIRD PUMP ELEMENT CONTROL
CO : Open circuit
NOTES
CC.0
Disconnect the injection computer connector and the third element solenoid valve
connector.
Check the resistance of the solenoid valve and its insulation to earth:
the resistance should be 25 at 20 C.
Replace the solenoid valve, if necessary.
track 1 of the solenoid valve track A21 of the injection
computer
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-54
S9W BOSCH MS6.3
DF114
CONTINUED 1
NOTES
CC.1
Check the insulation to 12 V on tracks A21 and A20 of the ECU connector.
Check the resistance of the third element solenoid valve and its insulation to
+12 V: the resistance should be 25 at 20 C.
Replace the third element solenoid valve.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-55
S9W BOSCH MS6.3
DF114
CONTINUED 2
NOTES
the third element solenoid valve control current is too low,
CO
Check the resistance and insulation to earth of the solenoid valve: the resistance
should be 25 at 20 C.
Replace the solenoid valve, if necessary.
computer
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-56
S9W BOSCH MS6.3
DF137
RAIL PRESSURE REGULATION FUNCTION
2.DEF: Measured pressure lower than the required pressure
3.DEF: Measured pressure higher than the required pressure
4.DEF: Measured pressure too low
5.DEF: High current output above the maximum
6.DEF: Valve jammed
NOTES
the measured pressure is more than 1450 mbar.
1.DEF
Check the operation of the pressure sensor, engine stopped and ignition switched
on for at least 2 minutes; the pressure in the rail should be approximately equal to
0 bar. If not, replace the fuel pressure sensor.
If the sensor is operating correctly, the control valve must be jammed closed.
connector.
Check the resistance of the fuel pressure solenoid valve and its insulation to earth:
the resistance should be 2.4 at 20 C.
injection computer
injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
S9W BOSCH MS6.3
DF137
CONTINUED 1
NOTES
the rail pressure is 300 bar lower than the set value.
2.DEF
If the sensor is operating correctly, the regulating valve will show signs of seizing or
the High Pressure pump is unable to raise the pressure.
connector.
Check the resistance of the fuel pressure solenoid valve and its earth insulation:
injection computer
injection computer
If the pump regulating valve is seized, the pressure will be unstable and will not reach
the set value.
If the high pressure pump is not operating correctly, the pressure may stabilise at
approximately the same value when the vehicle is used at full load; this may also be
due to deterioration of the safety valve (out of adjustment).
AFTER REPAIR
13B-57
vnx.su
DIESEL INJECTION
13B
13B-58
S9W BOSCH MS6.3
DF137
CONTINUED 2
NOTES
the rail pressure is 300 bar higher than the set value.
3.DEF
If the sensor is operating correctly, the regulating valve will show signs of seizing.
connector.
Check the resistance of the fuel pressure solenoid valve and its insulation to
earth: the resistance should be 2.4 at 20 C.
injection computer
injection computer
If the pump regulating valve is seized, the pressure will be unstable and will not reach
the set value.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-59
S9W BOSCH MS6.3
DF137
CONTINUED 3
NOTES
Deal with DF082 first if present or stored.
the measured pressure in the rail does not rise rapidly,
the regulating valve control current has a surge of more than 3 A.
4.DEF
5.DEF
Check that the high pressure injection section has no leaks.
Check that the fuel tank is not empty.
Check the condition of the diesel fuel filter and replace it if necessary.
Check for any possible clogging of a fuel pipe from the tank to the high pressure
pump.
Check that the booster pump is operating correctly (fuel pressure: 1.5 - 3 bar and
155 l/h).
Check the continuity and insulation to + 12 V of the following tracks:
injection computer
injection computer
Disconnect the pipe from the safety valve outlet and connect to it a transparent tube,
put the other end of the tube into an empty container, preferably also transparent.
Start the engine and check that the safety valve does not leak. Replace the valve if
necessary.
If everything is correct, replace the high-pressure pump.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-60
S9W BOSCH MS6.3
DF137
CONTINUED 4
NOTES
Deal with DF082 first if present or stored.
the pressure does not line up with the set pressure although it is controlled by the
valve.
6.DEF
Delete the fault and carry out a road test.
If the fault recurs, replace the high-pressure pump.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-61
S9W BOSCH MS6.3
DF082
LOW-PRESSURE PUMP RELAY CIRCUIT
CO : Open circuit
NOTES
with + after ignition switched on and engine stopped.
CC.0
Disconnect the injection computer connector and the low pressure pump relay
connector.
Check the resistance of the relay and its insulation to earth: the resistance should
be 25 at 20 C.
Replace the relay if necessary.
track 1 of the relay track A7 of the injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-62
S9W BOSCH MS6.3
DF082
CONTINUED 1
NOTES
CC.1
Check the resistance of the relay and its insulation to + 12 V: the resistance should
be 25 at 20 C.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-63
S9W BOSCH MS6.3
DF082
CONTINUED 2
NOTES
the relay control current is too low,
CO
Check the resistance and insulation to earth of the relay: the resistance should be
25 at 20 C.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-64
S9W BOSCH MS6.3
DF012
BATTERY VOLTAGE
1.DEF: Feed voltage too high (more than 18 V)
3.DEF: Feed voltage too high (between 16 and 18 V)
2.DEF: Feed voltage too low (less than 6.5 V)
4.DEF: Feed voltage too low (between 6.5 and 12 V engine running)
NOTES
the computer feed voltage exceeds 16 V.
1.DEF
3.DEF
Check the charging circuit. The feed voltage should be approximately 14.4 V and
should never exceed 15 V; repair if necessary.
If the charging circuit is operational, contact your Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-65
S9W BOSCH MS6.3
DF012
CONTINUED
NOTES
voltage less than 12 V with engine running or 6.5 V with engine stopped.
2.DEF
4.DEF
Using a multimeter, measure the voltage across the battery terminals.
If the voltage is less than 10.2 V, carry out a check on the charging circuit.
If the voltage is correct, use a multimeter to measure the voltage at the injection
computer terminals, tracks B9, B41, B10, B22 (+ after ignition) and tracks B12,
B43, B24 (power earth).
If the voltage indicated by the multimeter is the same as the battery voltage, contact
your Techline.
If the voltage displayed by the multimeter is not identical to the battery voltage, check
the condition and continuity of the following lines:
tracks B9, B41, B10 and B22 to track 5 of the main relay
tracks B12, B43, B24 to earth point M10
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-66
S9W BOSCH MS6.3
DF017
MAIN RELAY CIRCUIT
DEF : Feed relay permanently closed
NOTES
the computer detects a voltage on tracks B9, B41, B10 and B22 when the computer
is not activating the main relay earth.
DEF
Confirm the fault by checking the presence of + 12 volts on tracks B9, B41, B10
and B22 with the ignition switched off.
Disconnect injection computer connector B. If the relay loses its earth connection
and cuts off the power feed, contact the Techline.
If the relay is still active, disconnect the relay and check the earth insulation on
track B40 of the ECU connector to track 2 of the main relay.
If the electric wiring is not faulty, replace the main relay.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-67
S9W BOSCH MS6.3
DF036
ACCELERATOR PEDAL POSITION SENSOR CIRCUIT
CO : Open circuit
1.DEF: Inconsistency of the signal
2.DEF: Supply voltage too high
NOTES
line fault on track B2 or B35,
CC.0
CO
Disconnect the injection computer connector and the pedal position sensor
connector.
Check the resistance of the pedal position sensor and its insulationto earth:
the resistance should be 1134 with no load and 2010 with full load at 20 C.
Replace the pedal position sensor if necessary.
track 3 of the pedal position sensor track B2 of the injection
computer
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-68
S9W BOSCH MS6.3
DF036
CONTINUED 1
NOTES
line fault on track B2 or B27,
CC.1
connector.
Check the resistance of the pedal position sensor and its insulation to earth:
Check the continuity and insulation (earth and + 12 V) on the following tracks:
computer
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-69
S9W BOSCH MS6.3
DF036
CONTINUED 2
NOTES
the no load signal and the load signal are outside the no load range.
1.DEF
Check the operation of the no load switch, using state ET016.
If the state remains permanently active or inactive, deal with fault DF051.
connector.
Check the resistance of the pedal position sensor and its insulation to earth:
computer
computer
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-70
S9W BOSCH MS6.3
DF036
CONTINUED 3
NOTES
the feed voltage is higher than 5.2 V.
2.DEF
connector.
Check the insulation to + 12 V of the pedal position sensor feed:
pedal position sensor feed track 4 track B35 of the injection
computer
Reconnect the injection computer connector and check the presence of + 5 volts
across track B27 and track B35 with the ignition switched on.
If the voltage is higher, contact the Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-71
S9W BOSCH MS6.3
DF051
BRAKE PEDAL SWITCH CIRCUIT
DEF: Signal inconsistency
NOTES
the braking signal is active and the load signal is outside the no load position,
this fault may occur during a heel-and-toe action (toe of right foot on brake and heel
of right foot on accelerator) when driving the vehicle.
DEF
Check that feed fuse FU13 in the Fuse & Relay Unit is in good condition.
Use a multimeter to check the operation of the brake pedal switch: with the brake
pedal in the rest position, + 12 volts should be present on track B31 and 0 V on
track B26; brake pedal pressed, + 12 volts should be present on track B26 and 0 V
on track B31.
Replace the brake pedal switch if necessary.
connector.
Check the resistance of the pedal position sensor and its insulation to earth (see
Glossary): the resistance should be 1134 with no load and 2010 with full load at
20 C.
computer
computer
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-72
S9W BOSCH MS6.3
DF004
VEHICLE SPEED SENSOR CIRCUIT
DEF : Inconsistent sensor signal
NOTES
line fault on track B14 or B4.
CC.0
CC.1
DEF
Check the speed information lines, referring to the wiring diagram for the relevant
level of equipment, with or without tachograph.
Check the continuity and insulation on injection computer tracks B14 and B4 to the
tachograph or the speed sensor.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-73
S9W BOSCH MS6.3
DF097
CLUTCH CONTACT INFORMATION
DEF : Vehicle speed sensor coherence
NOTES
the speed signal varies rapidly without any gear change being detected.
DEF
Check that feed fuse FU13 in the Fuse & Relay Unit is in good condition.
Use a multimeter to check the operation of the clutch pedal switch,
Brake pedal in the rest position, + 12 volts should be present on track B38.
Brake pedal pressed, + 0 volts should be present on track B38.
Replace the clutch pedal switch if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-74
S9W BOSCH MS6.3
DF148
FAULT WARNING LIGHT CONTROL
CO : Open circuit
NOTES
control current is too high.
CC.1
Disconnect the injection computer connector and the black instrument panel
connector.
Check the continuity and insulation to 12 V on the following track:
black instrument panel connector track 17 track B23 of the
injection computer
Carry out the diagnostic procedure on the instrument panel to check the correct
operation of the warning light on the instrument panel.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-75
S9W BOSCH MS6.3
DF148
CONTINUED 1
NOTES
no current when the warning light is being activated,
warning light is permanently illuminated.
CC.0
Check there is no fuse in position FU43.
connector.
Check the continuity and earth insulation of the following track:
injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-76
S9W BOSCH MS6.3
DF148
CONTINUED 2
NOTES
warning light is extinguished.
CO
connector.
Check the continuity and earth insulation on the following track:
injection computer
Fit a fuse in position FU43 to test the operation of the warning light.
Replace the instrument panel if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-77
S9W BOSCH MS6.3
DF144
COMPRESSOR CONTROL RELAY LINE
CO : Open circuit
NOTES
CC.1
Disconnect the injection computer connector and the air conditioning compressor
relay.
Check the continuity and insulation to +12 V on the following track:
track 1 of the compressor relay track A35 of the injection
computer
Carry out the diagnostic procedure on the relay and replace it if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-78
S9W BOSCH MS6.3
DF144
CONTINUED
NOTES
no current when the relay is activated,
compressor permanently active.
CC.0
CO
Disconnect the injection computer connector and the air conditioning compressor
relay.
Check the continuity and insulation to earth of the following track:
track 1 of the compressor relay track A35 of the injection
computer
Carry out the fault finding procedure on the relay and replace it if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-79
S9W BOSCH MS6.3
DF068
ENGINE IMMOBILISER LINE
DEF : Immobiliser line fault
NOTES

the injection computer detects a short circuit to earth or an open circuit on the
immobiliser line.
DEF
Check the continuity and earth insulation of the following track:
track 6 of the immobiliser unit track A14 of the injection
computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-80
S9W BOSCH MS6.3
DF185
INLET AIR HEATER PLUG
CO : Open circuit
NOTES
CC.1
Disconnect the injection computer connector and the inlet air heater plug relay
connector.
Check the continuity and insulation to +12 V on the following track:
track 2 of the relay (980 BIM
engine connexion unit) track B42 of the injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-81
S9W BOSCH MS6.3
DF185
CONTINUED
NOTES
the control current is zero.
CC.0
CO
connector.
track 2 of the relay (980 BIM
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-82
S9W BOSCH MS6.3
DF187
INLET AIR HEATER SOLENOID VALVE
CO : Open circuit
NOTES
CC.1
connector.
Check the continuity and insulation to + 12 V on the following track:
track A2 of the relay (980 BIM
Carry out the diagnostic procedure on the relay and replace it if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-83
S9W BOSCH MS6.3
DF187
CONTINUED
NOTES
the control current is zero.
CC.0
CO
connector.
track A2 of the relay (980 BIM
Check the condition of fuse FU13 10A which feeds the coils of the two power relays
(980 BIM (engine connection unit)).
Check the continuity of the line connecting fuse FU13 10A to tracks 1 and A1 of the
two power relays (980 BIM (engine connection unit)).
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-84
S9W BOSCH MS6.3
DF186
INLET AIR HEATER AUTOMATIC CONTROL
DEF : Inoperative
NOTES
the temperature has not increased although the heater system has been switched on.
DEF
Check the condition of pre-heater plug fuse FU7 60A and solenoid valve fuse
FU34 20A.
Check the condition of fuse FU13 10A which feeds the coils of the two power relays.
Check the condition of the feed lines between fuse FU7 and track 3 of the pre-heater
plug relay (980 BIM engine connection unit) and fuse FU34 and track A3 of the
relay (980 BIM engine connection unit).
Check the continuity of the line connecting fuse FU13 10A to tracks 1 and A1 of the
two power relays.
Remove the two relays.
Check the continuity between heater plug relay track 5 and the heater plug.
Check the continuity between heater solenoid valve relay track A5 and the heater
solenoid valve.
Check both the heater plug and heater solenoid valve power relays and replace them
if necessary.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-85
S9W BOSCH MS6.3
DF189
CYLINDER 1 INJECTION BALANCING
DEF : Lack of correlation
NOTES
the computer detects a lack of correlation between the fuel flow setting and the
charge actually injected.
DEF
Check that the high-pressure injection section has no leaks.
Check for any possible clogging of a fuel pipe from the tank to the high-pressure
pump.
155 l/h).
injection computer
injection computer
Check the resistance of injector No.1 and its insulation to earth (see Glossary):
If everything is correct, replace the flow limiter on the high-pressure pipe to injector
No.1.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-86
S9W BOSCH MS6.3
DF190
NOTES
DEF
pump.
155 l/h).
injection computer
injection computer
No.2.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-87
S9W BOSCH MS6.3
DF191
NOTES
DEF
pump.
155 l/h).
injection computer
injection computer
No.3.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-88
S9W BOSCH MS6.3
DF192
NOTES
DEF
pump.
155 l/h).
injection computer
injection computer
Check the resistance of injector No.4 and its insulationto earth (see Glossary):
No.4.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-89
S9W BOSCH MS6.3
DF193
POWER STAGE 1 (CYLINDERS 1 AND 4)
CC : Short circuit
CO : Open circuit
NOTES
the injector control voltage exceeds 100 V with an open circuit,
the injector control voltage is less than 20 V with a short circuit.
CC
CO
Any other present fault MUST be dealt with before this one.
Delete the fault and then carry out a road test.
If the fault recurs, contact your Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-90
S9W BOSCH MS6.3
DF194
POWER STAGE 2 (CYLINDERS 2 AND 3)
CC : Short circuit
CO : Open circuit
NOTES
the injector control voltage exceeds 100 V with an open circuit,
the injector control voltage is less than 20 V with a short circuit.
CC
CO
Any other present fault MUST be dealt with before this one.
Delete the fault and then carry out a road test.
If the fault recurs, contact your Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-91
S9W BOSCH MS6.3
DF195
DIESEL FUEL FILTER HEATER CONTROL
CO : Open circuit
NOTES
CC.1
Disconnect the injection computer connector and the fuel filter heater relay.
track 2 of the heater relay track A32 of the injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-92
S9W BOSCH MS6.3
DF195
CONTINUED
NOTES
no current when the relay is activated,
CC.0
CO
Disconnect the injection computer connector and the fuel filter heater relay.
Check the continuity and insulation to earth of the following tracks:
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-93
S9W BOSCH MS6.3
DF188
INLET AIR HEATER WARNING LIGHT CIRCUIT
CO : Open circuit
NOTES
CC.1
connector.
brown instrument panel connector track 1 track B21 of the
injection computer
Carry out the fault finding procedure on the instrument panel to check the correct
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-94
S9W BOSCH MS6.3
DF188
CONTINUED 1
NOTES
warning light is permanently lit.
CC.0
connector.
injection computer
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-95
S9W BOSCH MS6.3
DF188
CONTINUED 2
NOTES
warning light is extinguished.
CO
connector.
Check the continuity and insulation to earth on the following track:
injection computer
Carry out the fault finding procedure on the instrument panel to check the correct
AFTER REPAIR
vnx.su
DIESEL INJECTION
13B
13B-96
S9W BOSCH MS6.3
DF001
DF175
DF176
DF177
DF178
DF179
DF180
COMPUTER
NOTES
DEF
If the fault is still present, contact your Techline.
AFTER REPAIR
vnx.su
DIESEL INJECTION
Fault finding - Customer complaints
13B
13B-97
S9W BOSCH MS6.3
NOTES
Only refer to this customer complaint after a complete check using the diagnostic tool.
Customer complaints
THE ENGINE DOES NOT TURN OVER WHEN THE STARTER IS OPERATED CHART 1
THE ENGINE TURNS OVER TOO SLOWLY WHEN THE STARTER IS OPERATED CHART 1
THE ENGINE TURNS OVER BUT DOES NOT START CHART 2
THE ENGINE STARTS BUT DOES NOT ACCELERATE OR STALLS CHART 2
ENGINE JERKING CHART 3
ROUGH IDLING CHART 4
OVERHEATING CHART 5
THE ENGINE DOES NOT REACH ITS OPERATING TEMPERATURE CHART 6
THE ENGINE TAKES TOO LONG TO REACH ITS OPERATING
TEMPERATURE
CHART 6
EXCESSIVELY HIGH FUEL CONSUMPTION CHART 7
LACK OF POWER CHART 7
EXCESSIVE OIL CONSUMPTION CHART 8
MAJOR VIBRATIONS CHART 9
HEAVY BLACK SMOKE FROM EXHAUST CHART 10
HEAVY WHITE SMOKE FROM EXHAUST CHART 11
HEAVY BLUE SMOKE FROM EXHAUST CHART 12
NO DIALOGUE WITH ENGINE MANAGEMENT COMPUTER CHART 13
vnx.su
DIESEL INJECTION
Fault finding - Fault location chart
13B
13B-98
S9W BOSCH MS6.3
FAULT FINDING
CHART 1
The engine does not turn over when the starter is operated
The engine does not turn over when the starter is operated
NOTES
Before carrying out any work on the diesel injection system, it is imperative to consult
Repair Manual Section 82 IMMOBILISER and carry out a conformity check.
Check the battery charge condition.
Check the condition of the battery connections.
Check that there is no corrosion on the engine earth braids.
Check starter motor connections.
Make sure that a +12 V voltage is present on the starter motor terminal during starter action.
Check starter motor operation.
Check that oil is present in the crankcase to avoid any engine seizing.
Check that the crankshaft is not locked by performing a crankshaft rotation.
Permanent seizing may be due to:
1) Seizing of equipment driven by the accessories belt: remove the accessories belt and check that all the
equipment driven by the accessories belt turns correctly.
2) Seizing of the crankshaft itself, due to the cylinders filling up with fluid (diesel oil, coolant, etc.): remove
the pre-heater plugs to make sure there is no fluid inside the combustion chambers.
The presence of diesel fuel in the combustion chambers may be due to the injectors being permanently open.
The presence of a fluid such as coolant or engine oil is a sign of failure of the cylinder head gasket or a crack
in one of the cylinder head or engine cylinder components.
3) Destruction of the timing belt causing damage to the timing system components.
4) Damage to moving parts requiring replacement of the engine.
AFTER REPAIR Carry out a road test followed by a test using the diagnostic tool.
vnx.su
DIESEL INJECTION
13B
13B-99
S9W BOSCH MS6.3
FAULT FINDING
CHART 2
The engine turns over but does not start
The engine starts but does not accelerate or stalls
NOTES
Before carrying out any work on the diesel injection system, it is imperative to consult
Repair Manual Section 82 IMMOBILISER and carry out a conformity check.
Make sure that fuel is present in the tank, and check the operation of the pre-heater plugs.
Perform fault finding on the diesel injection system using a diagnostic tool, and deal with any fault detected.
Check the condition of the air intake circuit and make sure there is no obstruction in the intake circuit. Check
for possible seizing of the turbocharger shaft.
Measure the rail pressure using the "Settings" menu while the starter motor is operating. The pressure should
be higher than 170 bar and the engine speed signal should be more than 250 rpm.
Remove the diesel filter and check its condition.
Empty the contents of the diesel fuel filter bowl into a transparent container and allow the diesel fuel to settle
for half an hour. Assess the quality of the diesel oil from its appearance.
Check that no paraffin wax has crystallised in the low pressure fuel pipes due to a sharp drop in the external
temperature.
Rinse the fuel circuit and replace the fuel and the diesel filter if necessary.
If metal particles are present at the bottom of the container, a serious fault must have occurred in the injection
system (e.g. damage inside the high-pressure pump). The particles may have entered the high-pressure
injection system and contaminated the injectors, causing them to seize. In that case, the complete injection
system must be replaced (high-pressure pump, injection rail, injectors, high-pressure injector pipes, etc.).
Remove the pre-heater plugs and measure the engine compressions as described in the Repair Manual.
The compressions should be in the region of 22 - 26 bar.
vnx.su
DIESEL INJECTION
13B
13B-100
S9W BOSCH MS6.3
FAULT FINDING
CHART 3
Engine jerking
NOTES None.
Check the condition of the air intake circuit and make sure there is no obstruction in the intake circuit. Check
for possible seizing of the turbocharger shaft.
Measure the rail pressure using the "Settings" menu while the engine is misfiring. The rail pressure value
should remain stable when the engine speed is stable. The rail pressure loop difference must not exceed
40 bars. Rail pressure instability may be due to seizing of the control solenoid valves or a failure of the high-
pressure pump.
Remove the diesel fuel filter and check its condition.
Empty the contents of the diesel fuel filter bowl into a transparent container and leave the fuel to settle for half
an hour. Assess the quality of the fuel according to its appearance.
Check that no paraffin wax has crystallised in the low pressure fuel pipes due to a sharp drop in the external
temperature.
If metal particles are present at the bottom of the container, a serious fault must have occurred in the injection
system (e.g. damage inside the high-pressure pump). The particles may have entered the high-pressure
injection system and contaminated the injectors, causing them to seize. In that case, the complete injection
system must be replaced (high-pressure pump, injection rail, injectors, high-pressure injector pipes, etc.).
vnx.su
DIESEL INJECTION
13B
13B-101
S9W BOSCH MS6.3
FAULT FINDING
CHART 4
Unstable idle speed
NOTES None.
Check the condition of the air intake circuit and make sure there is no air leak in the intake circuit. Check for
possible seizing of the turbocharger shaft.
Check the resistance of the exhaust gas recirculation valve and check if the slide of the valve is seized.
Measure the rail pressure using the "Settings" menu
during phases of unstable idle speed. The rail pressure value should remain stable when the engine speed is
stable. The rail pressure loop difference must not exceed 40 bar. Rail pressure instability may be due to
seizing of the control solenoid valves or a failure of the high-pressure pump.
Remove the diesel filter and check its condition.
Empty the contents of the diesel fuel filter bowl into a transparent container and leave the fuel to settle for half
an hour. Assess the quality of the fuel according to its appearance.
vnx.su
DIESEL INJECTION
13B
13B-102
S9W BOSCH MS6.3
FAULT FINDING
CHART 5
Overheating
NOTES None.
Use the command mode to check that the cooling fan is operating correctly.Repair if necessary. Check that
the cooling system is correctly filled.
Check correct opening of the thermostat (start of opening at 82 C - fully open at 88 C). For an engine
temperature greater than 85 C the bottom hose of the cooling radiator should not be cold; replace the
thermostat if necessary.
Make sure that the coolant pump is operating correctly by checking the presence of a coolant fluid return flow
from the expansion bottle. In the event of a fault, check for possible clogging of the return path from the
expansion bottle before performing a fault finding test for a coolant pump failure.
Compare the temperature values given by the injection coolant temperature sensor and the value given by an
external temperature sensor (e.g. OPTIMA station, etc.). If the values are inconsistent, replace the coolant
temperature sensor.
If the fault is still present, rinse the cooling circuit and check that the radiator is not clogged.
Clean the front of the radiator to remove any contamination from the radiator fins. Replace the expansion bottle
cap.
vnx.su
DIESEL INJECTION
13B
13B-103
S9W BOSCH MS6.3
FAULT FINDING
CHART 6
The engine does not reach its operating temperature
The engine takes time to reach its operating temperature
NOTES None.
Check that the engine does reach its operating temperature during motorway driving.
Check whether the thermostat has seized.
Compare the temperature values given by the injection coolant temperature sensor and the value given by an
external temperature sensor (e.g. OPTIMA station, etc.). If the values are inconsistent, replace the coolant
temperature sensor.
If the value supplied by the injection coolant temperature sensor is correct, replace the thermostat.
vnx.su
DIESEL INJECTION
13B
13B-104
S9W BOSCH MS6.3
FAULT FINDING
CHART 7
Excessively high fuel consumption
Lack of power
NOTES None.
Check conformity of tyres and their pressure.
Check that the vehicle is not equipped with external devices affecting its aerodynamics.
Check the condition of the air filter and replace if necessary.
Check that the intake circuit is in sound condition and is neither leaky nor clogged (hose and air-air exchanger,
fouling of flowmeter).
Check that the engine does reach its operating temperature during motorway driving.
Check that the turbocharger is operating correctly (visual inspection and pressure measurement).
Remove the pre-heater plugs and measure the engine compressions as described in the Repair Manual.
The compressions should be in the region of 22 - 26 bar.
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DIESEL INJECTION
13B
13B-105
S9W BOSCH MS6.3
FAULT FINDING
CHART 8
Excessive oil consumption
NOTES None.
Check that the oil level is correct, and remove the excess if necessary.
Check the sealing of the engine block and turbocharger lubrication pipes, and the pipes and oil radiator. Repair
if necessary.
Check that the oil breather pipes are not crushed or clogged.
Remove the inlet hose from the turbocharger inlet and outlet. Check the absence of large quantities of oil in
the turbocharger or the inlet hoses:
a large quantity of oil in the turbocharger inlet hose indicates significant oil discharge via
the oil breather (engine wear or breather clogged, etc.).
a large quantity of oil in the turbocharger outlet hose indicates failure of the turbine shaft
sealing ring. Replace the turbocharger if necessary.
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DIESEL INJECTION
13B
13B-106
S9W BOSCH MS6.3
FAULT FINDING
CHART 9
Major vibrations
NOTES None.
Check the condition and tightness of the engine mountings.
Check the accessories drive pulley (damper). The rubber mounting must be in perfect condition and the pulley
must not exhibit any run-out when rotating. Replace if necessary.
Remove the accessories belt and start the engine. If the vibration has disappeared, find out which of the
accessories driven by the belt is faulty.
Check timing belt adjustment.
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DIESEL INJECTION
13B
13B-107
S9W BOSCH MS6.3
FAULT FINDING
CHART 10
Heavy black smoke from exhaust
NOTES None.
Check that the whole intake system is neither clogged nor leaky. Check the condition of the air filter and replace
if necessary.
Remove the inlet hose from the turbocharger inlet and check that the turbine shaft rotates very freely. Check
that the turbocharger axial and lateral play values are within tolerances.
Check for possible seizing of the turbocharger wastegate in the open position, and replace the turbocharger if
necessary (turbocharger seizing may be due to poor lubrication of the bearings: check for possible clogging of
the lubrication circuit and check the engine oil pressure).
Check that the exhaust gas recirculation valve is not locked in open position, replace it if necessary.
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DIESEL INJECTION
13B
13B-108
S9W BOSCH MS6.3
FAULT FINDING
CHART 11
Heavy white smoke from exhaust
NOTES
If the vehicle has not been used for a long time, let the engine reach its operating
temperature and, after first checking the coolant fluid level, perform a road test.
Check with the customer that the vehicle's engine has not overheated.
Check the coolant level. A sharp drop in the level indicates a cooling system leak or fluid consumption by the
engine via the cylinder head gasket.
Run the engine at idle speed until its operating temperature is reached, with the expansion bottle cap in place.
If the vehicle emits white smoke from the exhaust, slowly loosen the expansion bottle cap to reduce the
pressure in the cooling circuit. If the vehicle stops emitting smoke, one of the cylinder head gaskets is
damaged. Replace the cylinder head gasket.
Otherwise, check the quality of the diesel oil and make sure there is no water in the diesel filter. Run the engine,
supplying the diesel filter with clean diesel oil from a closed circuit external to the vehicle. If the vehicle operates
correctly, rinse the diesel supply circuit and the tank, and replace the fuel and the diesel filter.
vnx.su
DIESEL INJECTION
13B
13B-109
S9W BOSCH MS6.3
FAULT FINDING
CHART 12
Heavy blue smoke from exhaust
NOTES None.
Top up the oil level, and if the level is too high remove the excess.
Check that the oil breather pipes are not crushed or clogged.
Remove the inlet hose from the turbocharger inlet and outlet. Check that there is not a large quantity of oil in
the turbocharger or the inlet hoses:
a large quantity of oil in the turbocharger inlet hose indicates significant oil discharge via the
oil breather (engine compression ring wear or breather clogged, etc.).
a large quantity of oil in the turbocharger outlet hose indicates failure of the turbine shaft
sealing ring. Replace the turbocharger if necessary.
If the inlet system is clean, a small quantity of oil deposited on the walls of the inlet hoses is
acceptable. The oil consumption is undoubtedly due to an internal engine failure (e.g. valve
stem seal, oil ring, etc.).
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DIESEL INJECTION
13B
13B-110
S9W BOSCH MS6.3
CHART 13 No communication with the engine management computer
NOTES None.
Make sure that the tool is not the cause of the fault by trying to establish dialogue with a computer on another
vehicle. If the tool is not at fault, and dialogue is not possible with any other computer on the same vehicle,
a faulty computer may be causing interference on line K.
Trace which one through a process of elimination, successively disconnecting each ECU.
Also check the battery voltage.
Check the presence and condition of the engine fuses in the "engine fuse/relay box" (see wiring diagram).
Check the computer power supply on the connector side.
Check the earth connections.
Check the computer connector (crimping of wires to terminals, and condition of terminals).
Check the supply to the diagnostic socket:
+ before ignition on track 16.
+ after ignition en track 1
earth on tracks 4 and 5
Ensure the continuity and insulation of the following connections:
engine computer, connector A track 7, diagnostic socket track 3 line K
If dialogue is still impossible after these various checks, replace the engine computer.
If necessary, modify the configuration of the new computer to match the equipment options available on the
vehicle.
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DIESEL INJECTION
Fault finding - Component sheet
13B
13B-111
S9W BOSCH MS6.3
Manifold pressure sensor
Distinctive Pressure/Voltage transducer
Supply voltage 5 V 0.25
Type of circuit Active circuit
System fitted Bosch MS6.3 injection
Type of connector 4 tracks (1 Minus / 2 Air temperature / 3 Plus / 4 Pressure signal)
Description:
This sensor is used by the injection system to give a signal relating to the manifold pressure drop or the
turbocharger turbocharging pressure. It uses a piezoelectric device which produces an electric voltage proportional
to the stress applied to it (in this case, pressure). This signal is very weak and is amplified by an internal electronic
system which requires an external 5 V feed supplied by the injection computer.
Checking the sensor:
The sensor delivers a voltage proportional to the
manifold pressure:
2.5 bar absolute (1.5 bar relative) = 4.65 V
0.2 bar absolute (- 0.8 bar relative) = 0.4 V
Check first that the sensor is correctly fed with + 5 volts with the sensor connected.
Use a multivac pump connected to the sensor's vacuum coupling to check that the signal does corresponds to the
graph. Disconnect track 3 linking the computer to the sensor and connect the "+" lead of a multimeter (set at
between 5 and 10 V) to track 3 of the sensor and the "-" lead to track 2 of the sensor
(sensor earth still connected to the computer).
At atmospheric pressure, the voltage should be approximately equal to 1.7 V.
At an absolute pressure close to 2.5 bar, the voltage should be approximately equal to 4.65 V.
At an absolute pressure close to 0.2 bar, the voltage should be approximately equal to 0.4 V.
If the voltages do not correspond to the pressures, replace the sensor.
V
4.65
0.4
0.2 2.5 bar
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DIESEL INJECTION
13B
13B-112
S9W BOSCH MS6.3
Coolant/air/fuel temperature sensor
Distinctive Temperature/Resistance transducer
Resistance Depends on the temperature
Type of circuit Passive circuit
Type of connector 2 tracks
Description:
This sensor is used by the injection system to give a signal which represents the temperature of a component to
which the sensor is attached. This is a resistance with a negative temperature coefficient (the resistance decreases
as the temperature increases). A circuit inside the computer feeds the sensor at constant current. Variation of the
resistance causes the voltage at the sensor terminals to vary; this voltage is representative of the temperature.
The presence of yellow or clear wax inside the connector indicates that the sensor seal is broken. In that case,
replace the sensor.
First, use a multimeter to check the insulation of the sensor's two tracks from its metal base (if so equipped) or from
the engine earth. The resistance should in all cases be infinite and if this is not the case replace the sensor.
Using a multimeter, check the sensor's resistance in relation to the temperature. For this purpose refer to the table
below. If the values do not correspond, replace the sensor.
Coolant and diesel fuel sensor
in-line resistance in 20
Air temperature sensor
resistance in 20
Temperature in C 2
45313 39180 - 40
15462 13240 - 20
9397 8160 - 10
5896 5180 0
2500 2270 20
2057 2010 25
1175 1059 40
596 538 60
323 290 80
186 164 100
113 97 120
71 140
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DIESEL INJECTION
13B
13B-113
S9W BOSCH MS6.3
Distinctive Position/Resistance transducer
Resistance Depends on the angle
Type of circuit Passive circuit
Type of connector 6 tracks
Pin configuration:
track 2 > potentiometer earth,
track 4 > potentiometer feed, track 5 > no load switch signal
track 3 > potentiometer signal, track 6 > no load switch earth
Description:
This sensor is fitted with a potentiometer (variable resistance) and a no load switch. The position of the shaft
causes a variation in the sensor's internal resistance. The two signals are used by the injection computer to check
that the accelerator potentiometer is giving coherent signals.
Use a multimeter to measure the resistance of the potentiometer. Between tracks 2 and 3, the resistance should
be 1134 500 and between tracks 5 and 6 the resistance should be infinite.
At full load, the resistance between tracks 2 and 3 should be 2010 500 and between tracks 5 and 6 the
resistance should be 1004 500. If one of the tracks is not within these tolerances, replace the accelerator
potentiometer.
vnx.su
DIESEL INJECTION
13B
13B-114
S9W BOSCH MS6.3
Distinctive Position/Voltage transducer
Type of circuit Active circuit
Type of connector 3 tracks (1 Plus / 2 Signal / 3 Minus)
Description:
This sensor is used by the injection system to give a signal relating to the rail pressure (fuel pressure in the
common rail). It uses a piezoelectric device which produces an electric voltage proportional to the stress applied
to it (in this case, pressure). This signal is very weak and is amplified by an internal electronic system which
requires an external 5 V feed supplied by the injection computer.
The sensor delivers a voltage proportional to the rail
pressure:
1500 bars = 4.5 V
0 bar = 0.5 V
The formula is as follows:
where P is the pressure in bar, and:
U is the signal voltage in volts:
P
+ 0.5 = U
375
(U - 0.5) 375 = P
Check first that the sensor is correctly fed with + 5 volts with the sensor connected.
Reduce the pressure in the common rail and check that the sensor signal voltage is 0.5 V.
If the voltage is not correct, replace the sensor.
V
4.5
3.2
1.8
0.5
0 500 1000 1500 bar
vnx.su
DIESEL INJECTION
Fault finding - Glossary
13B
13B-115
S9W BOSCH MS6.3
Fault finding - Glossary
High-pressure pump 1350 bar max.
Pressure sensor Bolted to rail (pressure range: 0 to 1500 bar)
Injector 0.33 at 20 C
Pressure regulator Resistance = 2.4 at 20 C
Injection computer (ECU): 2 x 43 tracks
Accelerator pedal sensor Track resistance = 1134 - 2010 at 20C
No load switch resistance = 1700
Inlet air heater plug Resistance = 0.30 connector disconnected
Inlet air heater solenoid valve Resistance = 8 5
Air temperature sensor Resistance = 2270 200 at 20 C
Diesel fuel temperature sensor: Resistance = 2500 200 at 20 C
Engine coolant temperature sensor Resistance = 2500 200 at 20 C
Engine speed / camshaft sensor Induction sensor resistance = 860 86
Fan magnetic clutch Resistance = 6 at 20 C
Wastegate solenoid valve Resistance = 6 4 at 20 C
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Transmission
CLUTCH
MANUAL GEARBOX
FINAL DRIVE
DRIVESHAFT
77 11 320 042
vehicles are constructed".
FEBRUARY 2003
EDITION ANGLAISE
RENAULT.
RENAULT 2002
vnx.su
Transmission
Contents
Pages
20A
21A
26A
29A
CLUTCH
Exploded view 20A-2
Mechanism - Disc 20A-3
Thrust bearing 20A-5
Thrust bearing guide 20A-6
Steering wheel 20A-7
MANUAL GEARBOX
Ratios 21A-1
Lubricants 21A-2
Gearbox 21A-5
FINAL DRIVE
Consumables 26A-2
Final drive 26A-3
DRIVESHAFTS
Longitudinal transmission 29A-1
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CLUTCH
Identification
20A
20A-1
120A
CLUTCH
Identification
MECHANISM
PLATE
20 splines LG: Light Grey
D = 235 mm
E = 5.2 mm
Single plate dry clutch.
Hydraulic clutch release control.
Constant pressure clutch thrust bearing.
MECHANISM
PLATE
20 splines LG: Light Grey
D = 267 mm
E = 5.5 mm
Single plate dry clutch.
Hydraulic clutch release control.
Constant pressure clutch thrust bearing.
VEHICLE ENGINE
XHXE S9W 206
VEHICLE ENGINE
XHXE S9W 206
XHXF S9W 208
XHXG S9W 212
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CLUTCH
Exploded view
20A
20A-2
Exploded view
1 Tank
2 Master
3 Slave
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CLUTCH
Mechanism / Plate
20A
20A-3
Mechanism / Plate
REPLACEMENT
This operation is performed after the power train
has been removed and the gearbox has been
uncoupled.
REMOVAL
Separate the tabs (1) and remove the thrust bearing
simultaneously.
Remove:
the mechanism mounting bolts,
the mechanism and the clutch disc.
Check and replace any faulty parts.
REFITTING
Clean the clutch shaft splines and refit the assembly
without adding lubricant.
De-grease the friction face of the flywheel.
Fit the disc (step (2) on the engine flywheel side).
Tightening torques
mechanism mounting bolt on the
engine flywheel 3.9 daNm
starter mounting bolt 1.9 daNm
gearbox edge bolt 9.4 daNm
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CLUTCH
Mechanism / Plate
20A
20A-4
ALIGNMENT
Use the plastic centering device.
Refit the mechanism to the engine flywheel.
Gradually tighten the bolts in order to a torque of
3.9 daNm.
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CLUTCH
Thrust bearing
20A
20A-5
Thrust bearing
REPLACEMENT
This operation is carried out after the gearbox has
been uncoupled from the engine.
REMOVAL
Remove the thrust bearing by removing clip (1).
REFITTING
Ensure the thrust bearing slides correctly.
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CLUTCH
Thrust bearing guide
20A
20A-6
Thrust bearing guide
REPLACEMENT
been uncoupled from the engine.
REMOVAL
Remove:
the two mounting bolts (1) from the fork,
the three mounting bolts (2) from the thrust bearing
guide.
REFITTING
Refit the thrust bearing guide.
Tighten the thrust bearing guide bolts to torque
(2.3 daNm).
Refit the fork.
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CLUTCH
Flywheel
20A
20A-7
Flywheel
REPLACEMENT
been uncoupled from the engine and the clutch
has been removed.
REMOVAL
Remove the mounting bolts (1) from the engine
flywheel.
REFITTING
Refit the engine flywheel.
Position the engine flywheel bolts by hand.
Fit gauge rods (Mot. 1693) to centre the engine
flywheel in relation to the mounting hole on the
crankshaft.
Immobilise the engine flywheel using tool
(Rou. 604-01).
Tighten the engine flywheel bolts.
Remove the gauge rods (Mot. 1693).
Tighten the engine flywheel mounting bolts to torque
(3 daNm).
Tighten to an angle of 90 .
Remove the immobilisation tool (Rou. 604-01).
Rou. 604-01 Hub immobilisation tool
Mot. 1693 Engine flywheel centering gauge rod
Tightening torques
flywheel bolt 3 daNm + 90
gearbox edge nut 9.4 daNm
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GEARBOX
Ratios
21A
21A-1
121A
GEARBOX
Ratios
ZF 5S.200 GEARBOX
ZF 6S.300 GEARBOX
Vehicle Engine
Final
drive
ratio
First Second Third Fourth Fifth
Double cab
chassis
Cab chassis
S9W206 8X39 5.138 9.860 16.867 25.637 32.868
Cab chassis S9W206 8X41 5.208 9.996 17.099 25.990 33.321
Double cab
chassis
Cab chassis
S9W206 8X41 5.00 9.55 16.40 24.92 31.96
Van
Double cab
chassis
Cab chassis
S9W206 8X39 5.362 10.291 17.603 26.757 34.304
Vehicle Engine
Final
drive
ratio
First Second Third Fourth Fifth Sixth
Double cab chassis
Cab chassis
S9W208 10X39 4.762 8.113 12.518 18.003 24.842 32.046
Cab chassis
Double cab chassis
S9W208 10X41 4.827 8.225 12.691 18.252 25.184 32.488
Van
Double cab chassis
Cab chassis
S9W208 10X39 4.970 8.467 13.065 18.790 25.927 33.446
Double cab chassis S9W212 11X39 5.239 8.925 13.772 19.806 27.33 35.255
Bare chassis S9W212 10X37 5.349 9.114 14.063 20.225 27.907 36.000
Van
Double cab chassis
S9W212 11X39 5.467 9.315 14.373 20.672 28.524 36.795
Cab chassis
Double cab chassis
S9W212 9X41 4.345 7.403 11.423 16.428 22.669 29.243
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MANUAL GEARBOX
Lubricants
21A
21A-2
MANUAL GEARBOX
Lubricants
CAPACITY (in litres)
VISCOSITY GRADE
TRANSELF LD 75W 80 oil
ZF S5.200
1 Drain plug
2 Filler plug
ZF S5.200 2.2
ZF S6.300 2.7
Note:
Top up by overfilling.
vnx.su
MANUAL GEARBOX
Gearbox
21A
21A-3
Gearbox
REMOVAL
It is necessary to remove the power unit to remove the
gearbox (see Section 10A Engine assembly and
lower engine, Power unit).
Drain the gearbox.
Remove the clutch slave cylinder mounting.
Disconnect the starter motor feed.
Remove:
the engine speed sensor,
the three starter mounting bolts,
the closure panel mounting bolts.
Remove the gearbox edge mounting nuts.
Tightening torques
gearbox casing bolt 9.4 daNm
clutch slave cylinder mounting 0.7 daNm
starter mounting bolt 1.9 daNm
WARNING
Never depress the clutch pedal with the slave
cylinder removed.
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MANUAL GEARBOX
Gearbox
21A
21A-4
REFITTING
Ensure that the engine/gearbox centring studs are
fitted.
Refit the gearbox on the engine.
Tighten the gearbox edge nuts to torque (9.4 daNm).
Fill the gearbox (see Lubricants).
WARNING
Do not grease the clutch shaft splines.
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FINAL DRIVE
Identification
26A
26A-1
126A
FINAL DRIVE
Identification
A plate secured to the drive axle showing:
the drive axle type and its suffix,
the fabrication number,
the final drive.
Type of drive axle Final drive
P569 11X39
P669 X
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FINAL DRIVE
Consumables
26A
26A-2
Consumables
CAPACITY (1)
Filling is carried out through plug (1).
Draining the drive axle also includes draining the
wheel hubs.
Drive axle oil
Tranself 80W90W
P569 4.2
P669 5.5
Wheel hubs 0.5
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FINAL DRIVE
Final drive
26A
26A-3
Final drive
REMOVAL
Drain:
the wheel hubs,
the drive axle.
Remove:
the rear wheels,
the connecting bolts from the longitudinal driveshaft
marking its position in relation to the input flange.
Disconnect the longitudinal driveshaft from the final
drive.
Disconnect:
the left and right-hand brake pad wear connectors
(1),
the left and right-hand wheel sensor (2) connectors.
Unclip the drive axle stabiliser rod (3) .
Tightening torques
longitudinal driveshaft bolt 10 daNm
wheel nuts 36 daNm
Anti-roll bar bolts 9.8 daNm
Suspension lower bolt 3.5 daNm
final drive nuts 26 daNm
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FINAL DRIVE
Final drive
26A
26A-4
Remove brake pipe unions (4).
Disconnect the handbrake cables.
Remove the anti-roll bar return bar upper mountings
(5).
Remove the shock absorber lower mountings (6).
Position the engine trolley (Mot. 1390) under the drive
axle.
Remove the drive axle mountings.
Remove the drive axle.
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FINAL DRIVE
Final drive
26A
26A-5
REFITTING
fill the drive axle up with oil,
fill the wheel hubs up with oil,
check and adjust the handbrake control,
fill and bleed the braking circuit.
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TRANSMISSION
Longitudinal driveshaft
29A
29A-1
129A
TRANSMISSION
NOTE
The longitudinal driveshaft is sensitive to adjustment.
Consequently, no repairs are allowed.
The longitudinal driveshaft is divided into two sections.
The driveshaft must always be replaced as a whole.
REMOVAL
Mark the position of the driveshaft bearing mountings
in relation to the body using a spot of paint.
Uncouple the longitudinal driveshaft from the gearbox.
Disconnect the first section of the driveshaft from the
second.
Remove the mounting bolts from the longitudinal
driveshaft bearings.
Remove the first section of the longitudinal driveshaft.
Uncouple the second section of the longitudinal
driveshaft from the drive axle.
Tightening torques
bolt on gearbox output flange 10 daNm
bolt on final drive input flange 10 daNm
bolt on driveshaft flange 10 daNm
bearing mounting bolt 6.4 daNm
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TRANSMISSION
29A
29A-2
Remove the second section of the longitudinal
driveshaft (this operation requires two people).
REFITTING
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Chassis
GENERAL INFORMATION
FRONT AXLE MOUNTINGS
REAR AXLE MOUNTINGS
WHEELS AND TYRES
POWER ASSISTED STEERING
MECHANICAL COMPONENT CONTROLS
ANTI-LOCK BRAKING SYSTEM
77 11 320 062
FEBRUARY 2003
EDITION ANGLAISE
RENAULT.
RENAULT 2002
vnx.su
Chassis
Contents
Page
30A
31A
33A
35A
GENERAL INFORMATION
General diagram of braking circuits 30A-1
Brake circuit unions and pipes 30A-2
Brake fluid 30A-3
Structure and dimensions of the
main braking components 30A-4
Tightening torques 30A-5
Bleeding the brake circuit 30A-9
FRONT AXLE MOUNTINGS
Brake linings 31A-1
Brake calliper 31A-3
Hubs 31A-5
Brake disc 31A-6
REAR AXLE MOUNTINGS
Brake linings 33A-1
Parking brake 33A-2
Parking brake linings 33A-4
WHEELS AND TYRES
Technical specifications 35A-1
Wheel balancing 35A-4
Page
36B
37A
38C
Steering rack 36B-1
MECHANICAL COMPONENT
CONTROL
Master cylinder 37A-1
Brake servo 37A-2
Clutch release control 37A-3
External gear control 37A-4
Handbrake adjustment 37A-5
Brake limiter 37A-6
Location of components 38C-1
Allocation of computer tracks 38C-2
Hydraulic module track allocation 38C-3
Hydraulic unit 38C-4
Computer 38C-5
Bleeding the brake circuit 38C-6
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GENERAL INFORMATION
Diagram of braking circuits
30A
130A
GENERAL INFORMATION
Diagram of braking circuits
IMPORTANT
The following diagram is a general diagram; do not
use it as reference for the circuit connections and
allocations When replacing one of the components
of the brake circuit on a vehicle, always mark the
pipes before removing them so that they can be
reconnected in their original positions.
"H" BRAKING
with load sensitive compensator
"H" BRAKING
with ABS system
30A-1
vnx.su
GENERAL INFORMATION
Brake circuit connection and piping
30A
30A-2
Brake circuit connection and piping

The pipes between the master cylinder, callipers and
the hydraulic unit are connected using threaded
unions with a METRIC THREAD.
Consequently, only parts specified in the Parts
Catalogue for this vehicle should be used.
Identification of parts:
SHAPE of the ends of PIPES in steel or copper (A).
SHAPE of the THREADED HOUSINGS on
components (B).
GREEN OR BLACK pipe UNION: 6 external
hexagons measuring 11 mm or 12 mm (C).
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GENERAL INFORMATION
Brake fluid
30A
30A-3
Brake fluid
BRAKE FLUID REPLACEMENT INTERVALS
Our Brake technology, in particular our disc brakes
which have hollow pistons which transfer little heat,a
low volume of fluid in the cylinder and sliding callipers
avoiding the need for a fluid reservoir in the least
cooled area of the wheel), has allowed us to avoid the
risk of vapour lock as far as possible, even if the
brakes are used intensively (in mountainous areas).
Current brake fluids still deteriorate slightly during the
first few months of use, however, due to a slight take-
up of water, and replacement of the fluid is therefore
recommended (refer to vehicle's Warranty and
Servicing Handbook).
Topping up the level
Wear of the brake pads will cause a gradual drop in
the fluid level in the reservoir. The fluid should not be
topped up as the level will rise again when the pads
are changed. However, the level of brake fluid should
not go below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will
cause a risk of major leaks, mainly due to damage to
the cups. To avoid these risks, it is essential to keep to
brake fluids which have been checked and approved
by our laboratories and which conform to Standard
SAE J 1703 DOT 4.
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GENERAL INFORMATION
Dimensions and structure of main braking components
30A
30A-4
Dimensions and structure of main braking components
BRAKE FLUID
Conforms to SAE J 1703 DOT 4 standards.
FRONT BRAKES (3.5 t to 5 t vehicle) (in mm)
Disc diameter
Disc thickness
Minimum disc thickness
Maximum disc run-out
Brake pad thickness (including mounting)
Minimum thickness of brake pads (including mounting)
290
22
19
0.05
20
7
FRONT BRAKES (5.5 T to 6.5 T) (in mm)
Disc diameter
Disc thickness
290
26
23
20
7
REAR BRAKES (in mm)
Disc diameter
Disc thickness
Maximum disc run-out
290
22
19
0.05
20
7
PARKING BRAKES (in mm)
Drum diameter
Maximum diameter of drums
Thickness of brake pads (mounting not included)
Minimum thickness of brake pads (mounting not included)
172
173
6
3.5
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GENERAL INFORMATION
Tightening torques (in daNm)
30A
30A-5
FRONT AXLE
A 5
B 5.5
C 8
D 17.8
E 36
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GENERAL INFORMATION
30A
30A-6
FRONT AXLE
A 5.5
B 8
C 9
D 9.8
E 15.5
F 17
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GENERAL INFORMATION
30A
30A-7
REAR AXLE FITTED WITH FINAL DRIVE 569
A 3.5
B 4
C 5.5
D 8
E 9.8
F 15
G 26
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GENERAL INFORMATION
30A
30A-8
REAR AXLE FITTED WITH FINAL DRIVE 669
A 3.5
B 5.5
C 6
D 8
E 16
F 26
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GENERAL INFORMATION
Bleeding the brake circuit
30A
30A-9
To ensure correct operation, a brake circuit must
be free of gas (external air, water vapour etc.).
Whenever the circuit is opened, the air penetrating
the circuit must therefore be bled out after it is
closed.
As the brake fluid ages (see service intervals) it
absorbs a significant amount of moisture which
may create water vapour in the circuit, in certain
extreme conditions. This ageing process means
that the circuit must be drained completely and
then the air contained in it must be bled.
Prerequisites for any bleeding of air from the brake
circuit:
make sure that there are no leaks in the fuel system,
fill brake fluid reservoir (1) to maximum level,
depress the brake pedal several times, so that the
moving components of the braking system (pistons,
brake shoes, discs or drums) all make contact with
each other,
add brake fluid (1) to top up the level in the reservoir,
set up the bleeding device and fill the brake fluid level
(1) to maximum (refer to the instructions), and apply
a pressure of (between 2 and 2.5 bar) to the device.
Only one bleeding operation is possible on this
vehicle: the "conventional" bleed operation. The ABS
circuit cannot be bled.
(1) Brake fluid SAE J 1703 F DOT 4.
Essential equipment
Brake circuit bleeding device
(approved by RENAULT)
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GENERAL INFORMATION
30A
30A-10
THE CLASSIC OR CONVENTIONAL BLEED
This procedure must be used after one of the following
components has been removed or replaced:
the master cylinder,
the hydraulic assembly (new and pre-filled),
a rigid pipe,
a hose,
a calliper.
Precautions to be taken during this braking circuit
bleeding operation:
the vehicle ignition must be off to ensure that the
hydraulic assembly solenoid valves do not operate,
Check the brake fluid levels of the braking circuit and
the bleeding device.
Connect the bleeding device to the braking circuit,
paying attention to the features of this equipment (refer
to the operating instructions).
Bleed the circuit by opening the bleed screws in the
following order (remember to close them after the
operation):
rear right-hand circuit,
rear left-hand circuit,
front right-hand circuit,
front left-hand circuit.
With the engine switched off, check the pedal travel, if
it is not correct, restart the bleeding procedure.
Top up the brake fluid level in the reservoir after
disconnecting the bleeding device. Check the
tightness of the bleed screws and that the sealing caps
are all present.
Confirm the efficient regulation of the hydraulic unit by
performing a road test.
The effectiveness and balance of the vehicle braking
system may be checked on a brake test bench or by
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FRONT AXLE
Brake pads
31A
31A-1
131A
FRONT AXLE
Brake pads
REMOVAL
Remove:
the wheel,
the brake calliper lower guide bolt.
Disconnect the electrical connector from the wear
warning strips.
Pivot the calliper upwards around the upper guide bolt.
Remove the pads.
Check the condition of the dust seals, the pistons and
the anti-vibration plate (replace if necessary).
REFITTING
Push back the pistons using tool (Fre. 823).
Tightening torques
wheel nuts 36 daNm
calliper pillar bolt 2.8 daNm
bleed screw 1.4 daNm
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FRONT AXLE
Brake pads
31A
31A-2
Fit the new pads (and the anti-vibration plate if
necessary).
Thread the wear warning strip cable through the spring
hole towards the outside of the calliper.
Pivot the calliper downwards.
Apply LOCTITE in the fork hole and tighten the
calliper pillar bolt to torque (2.8 daNm).
IMPORTANT
Depress the brake pedal several times to bring the
pistons, the brake pads and discs into contact.
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FRONT AXLE
Brake calliper
31A
31A-3
Brake calliper
REMOVAL
Remove the wheel.
In the passenger compartment, t a pedal press (to
limit the amount of brake uid which will run out).
warning strips.
Loosen the brake uid supply hose without removing it.
Check the condition of the hoses and replace them if
necessary. The brake hose must also be replaced
when the calliper is replaced.
Remove the two mounting bolts from the brake
calliper.
REFITTING
Apply LOCTITE in all the calliper holes, then ret the
calliper mounting bolts.
Check the condition of the pads and replace them if
necessary.
Bleed the circuit (using a bleeding device).
REPAIR
Replacing the pistons
Remove the brake calliper.
Insert the pistons into their seals (be careful not to
damage the piston seals).
Disengage the plate retaining spring.
Remove the compressed air pistons from the calliper
brake uid supply hole, taking care not to drop the
piston.
Disengage and remove the gaiters (3).
Remove the seals (1) from their respective housings.
Remove the bleed screw (5).
Wash and degrease the calliper body and the pistons.
Clean the seals and gaiters with a clean cloth.
Grease the new seals (1) and the external diameter of
the pistons (4) with the grease supplied.
Tightening torques
wheel nuts 36 daNm
calliper mounting bolt 18 daNm
calliper pillar bolt 2.8 daNm
bleed screw 1.4 daNm
calliper hydraulic unionr 1.8 daNm
IMPORTANT
IMPORTANT
The complete calliper must automatically be
replaced if the calliper bore is scored.
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FRONT AXLE
Brake calliper
31A
31A-4
Ret the seals (1) into the calliper housing (2).
Grease the gaiters (3).
Fit the gaiters (3) to the calliper.
Insert the bleed screw (5) into the calliper body.
Bleed the air from the seals.
Tighten the bleed screw to torque (1.8 daNm).
Ret the plates and the spring.
Tighten the calliper to torque (18 daNm).
Replace the pillars and the gaiters
Remove the brake calliper.
Ret the pistons using tool (Fre. 823) until they are at
the bottom of their bores.
Remove the two calliper pillars and their respective
gaiters.
Carefully clean the internal surface of the calliper pillar
guides.
With the grease supplied, grease:
the whole internal surface of the calliper pillar guides
(2),
the pillar external diameter (7),
the interior of the new gaiters (6).
Fit the rst gaiter (6) on one of the two calliper pillar
guides (2).
Fit the pillar (7) into its guide, threading it through the
side without the gaiter.
Fit the second gaiter (6) on the calliper (2), after axially
positioning the pillar so as to attach the gaiter.
Repeat these operations with the second pillar.
Tighten the pillar bolts to torque (2.8 daNm).
Tighten the calliper to a torque of 18 daNm.
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FRONT AXLE
Hubs
31A
31A-5
Hubs
REFITTING
Grease the stub-axle.
Ret the hub (8).
Fit the bearing (9).
Tighten the stub-axle nut (6) to torque (5 daNm)
while turning the hub several times in both directions.
Release the nut by approximately 72 .
Retighten the nut to torque (5 daNm) and lock it.
Special notes of vehicles tted with ABS:
Adjust the sensor so that it comes into contact with the
toothed wheel.
REMOVAL
Remove in the order indicated below.
WARNING
Each hub must be fitted with bearings of the same
marque.
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FRONT AXLE
Brake discs
31A
31A-6
Brake discs
REMOVAL
Remove the disc / hub assembly (see previous
operation).
Disconnect the disc from the hub.
REFITTING
Ret the disc onto the rim holder.
Tighten the disc mounting bolts to torque
(5.5 daNm).
Ret the disc / hub assembly.
Tightening torques
brake disc mounting bolt 5.5 daNm
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REAR AXLE COMPONENTS
Brake pads
33A
33A-1
133A
Brake pads
REMOVAL
Remove the rear wheels.
warning strip.
Unscrew the two mounting bolts on the pillar guides.
Hang the calliper body on the suspension using a
hook, taking care not to damage the hose.
Remove both of the used brake pads from the calliper.
Push back the pistons using the tool (Fre. 823).
Check:
the condition of the hose and replace it if necessary,
the condition of the dust seals,
the condition of the pistons.
REFITTING
Fit the new brake pads, placing the pad with a wear
warning strip on the side closest to the piston.
Pass the wear warning strip cable through the spring
hole, towards the outside of the calliper.
Ret the pillars to the calliper carrier.
Fit and torque tighten the two calliper pillar bolts
(3 daNm).
Take care not to toe-in the seals when carrying out this
operation.
Torque tighten the wheel nuts (36 daNm).
Tightening torques
wheel nuts 36 daNm
calliper pillar bolts 3 daNm
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Parking brake
33A
33A-2
Parking brake
REMOVAL
Remove the rear wheels.
Unscrew the calliper mounting bolts.
warning strip.
Hang the calliper body on the suspension using a
hook, taking care not to damage the hose.
Remove the ten mounting bolts and remove the half
axle from the driveshaft.
Release the tensioner lock nut and use the tensioner
to create play on the cable.
Remove the hub nut from the "hub/disc" assembly.
Unclip the end of the parking brake cable.
Remove the parking brake cable stop rst and then the
cable.
Check that the O-ring on the stop is not damaged.
Tightening torques
parking brake bolts 0.6 daNm
hub nut 10 daNm
driveshaft axle bolts 9 daNm
calliper bolts 18 daNm
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Parking brake
33A
33A-3
Remove the eight mounting bolts from the parking
brake on the rear nal drive shaft.
Remove the whole parking brake.
Carefully clean the attachment surface of the rear nal
drive shaft and the centring point of the parking brake.
REFITTING
Place the parking brake on the centring point of the
rear nal drive shaft.
Torque tighten the eight parking brake bolts
(0.6 daNm).
Fit the end of the cable into the parking brake.
Press the sheath and then correctly position the stop in
its housing, attaching the sleeve to the lever.
If necessary, use a screwdriver to separate the pads
slightly, thereby reducing the load on the springs.
Ret the "hub/disc" assembly to the nal drive.
Tighten the hub nut to a torque of 20 daNm and then
unscrew the nut.
Torque tighten the hub nut to 10 daNm and then
caulk it.
Adjust the parking brake (refer to the Handbrake
adjustment section).
Ret the driveshaft half axle and then torque tighten
the eight parking brake bolts (9 daNm 0.9).
Ret the calliper.
Torque tighten the calliper bolts to 18 daNm.
IMPORTANT
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Parking brake pads
33A
33A-4
Parking brake pads
ADJUSTMENT
Remove the plug on the adjustment tumblewheel.
Separate the pads using the adjustment tool (part
number RVI: 50 00 26 24 87) on adjustment
tumblewheel (1) until the disc can no longer be turned
by hand.
Turn the adjustment tumblewheel back two or three
positions.
Move the parking brake lever to the 3
rd
position.
Use the tensioner to tension the handbrake cable until
the disc can no longer be turned by hand.
Release the parking brake lever.
Move the parking brake lever until all components are
correctly positioned.
Move the lever to the 4
th
position and check that the
disc cannot be turned by hand (if not, carry out the
procedure again).
Lock the lock nut on the tensioner.
WARNING
If the rear discs and the parking brake are replaced
together, only the cable needs to be adjusted.
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WHEELS AND TYRES
Specifications
35A
35A-1
135A
WHEELS AND TYRES
Specifications
WHEEL RIMS
The identification mark is inscribed on them.
The marking gives the main dimensional specifications of the wheel.
The marking may be complete:
Example: 5 1/2 J 14 4 CH 36
or in abbreviated form:
Example: 5 1/2 J 14
Maximum run-out: 1.2 mm measured on the rim
edge (at G).
Maximum eccentricity: 0.8 mm measured on the
pressure face of the tyre beads.
A B C D E F
Type of
wheel
Width
(in inches)
Rim edge
profile
NOMINAL
(in inches)
under tyre bead
Number
of holes
Tyre bead
profile
Offset
(in mm)
5 1/2 J 14
4 CH 36
5 1/2 J 14 4 CH 36
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WHEELS AND TYRES
Specifications
35A
1 2 4 5 6 3
6
3
1
2
4
5
35A-2
TYRES
Example of identification marking
195/70 R 13 108 L
195 / 70 R 13 108 L
195 Width of the tyre in mm (l) section
height
70 Ratio h/w
width
R Radial structure
13 Internal diameter in inches (). Corresponds to the diameter of the rim.
108 Tyre load suffix (1000 kg maximum)
L Speed code 75 mph (120 km/h) maximum
Some speed symbols: Maximum speed km/h
J
K
L
M
N
P
100
110
120
130
140
150
Types of structure:
Cross ply
Radial
Bias belted
No marking
R
B (Bias belted)
85920R2
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WHEELS AND TYRES
Specifications
35A
35A-3
Wheel nut tightening torque: 36 daNm.
The values given are for a fully laden vehicle or for motorway driving. For vehicles with a chassis to be fitted with
equipment which is likely to alter the axle loads, refer to the manufacturers information relating to the type, brand
and operation of the vehicle.
Tyre pressures must be checked when cold. The increase in temperature during driving increases the pressure by
0.2 to 0.3 bar.
If the pressure is checked when the tyres are warm, take this increase into account and never deflate the tyres.
Type of tyre Load in n on axle according to tyre fittings Tyre inflation pressure
in Bar
Basic rear wheel paired rear wheel
185/75 R16 C 1300 2440 3.0
1480 2760 3.5
1800 3400 4.75
185/75 R16 1480 3760 3.5
1640 3080 4.0
1800 3400 4.75
195/65 R16 C 1440 2660 3.5
1600 3020 4.0
1745 3295 4.5
1800 3400 4.75
195/75 R16 C 1350 2565 3.0
1560 2965 3.5
1760 3345 4.0
1950 3700 4.75
205/75 R16 C 1520 2850 3.0
1820 3420 3.75
2120 4000 4.75
205/80 R15 P 1600 3000 7.25
215/75 R16 C
(6-tonne vehicle)
1660 3080 3.0
1880 3520 3.5
2300 4360 4.75
215/75 R16 C
(6.5-tonne vehicle)
2040 3920 4.0
2300 4360 4.5
2500 4720 5.25
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WHEELS AND TYRES
Wheel balancing
35A
35A-4
Wheel balancing
BALANCE WEIGHTS
Only use weights supplied by the Parts Department
which are:
secured to the metal rims by hooks (hooks
incorporated in the weight),
fitted by hooks (flat hooks) or self adhesive for alloy
wheels.
A Steel rim
B Alloy wheel rim
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Steering rack
36B
36B-1
136B
Steering rack
REMOVAL
Fit a steering wheel immobiliser.
Remove the front left-hand wheel.
The marks indicated on the drawing below correspond to the order of
removal.
Tightening torques
cardan bolt 2.3 daNm
steering rack bolt 5.5 daNm
track rod end bolt 11 daNm
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Steering rack
36B
36B-2
REFITTING
Set the steering rack at the centre point (1) (marks
aligned).
Bleeding the steering hydraulic circuit
Fill the fluid reservoir.
Press the starter several times to turn the pump.
Top up the oil level as necessary.
Start the engine when the oil level is stabilised.
Turn the steering wheel from lock to lock several
times, then immobilise the wheels having set them
straight.
Open the bleed screw (2) (without turning the steering
wheel) until the fluid flows with no air.
Repeat the steering and bleeding operation three
times to make sure the circuit has been bled
completely.
Top up the fluid level if necessary.
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Master cylinder
37A
37A-1
137A
Master cylinder
REMOVAL
Fit a pedal press to prevent brake fluid from flowing
out.
Disconnect the brake fluid level sensor connector and
remove the plug.
Drain the brake fluid reservoir as much as possible.
Take out the pin and remove the reservoir.
Remove:
the pipes and mark their position,
the two brake servo mounting nuts.
REFITTING
Check the length of the pushrod.
Dimension X = 22.3 mm.
Adjustment with the gauge (P).
Fit the master cylinder in alignment with the brake
servo so that the pushrod (P) enters the master
cylinder housing correctly.
Fill the brake fluid reservoir and bleed the braking
circuit (refer to Section 38C).
MAXIMUM GROSS VEHICLE WEIGHT < 5 T
Tightening torques
hydraulic pipe unions 1.4 daNm
brake servo mounting nuts 2.3 daNm
NOTE:
For vehicles with a maximum gross vehicle weight
greater than 5 tonnes, the master cylinder is
integrated with the brake servo. Consequently,
replace the brake servo / master cylinder assembly.
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Brake servo
37A
37A-2
Brake servo
REMOVAL
Remove the master cylinder (see the Master cylinder
operation).
Disconnect the brake servo flexible vacuum union.
In the passenger compartment
Remove the pin (A) from the clevis connecting the
brake pedal to the pushrod by moving the clip.
Remove:
the four brake servo mounting nuts,
the brake servo.
REFITTING
Before refitting, check X = 22.3 mm.
Bleed the brake circuit.
Tightening torques
brake servo mounting nut 2 0.3 daNm
brake servo on bulkhead 2.3 daNm
NOTE:
For vehicles with a maximum gross vehicle weight
greater than 5 tonnes, the master cylinder is
integrated with the brake servo. Consequently,
replace the brake servo / master cylinder assembly.
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Clutch release control
37A
37A-3
Clutch release control
The master and slave cylinder form a single
assembly. The hydraulic circuit cannot be bled.
REMOVAL
Depress the brake pedal.
Fit a pedal press to the clutch pedal to prevent any risk
of damage.
Remove the ball joint from the master cylinder on the
clutch pedal.
Fit a hose clamp between the reservoir and the clutch
master cylinder.
Remove:
the reservoir hose on the master cylinder,
the master cylinder (bayonet type mounting).
Remove:
the two clutch slave cylinder mounting bolts,
the master / slave cylinder assembly.
REFITTING
Fit the slave cylinder onto the gearbox.
Check that the pushrod is securely in place in the fork.
Remove the pedal press.
Press the clutch pedal down fully, then slowly return it
to engaged position.
Wait approximately 10 seconds. From then on the
control is operational.
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External gear control
37A
37A-4
External gear control
REMOVAL OF THE CONTROL UNIT
Remove the gear lever console.
Remove:
the clips (1) from the cables on the unit.
Disconnect ball joints (2).
REFITTING
DO NOT LUBRICATE THE BALL JOINTS.
REMOVAL OF THE GEAR SHIFT AND GEAR
SELECTION CABLES
Remove:
the central console,
the ball joints (2) from the gear control cables,
the clips (1) from the cables on the plate,
the two nuts (4).
Engine compartment side
Remove:
the gearbox shield,
the ball joints and clips of the cables on the gearbox.
Release the cables throught the engine compartment.
REFITTING
DO NOT LUBRICATE THE BALL JOINTS.
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Parking brake adjustment
37A
37A-5
Parking brake adjustment
ADJUSTMENT PROCEDURE
Place the vehicle on axle stands so that the rear
wheels are suspended.
Remove the adjustment wheel plug.
Turn the adjustment wheel (1) using the adjustment
tool (RVI part number: 5000262487) to separate the
brake shoes until the disc can no longer be turned by
hand.
Adjust the parking brake cable for the left-hand wheel:
towards A to slacken the parking brake,
towards B to tighten the parking brake.
Conversely, for the right-hand wheel:
towards A to tighten the parking brake,
towards B to slacken the parking brake.
In the passenger compartment, position the parking
brake lever at the 3
rd
notch.
Turn the tension wheel beneath the vehicle, tensioning
the cable until the disc can no longer be turned by
hand.
Move the parking brake lever several times to ensure
that all the components are in place.
Position the parking brake lever at 4
th
notch.
Check that the disc can no longer be turned by hand. If
it can, repeat the operation.
Lock the tension wheel lock nut.
Note:
If the rear discs and the parking brake are replaced
together, no adjustment is necessary, apart from on
the cable.
Note:
If a single parking brake is replaced, before carrying
out the operation check that the cable end piece is
correctly positioned and attached to its respective
lever.
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Brake compensator
37A
37A-6
Brake compensator
According to the fitting, use the attachment point of the
spring on the lever to ensure correct operation of the
compensator.
Spring attachment point on vehicle fitted with parabolic
rear suspension.
Spring attachment point on vehicle equipped with
underslung parabolic rear suspension.
Spring attachment point on 5.5 T van.
Fre. 244-03 Brake circuit check pressure gauge
Fre. 1085-01 Brake circuit check pressure gauge
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Brake compensator
37A
37A-7
ADJUSTMENT
1 - Procedure using pressure measurement
For this procedure, use the value plate on the driver's
seat mounting.
Using weighing machines, take a reading of load P
beneath the vehicle's rear axle.
Connect a pressure gauge (P1) in place of the bleed
screw on one front calliper.
Connect a pressure gauge (P2) in place of the bleed
screw on one rear calliper.
Depress the brake pedal until pressure P1 = 130 bar
is obtained.
Find the pressure displayed on P2 and compare it to
the pressure indicated on the corrector plate according
to load P.
Adjust the limiter if necessary.
If possible, take different measurements under
different loads on the rear axle.
After making adjustments, replace the pressure
gauges with the bleed screws and bleed the brake
hydraulic circuit.
Make adjustments, without depressing the brake
pedal.
2 - Procedure with spring extension measurement
For this simplified method, use the corresponding
vehicle diagram.
The various faults linked to the brake circuit (worn
suspension fatigue, bent control lever, etc.) are not
taken into account.
Using weighing machines, take a reading of load P
beneath the vehicle's rear axle.
Measure the spring extension A against the value
plate.
Adjust the limiter if necessary.
If possible, take different measurements under
different loads on the rear axle.
If there is any doubt, refer to the pressure procedure.
Make adjustments, without depressing the brake
pedal.
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38C
38C-1
138C
LIST OF COMPONENTS
1 Fuse and relay box connection unit
2 Engine compartment connection unit connection unit
3 ABS warning light
4 Hydraulic pump with pressure modulation unit
5 Modulating solenoid valve
6 Diagnostic socket
7 ABS computer relay
8 ABS safety relay
9 Rear right-hand wheel speed sensor
10 Rear left-hand wheel speed sensor
11 Front right-hand wheel speed sensor
12 Front left-hand wheel speed sensor
13 ABS computer
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38C
38C-2
1438C
Connector X1
Connector X2
X3 connector
1
2
3
4
5
6
7
8
---
---
---
---
Front left-hand wheel speed sensor supply
Front left-hand wheel speed sensor signal
Rear right-hand wheel speed sensor signal
Front right-hand wheel speed sensor signal
Front right-hand wheel speed sensor
supply
Rear right-hand wheel speed sensor
supply
Rear left-hand wheel speed sensor signal
Rear left-hand wheel speed sensor supply
1
2
5
8
12
18
---
---
---
+ Before ignition supply

+ After ignition supply
Diagnostic socket
Hydraulic pump motor signal
(measurement of current)
Earth
Warning light
1
2
3
4
5
7
8
10
Front left-hand exhaust solenoid valve

control
Front left-hand intake solenoid valve
control
Hydraulic module earth monitor signal
Front right-hand exhaust solenoid valve
control
Front right-hand intake solenoid valve
control
Rear left-hand exhaust solenoid valve
control
Rear left-hand intake solenoid valve control
Rear right-hand exhaust solenoid valve
control
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Hydraulic module track allocation
38C
38C-3
1538C
Hydraulic module track allocation
Connector 118 FAA 118 FAA connector
Track Description
1
2
Hydraulic pump supply
Earth
Track Description
1
2
3
4
5
6
7
8
9
10
11
12
13
Front left-hand exhaust solenoid valve
control
Front left-hand intake solenoid valve control
Solenoid valve earth
Rear right-hand intake solenoid valve
control
Rear right-hand exhaust solenoid valve
control
Hydraulic module earth monitor signal
Not connected
Front right-hand exhaust solenoid valve
control
Front left-hand intake solenoid valve control
Rear left-hand intake solenoid valve control
Rear left-hand exhaust solenoid valve
control
vnx.su
Hydraulic unit
38C
38C-4
1638C
Hydraulic unit
The hydraulic unit consists of eight solenoid valves.
1 front circuit input
2 rear circuit input
3 output to the front left-hand wheel
4 output to the right-hand front wheel
5 output to the rear left-hand wheel
6 output to the rear right-hand rear wheel
The hydraulic unit is located at the front left-hand side
of the vehicle.
REMOVAL
Fit a pedal press to limit the flow of brake fluid.
Disconnect the pipes on the hydraulic unit.
Disconnect the computer connector.
Remove the hydraulic unit.
REFITTING
Reconnect the pipes observing their colours.
Green: output to the front left-hand side,
Red: output to the front right-hand side,
Blue: output to the rear left-hand side,
Yellow: output to rear right-hand side.
Check that there are no leaks.
Tightening torques
pipe unions M10 X 100
M12 X 100
1.2 daNm
1.5 daNm
Note:
First disconnect the pipes from the master cylinder to
the hydraulic unit and immediately plug the holes
with the protective plugs. Then remove the pipes
leading to the wheel cylinders and also plug the
holes.
Note:
The hydraulic units supplied with the spare parts are
pre-filled.
vnx.su
Computer
38C
38C-5
738C
Computer
REMOVAL
Remove the computer cover.
Disconnect the computer connectors.
Remove the four computer mounting bolts.
Disconnect the pump connector.
Remove the computer.
REFITTING
The computer configures itself automatically when it is
first switched on.
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38C
38C-6
838C
Prerequisites for any bleeding of air from the brake
circuit:
make sure that there are no leaks in the fuel circuit,
fill the brake fluid reservoir (1) to maximum level,
depress the brake pedal several times, so that the
moving components of the braking system (pistons,
brake shoes, discs or drums) all make contact with
each other,
add brake fluid (1) to top up the level in the reservoir,
set up the bleeding device and top up the brake fluid
level (1) to its maximum (refer to the driver's
handbook, the advised pressure being between
2 bar and 2.5 bar).
Only one bleeding operation can be carried out on this
vehicle: the conventional bleeding operation. The ABS
circuit cannot be bled.
THE CLASSIC OR CONVENTIONAL BLEED
This procedure must be used after one of the following
components has been removed or replaced:
the master cylinder,
the hydraulic assembly (new and pre-filled),
a rigid pipe,
a hose,
a calliper.
Precautions to be taken during this braking circuit
bleeding operation:
The ignition must be switched off to ensure that the
hydraulic unit solenoid valves do not operate.
Check the brake fluid levels of the braking circuit and
the bleeding device.
Connect the bleeding device to the braking circuit,
paying attention to the features of this equipment (refer
to the operating instructions).
Bleed the circuit by opening the bleed screws in the
following order (remember to close them after the
operation):
rear right-hand circuit,
rear left-hand circuit,
front right-hand circuit,
front left-hand circuit.
With the engine switched off, check the pedal travel,
if it is not correct, restart the bleeding procedure.
Top up the brake fluid level in the reservoir after
disconnecting the bleeding device. Check the
tightness of the bleed screws and that the sealing caps
are all present.
Confirm the efficient regulation of the hydraulic unit by
The effectiveness and balance of the vehicle braking
system may be checked on a brake test bench or by
Essential equipment
Brake circuit bleeding device
(approved by RENAULT)
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77 11 315 522
APRIL 2002
EDITION ANGLAISE
RENAULT.
RENAULT 2002
Chassis
vnx.su
Chassis
Contents
Page
38C ANTI-LOCK BRAKING SYSTEM
Computer track nomenclature 38C-2
Complete electrical check 38C-3
Customer complaints 38C-4
Fault finding chart 38C-5
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General information
38C
38C-1
138C
General information
SPECIAL NOTES
The CLIP and NXR diagnostic tools cannot be used for fault finding on the Master Propulsion ABS computer.
FAULT FINDING PROCEDURE:
Braking fault (ABS warning light does not switch on: check the braking system with a road test by
disconnecting the ABS system (disconnect the wheel speed sensor or the computer supply voltage fuse).
If the braking fault persists during the road test, the ABS system is not faulty: check the hydraulic and
mechanical circuit of the braking system (condition of brake pads and discs, etc).
If the braking fault disappears during the road test, then the ABS system is faulty: perform a complete check of
the wiring or refer to the customer complaints.
Braking fault (ABS warning light switches on): perform a complete check of the wiring or refer to the customer
complaints.
If checking the wiring does not reveal the faulty component, visually check the general condition of the wiring and
clean the wheel speed sensor connectors and the three computer connectors (using a cleaning product for
connections).
OPERATION OF THE ABS WARNING LIGHT
When the ignition is switched on, the warning light comes on for 3 seconds, then goes out
If the ABS system is faulty, the ABS warning light (orange) is lit permanently.
After repairing the fault, the warning light stays lit. It is then advisable to drive at over 6 mph (10 km/h) to confirm
the repair and turn the warning light off.
If the warning light remains on after driving, the ABS system is still faulty.
COMPONENT RESISTANCE VALUES
Exhaust solenoid valve resistance values..........3.3 0.5 ,
Inlet solenoid valve resistance values................6.6 0.5 ,
Wheel speed sensor resistance values..............950 80 ,
Hydraulic pump resistance values......................0.025 .
SPECIAL NOTES
For Master Propulsion fitted with an electric retarder (on the propeller shaft), the ABS computer controls an
additional relay. This relay is controlled during a regulation phase by track 12 of connector X3 to cut off the retarder
to avoid wheel locking.
When replacing an ABS computer on a vehicle fitted with an electric retarder, you must configure the computer in
order to program the retarder suppression function.
This configuration is indispensable for the ABS system to operate safely.
To carry out this configuration, call the local RENAULT VEHICLES MANUFACTURER assistance network to
obtain a random code. This code will then be transmitted to the computer through the RENAULT VEHICLES
MANUFACTURER diagnostic tool (DIAGNOSTICA).
ABS X24 - 1.1
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List of computer tracks
38C
38C-2
List of computer tracks
Connector X1 (9-track black)
Track 1 Track 1 front left-hand wheel speed sensor. Track 6 Track 1 rear right-hand wheel speed sensor.
Track 2 Track 2 front left-hand wheel speed sensor. Track 7 Track 2 rear left-hand wheel speed sensor.
Track 3 Track 2 rear right-hand wheel speed sensor. Track 8 Track 1 rear left-hand wheel speed sensor.
Track 4 Track 1 front right-hand wheel speed sensor. Track 9
Track 5 Track 2 front right-hand wheel speed sensor.
Connector X2 (18-track black)
Track 1 + 12 volts supply before ignition Track 10
Track 2 + 12 volts supply after ignition Track 11
Track 3 Track 12 Earth.
Track 4 Track 13
Track 5 Line K Track 14
Track 6 Track 15
Track 7 Track 16
Track 8 Track 1 hydraulic pump / track 5 pump relay Track 17
Track 9 Track 18
ABS warning light control (direct or through
relay)
Connector X3 (15-track grey)
Track 1
Track 1 of the hydraulic unit 13-track
connector (front left-hand solenoid outlet
valve).
Track 9
Track 2
connector (front left-hand solenoid inlet
valve).
Track 10
connector (rear right-hand solenoid outlet
valve).
Track 3
connector (reference earth).
Track 11
connector (rear right-hand solenoid inlet
valve).
Track 4
connector (front right-hand solenoid outlet
valve)
Track 12
Track 1 of the retarder suppression relay
(on vehicles fitted with an electric retarder).
Track 5
connector (front right-hand solenoid inlet
valve).
Track 13
Track 6 Track 14
Track 7
connector (rear left-hand solenoid outlet
valve).
Track 15
Track 1 of the ABS relay (hydraulic pump
relay 439 FAA).
Track 8
connector (rear left-hand solenoid inlet valve)
ABS X24 - 1.1
vnx.su
Complete electrical check
38C
38C-3
Complete electrical check
The information below allows you to check the wiring of the ABS system at the connectors using a multimeter.
Ohmmeter measurement of connector X1 tracks (9-track black):
Front right-hand wheel speed sensor: measure between track 4 and track 5 950 80
Front left-hand wheel speed sensor: measure between track 1and track 2 950 80
Rear right-hand wheel speed sensor: measure between track 6 and track 3 950 80
Rear left-hand wheel speed sensor: measure between track 7 and track 8 950 80
Computer supply measurements (connector X2, 18-track black):
With the voltmeter in direct current measuring position, there should be between 10.5 and 14.5 volts between the
tracks:
1 (+) and 12 (-) for the before ignition supply
2 (+) and 12 (-) for the after ignition supply
Continuity between tracks:
Connector X2 track 8 Track 1 of the 2-track hydraulic pump connector
Track 5 of the pump relay (439 FAA in the engine compartment connection unit)
For instrument panels with speedometer
Connector X2 track 18 Track 2 of the ABS warning light starter relay (439FBA)
For instrument panels without speedometer
Connector X2 track 18 Track 14 of the instrument panel red 15-track connector
Front right-hand inlet solenoid valve: measure between track 5 and track 3 6.6 0.5
Front left-hand inlet solenoid valve: measure between track 2 and track 3 6.6 0.5
Rear right-hand inlet solenoid valve: measure between track 11 and track 3 6.6 0.5
Rear left-hand inlet solenoid valve: measure between track 8 and track 3 6.6 0.5
Front right-hand exhaust solenoid valve: measure between track 4 and track 3 3.3 0.5
Front left-hand exhaust solenoid valve: measure between track 1 and track 3 3.3 0.5
Rear right-hand exhaust solenoid valve: measure between track 10 and track 3 3.3 0.5
Rear left-hand exhaust solenoid valve: measure between track 7 and track 3 3.3 0.5
Continuity between tracks:
Connector X3 track 3 Track 8 of the hydraulic unit 13-track connector
Connector X3 track 15 Track 1 of the ABS relay (hydraulic pump relay 439 FAA)
For Master Propulsion fitted with an electric retarder (on propeller shaft)
Connector X2 track 12 Track 1 of the retarder suppression relay
ABS X24 - 1.1
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38C
NOTES None.
LOCKING OF ONE OR MORE WHEELS CHART 1
DRIFT CHART 2
UNEXPECTED ABS OPERATION AT LOW SPEEDS AND WHEN LITTLE PRESSURE
APPLIED TO BRAKE PEDAL CHART 3
UNEXPECTED ABS OPERATION ON A POOR ROAD SURFACE CHART 4
UNEXPECTED ABS OPERATION WITH USE OF SPECIAL EQUIPMENT
(radio, car phone, CB, etc) CHART 5
SPONGY PEDAL CHART 6
BRAKE PEDAL VIBRATION CHART 7
PULLING CHART 8
ABS WARNING LIGHT DOES NOT COME ON WHEN THE IGNITION IS SWITCHED ON
(vehicles fitted with a warning light starter relay: Master Propulsion with speedometer) CHART 9
ABS WARNING LIGHT DOES NOT COME ON WHEN THE IGNITION IS SWITCHED ON
(vehicles without warning light starter relay: Master Propulsion without speedometer) CHART 10
ABS WARNING LIGHT STAYS ON (engine running)
(vehicles fitted with a warning light starter relay: Master Propulsion with speedometer) CHART 11
ABS WARNING LIGHT STAYS ON (engine running)
(vehicles without warning light starter relay: Master Propulsion without speedometer) CHART 12
NOISE FROM THE PUMP, PIPES OR HYDRAULIC UNIT CHART 13
SPONGY BRAKE PEDAL TRAVEL AFTER ABS REGULATION PHASE
(with irregular pedal when regulation has been entered) CHART 14
ABS X24 - 1.1
38C-4
vnx.su
Fault finding - Fault finding chart
38C
CHART 1 Locking of one or more wheels.
NOTES
NOTE: the diagnostic tool cannot be used for fault finding on the Master Propulsion
ABS computer.
Reminder: wheel locking on a vehicle fitted with ABS or squealing tyres, experienced as locking by the
customer, may be linked to a normal reaction of the system and should not automatically be considered as
faults:
locking authorised below 3.6 mph (6 km/h) (the system no longer triggers regulation),
braking with ABS regulation on very poor road surfaces (significant squealing).
Conversely, if there is actually wheel locking, raise the vehicle so that you can turn the wheels in order to
check: a possible inversion in the wheel sensor electric connection:
Lift the wheels one by one to check with the multimeter or oscilloscope that the wheel sensor signal concerned
reaches the ABS computer. The signal transmitted by the wheel sensors is a sinusoidal signal, the amplitude
and frequency of which vary with wheel speed. This signal is measured more accurately with an oscilloscope
or analogue multimeter (with pointer).
To take this measurement, you must connect the oscilloscope (with a time base of 100 ms / division and a 0.5
volts / division calibre) or the analogue multimeter (alternating voltage measuring position) between the tracks
below:
Wheel to test Connector X1 (9-track black) of the ABS computer
Front left-hand wheel Measure between track 1 and track 2
Front right-hand wheel Measure between track 4 and track 5
Rear left-hand wheel Measure between track 7 and track 8
Rear right-hand wheel Measure between track 3 and track 6
Turning the raised wheel, the signal should vary between 0.1 volts and 2 volts (turning by hand) and
should arrive at the tracks mentioned above.
NOTE: if the measurement is taken with an analogue multimeter (measuring alternating voltage), you must
choose the 4-volt measurement scale to obtain the maximum amplitude of the signal. The multimeter pointer
only varies slightly with this measurement scale. To display the signal variation better, you can select a lower
measurement scale (400 millivolts) which allows the multimeter pointer to vary more but does not allow the
amplitude of the signal to be displayed.
AFTER REPAIR Carry out a road test to confirm that the fault has been rectified.
ABS X24 - 1.1
38C-5
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38C
38C-6
CHART 1
CONT
If the signal does not reach the computer tracks of the wheel concerned: disconnect the connector X1
(9-track) of the ABS computer to check the insulation (in relation to + 12 volts and to the earth), the continuity
and absence of interference resistance of the connections:
Connector X1 (9-track black) Wheel speed sensor
of the ABS computer
Connector X1 track 4 Track 1 of the front right-hand sensor (black wire)
Connector X1 track 5 Track 2 of the front right-hand sensor (white wire)
Connector X1 track 1 Track 1 of the front left-hand sensor (white wire)
Connector X1 track 2 Track 2 of the front left-hand sensor (black wire)
Connector X1 track 6 Track 1 of the rear right-hand sensor (white wire)
Connector X1 track 3 Track 2 of the rear right-hand sensor (black wire)
Connector X1 track 8 Track 1 of the rear left-hand sensor (white wire)
Connector X1 track 7 Track 2 of the rear left-hand sensor (black wire)
If the previous tests have not revealed faulty connections but the signal does not reach the computer tracks of
the wheel concerned, you must check the faulty sensor conformity.
Disconnect the faulty sensor and check its resistance by measuring between the two tracks. Replace if its
resistance is not equal to 950 + 80 .
If the fault persists (no sensor signal), check that the sensor is correctly attached (the air gap is not adjustable,
but a bad sensor mounting may modify the air gap). Refer to the ABS Repair Method.
If the wheel sensors transmit a correct signal to the computer but the fault persists: the problem may stem from
a possible inversion in the hydraulic connection of the ABS unit pipes. In this case, it is necessary to check the
conformity of the hydraulic unions by referring to the ABS Workshop Repair Manual.
If the electric and hydraulic connections are correct but the fault persists: replace the ABS hydraulic unit (bleed
the brakes in the conventional way).
ABS X24 - 1.1
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38C
38C-7
CHART 2 Drift
NOTES
ABS computer.
Disconnect one wheel speed sensor. Start
the engine and check that the ABS fault
warning light comes on. Road test the
vehicle with only ABS out of service.
Does the fault persist under these
conditions?
NO
Normal behaviour linked to the operation of
the system during the regulation phase in
particular on surfaces with uneven grip or
which are poorly coated.
YES
Road handling fault not connected with
the ABS. Check the state and conformity
of the brake linings, check the tyre
pressure, front axle, brake callipers,
etc.
ABS X24 - 1.1
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38C
38C-8
CHART 3
Unexpected ABS operation at low speed
and with light pedal pressure
NOTES
ABS computer.
Special notes:
Warning: ABS regulation may be unresponsive when the vehicle is driven on surfaces
such as icy roads, cobbled streets, etc.
It is possible to feel brake pedal vibrations which are linked to reactions of the system in particular situations:
crossing rumble strips,
tight cornering with lifting of the inside rear wheel.
Check the correct adjustment and operation of the brake pressure regulator (see Workshop Repair Manual).
If the problem persists, check the wheel speed sensor signals (micro-cuts): Disconnect connector X1 (9-track)
of the ABS computer, to check the insulation (in relation to + 12 volts and to the earth), the continuity and
absence of parasite resistance of the connections:
Connector X1 (9-track black) Wheel speed sensors
of ABS computer
Connector X1 track 4 Track 1 of the front right-hand sensor (black wire)
Connector X1 track 5 Track 2 of the front right-hand sensor (white wire)
Connector X1 track 1 Track 1 of the front left-hand sensor (white wire)
Connector X1 track 2 Track 2 of the front left-hand sensor (black wire)
Connector X1 track 6 Track 1 of the rear right-hand sensor (white wire)
Connector X1 track 3 Track 2 of the rear right-hand sensor (black wire)
Connector X1 track 8 Track 1 of the rear left-hand sensor (white wire)
Connector X1 track 7 Track 2 of the rear left-hand sensor (black wire)
If the fault persists (no sensor signal), check that the sensors are correctly attached (the air gap is not
adjustable, but incorrect sensor mountings may modify the air gap). Refer to the ABS Repair Method.
ABS X24 - 1.1
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38C
38C-9
CHART 4 Unexpected ABS operation on a poor road surface
NOTES
ABS computer.
On poor road surfaces it is normal to feel hesitation and vibrations of the pedal as well as grating which is more
significant than on good surfaces. The result is the impression of a variation in efficiency which should be
considered normal.
ABS X24 - 1.1
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38C
38C-10
CHART 5
Unexpected ABS operation with use of special equipment
(radio, car phone, CB, etc)
NOTES
ABS computer.
Check that the equipment which is causing the problem is approved.
Check that the equipment has been correctly installed with no alteration to the original wiring, in particular
that of the ABS (unauthorised connections to earth and + battery feed or before ignition feed).
ABS X24 - 1.1
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38C
38C-11
CHART 6 Spongy pedal
NOTES
ABS computer.
The spongy pedal effect is caused by the presence of air in the brake circuits.
Bleed the circuits in the conventional way starting with the rear right brake, followed by rear left, front left
and finally front right. Repeat the operation if necessary.
ABS X24 - 1.1
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38C
38C-12
CHART 7 Brake pedal vibration
NOTES
ABS computer.
These vibrations are a normal reaction of the brake pedal during the ABS regulation phase.
ABS X24 - 1.1
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38C
38C-13
CHART 8 Pulling
NOTES
ABS computer.
Disconnect one wheel speed sensor. Start
the engine and check that the ABS fault
warning light comes on. Road test the
vehicle with only ABS out of service.
Does the fault persist under these
conditions?
NO
Lift the vehicle so that you can turn the
wheels and check whether:
the speed sensors have been incorrectly
connected,
the pipes on the hydraulic unit have been
reversed.
For these two tests, refer to and apply the
methods described in CHART 2.
If the fault persists, replace the hydraulic unit.
YES
If the brake pedal travel is relatively long,
bleed the brake circuit.
If the travel is normal, check the tyre
pressures, the front axle or look for any
leaks in the circuit.
ABS X24 - 1.1
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38C
38C-14
CHART 9
The ABS warning light does not light up when ignition switched on
(vehicles fitted with a warning light starter relay:
Master Propulsion with speedometer)
NOTES
ABS computer.
Check the instrument panel fuses on the passenger compartment fuse board (if the problem affects all instrument
panel operations).
With the ignition switched off, disconnect connector X2 (18-track) of the ABS computer and check the
insulation, continuity and absence of interference resistance of the connections:
ABS warning light relay (439 FBA Connector X2 (18-track black) of the
in the engine connection unit) ABS computer
Track 2 Track 18
Instrument panel
Track 3 Track 5 of the white 10-track connector
Check the presence of an earth on track 4 and a 12-volt after ignition supply on track 1 of the ABS warning
light starter relay (439 FBA).
Repair if necessary (refer to the instrument panel electrical wiring diagram).
The instrument panel and ABS computer connectors are connected
electrically, connect track 18 of ABS computer connector X2 (18-track)
to the earth (using a shunt).
Does the ABS warning light come on?
NO
Replace the ABS warning light starter relay (439 FBA).
Is the fault still present?
YES
Check the condition of the ABS warning light bulb
and its supply. If the fault persists, check the
operation of the instrument panel.
If the previous tests have
not solved the problem,
replace the ABS computer.
End of fault finding.
YES
ABS X24 - 1.1
NO
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38C
38C-15
CHART 10
The ABS warning light does not light up when the ignition is
switched on
(vehicles without warning light starter relay: Master Propulsion without
speedometer)
NOTES
ABS computer.
Check the instrument panel fuses on the passenger compartment fuse board (if the problem affects all
instrument panel operations).
insulation, continuity and absence of interference resistance of the connection:
With the ignition on, disconnect one wheel speed sensor connector and turn the wheel to generate a fault.
Does the ABS warning light come on?
NO
Check the supplies, earths and correct
YES
If the previous tests have not solved the
problem, replace the ABS computer.
ABS X24 - 1.1
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38C
CHART 11
The ABS warning light stays on (engine running)
(vehicles fitted with a warning light starter relay:
Master Propulsion with speedometer)
NOTES
ABS computer.
Special notes:
If the ABS warning light is on permanently, it indicates the presence of a fault. After
repairing the fault(s), the warning light remains lit. To confirm the repair and switch off
the warning light, the computer needs to receive four correct wheel speed signals. To
do this, it is necessary to drive at over 6 mph (10 km/h).
Drive at over 6 mph (10 km/h).
Has the ABS warning light gone out?
NO
insulation in relation to the earth, continuity and absence of interference resistance of the connections:
ABS warning light relay (439 FBA Connector X2 (18-track black) of the
in the engine connection unit) ABS computer
Track 2 Track 18
Instrument panel
Track 3 Track 5 of the white 10-track connector
Disconnect the ABS warning light starter
relay (439 FBA).
YES
Replace the ABS warning light starter relay
(439 FBA).
YES
38C-16
YES
NO
NO
ABS X24 - 1.1
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38C
38C-17
CHART 11
CONT
Carry out a complete fault finding check on
the ABS wiring (see the section on complete
electrical checks).
NO
YES
ABS X24 - 1.1
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38C
38C-18
CHART 12
The ABS warning light stays on (engine running)
(vehicles without warning light starter relay: Master Propulsion without
speedometer)
NOTES
ABS computer.
Special notes:
If the ABS warning light is on permanently, it indicates the presence of a fault. After
repairing the fault(s), the warning light remains lit. To confirm the repair and switch off
the warning light, the computer needs to receive four correct wheel speed signals. To
do this, it is necessary to drive at over 6 mph (10 km/h).
insulation (in relation to the earth), continuity and absence of interference resistance of the connections:
Has the ABS warning light gone out? (ABS computer connector X2 reconnected)
NO
NO
Carry out a complete fault finding check on
the ABS wiring (see the section on complete
electrical checks).
NO
YES
YES
YES
ABS X24 - 1.1
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38C
CHART 13 Noise from the pump, the pipes or the hydraulic unit
NOTES
ABS computer.
Vibration of the unit: check the conformity of the hydraulic unit mountings on its support.
Vibration of pipes: check that all the pipes are correctly fitted in their securing clips and that there is no
contact between the pipes and the body.
Carry out the necessary repairs.
ABS X24 - 1.1
38C-19
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38C
CHART 14
Spongy brake pedal travel after
ABS regulation (with irregular pedal when
regulation has been entered)
NOTES
ABS computer.
This problem is caused by the presence of air in the hydraulic unit (ingress of air into the hydraulic unit
regulation pipes towards the brake circuits).
Bleed the brake circuits in the conventional way. If bleeding does not solve the problem: replace the hydraulic
unit (delivered pre-filled and therefore does not require bleeding of the secondary circuit, only conventional
bleeding of the braking system).
ABS X24 - 1.1
38C-20
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Heating and Ventilation
HEATING
AIR CONDITIONING
77 11 315 742
OCTOBER 2002
EDITION ANGLAISE
RENAULT 2002
vnx.su
Air conditioning
Contents
Page
61A
62A
HEATING
Control panel 61A-1
Control cables 61A-2
Fan assembly 61A-3
Air recirculation motor 61A-4
Radiator 61A-5
Distribution unit 61A-6
Resistor unit 61A-11
AIR CONDITIONING
General information 62A-1
Evaporator 62A-3
Compressor 62A-5
Condenser 62A-6
Dehydration canister 62A-7
Tri-function pressure switch 62A-8
Pressure relief valve 62A-9
Connecting pipes 62A-10
Evaporator sensor 62A-12
Air conditioning thermal cut-off switch 62A-13
vnx.su
HEATING
Control panel
61A
61A-1
161A
HEATING
Control panel
REMOVAL
Remove:
the ashtray,
the control panel,
the two bolts securing the control panel to the
dashboard.
Disconnect:
the control panel connector,
the control cables for the rotator arms.
REFITTING
Check the settings of the air distribution and air mixing
controls (see the Control cables operation).
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HEATING
Control cables
61A
61A-2
Control cables
REMOVAL
Remove:
the glove compartment,
the ashtray,
the control panel,
the control panel cables,
the cable on the distribution unit.
SPECIAL NOTES
To make it easier to remove the cables, twist the
sleeve to release it from the clip.
Mark the position of the sleeves in relation to the clips.
REFITTING
Route the cables through the control panel location.
ADJUSTMENT
Fit the cable on the control panel and leave it free at
the distribution unit flap.
Place the rotator and the associated flap at the travel
limit.
Fit the cable on the flap and clip the sleeve.
vnx.su
HEATING
Fan assembly
61A
61A-3
Fan assembly
REMOVAL
Remove the glove compartment.
Disconnect the power supply connector.
Remove the fan assembly mounting bolts.
Remove the fan assembly from underneath.
REFITTING
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HEATING
Air recirculation motor
61A
61A-4
Air recirculation motor
To improve the performance of the heater, the air
recirculation motor cuts in when the heating is on full
with a ventilation speed selected.
REMOVAL
Remove the two bolts from the air intake grille on the
bulkhead.
Remove:
mounting pin (1),
mounting bolts (2),
air intake duct (3),
the air recirculation motor mounting bolts.
REFITTING
Place the flap in the exterior air intake position.
Fit the motor sprocket to the flap sprocket in such a
way as to immobilise the flap in its position.
At this stage, check for correct operation.
vnx.su
HEATING
Radiator
61A
61A-5
Radiator
REMOVAL
Remove:
the glove compartment,
the ashtray,
the control panel,
the control panel cables,
the carpet mounting bolts in order to free the bottom
of the heater unit as much as possible,
the two reinforcement bracket mounting bolts and nut
(1).
Engine compartment end
Fit a hose clamp, remove the spring clips and the
heater hoses.
Passenger compartment end
Remove:
the three mounting bolts from the coolant pipe (2),
the two radiator mounting bolts and remove the
radiator.
REFITTING
vnx.su
HEATING
Air distribution unit
61A
61A-6
REMOVING THE DASHBOARD
WARNING: Handling the pyrotechnic systems (pretensioners or airbags) near a source of heat or a flame
is forbidden; there is a risk of triggering.
vnx.su
HEATING
61A
61A-7
REMOVAL
Remove screws (1) from the steering wheel airbag.
Disconnect the airbag connector (2).
Remove airbag module (3).
Remove:
steering wheel bolt (5),
the steering wheel,
the steering column half-shells,
the radio control mounting bolt (6),
radio control (7).
IMPORTANT: before starting any work on the
airbag system, lock the computer using the
diagnostic tools (see Section 8).
IMPORTANT: it is essential to mark the position
of the rotary switch and ensure that the wheels
are straight when removing it, so that strip (4) is
centred.
vnx.su
HEATING
61A
61A-8
Disconnect the connector (8).
Press on the two clips (9).
Remove:
rotary switch (10),
the ashtray,
the control panel,
the radio (if fitted),
the windscreen pillar trims.
Partially remove the door seal and remove the
dashboard side mounting bolts (11).
vnx.su
HEATING
61A
61A-9
Remove:
- the control switching assembly,
the steering column lower cover,
the dashboard upper cover mounting bolts,
the instrument panel.
Disconnect the speakers.
Remove the dashboard.
Detach the carpet.
Remove:
the reinforcement bracket mounting bolts,
the fan unit/heater casing pin.
Move the heater bulkhead towards the rear.
Release the coolant pipe.
Remove the distribution unit.
DASHBOARD REFITTING
Special notes on the rotary switch
Ensure that the wheels are straight.
Fit the rotary switch (13).
NOTE: the switch pins must be correctly engaged in
the immobiliser device on the steering column.
Connect connector (14).
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HEATING
61A
61A-10
Special notes on the steering wheel
Steering wheel bolt (15) must be replaced each time it
is removed and tightened to a torque of 4.5 daNm.
Special notes on the driver s airbag
Fit airbag module (16).
Connect connector (17).
Tighten the airbag module mounting bolts (18).
IMPORTANT: after refitting the airbag cushion, the
checking procedure for the correct operation of the
system must be applied:
unlock the computer using the diagnostic tool,
turn the anti-theft switch key to the on position,
leave the cabin and lock the vehicle,
reconnect the battery (the Airbag indicator light
should go out after 10 seconds).
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HEATING
Resistor unit
61A
61A-11
Resistor unit
REMOVAL
Remove the resistor unit.
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AIR CONDITIONING
General information
62A
62A-1
162A
AIR CONDITIONING
General information
vnx.su
AIR CONDITIONING
General information
62A
62A-2
A Passenger compartment
B Engine compartment
C External air
D To air mixing unit
E Bulkhead
F External or recirculated air
1 Compressor
2 Condenser
3 Dehydration canister
4 Tri-function pressure switch
5 High pressure bleed
6 Pressure relief valve
7 Pressure relief valve thermostatic regulation
8 Evaporator
9 Low pressure bleed
10 Heater fan assembly
11 Engine cooling fan
12 Engine radiator
13 High pressure liquid
14 Low pressure vapour
15 High pressure vapour
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AIR CONDITIONING
Evaporator
62A
62A-3
Evaporator
REMOVAL
Disconnect:
the battery,
the air filter.
Drain the R134a coolant circuit using the filling
equipment (refer to the procedure described in the Air
Conditioning manual).
Disconnect the R134a connecting pipes (1) from the
pressure relief valve.
Fit plugs to the hoses and the pressure relief valve.
Fit the hose clamps (2) and remove the heater hoses.
Remove the dashboard and the dashboard beam (see
Distribution unit).
Remove the distribution unit.
From the distribution unit, remove:
the evaporator sensor,
the side housing (3),
the eight retaining bolts (4) on the housing (5).
Carefully remove the evaporator with the housing (5).
TIGHTENING TORQUES (in daNm)
Evaporator pressure relief valve bolt 0.6
Pressure relief valve connecting hose
retaining bolt 0.8
Union on dehydration canister 1.2
Compressor connecting hose retaining bolt 0.8
AC thermal cut-off switch 2
Pressure switch 1
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AIR CONDITIONING
Evaporator
62A
62A-4
REFITTING
IMPORTANT: in order to prevent damage to the
evaporator when refitting it in the distribution unit, it is
preferable to refit it with its protective housing fitted (5).
Ensure that the evaporator sensor guide (6) is present.
Fit the pieces of foam (7).
For refitting operations, proceed in the reverse order to
removal.
Check that the pipes are not in contact with each other
(risk of noise).
Tighten the retaining screw (1) on the pressure valve
pipes to 0.8 daNm (ensure the seals are in good
condition).
NOTE: when refitting the dashboard, check:
that the electrical wiring is positioned correctly,
that the air flow ducts are fitted correctly.
Create a vacuum, then fill the R134a refrigerant circuit
using the filling unit (see the Air conditioning
procedure).
IMPORTANT: when replacing an evaporator, add
20 ml of P.A.G. SP10 oil to the circuit.
Use the same oil for refitting the seals taking care to
position them correctly.
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AIR CONDITIONING
Compressor
62A
62A-5
Compressor
REMOVAL
Drain the R134a refrigerant circuit (refer to the
procedure described in the Air conditioning manual).
Remove:
the compressor drive belt,
the connector (1),
the two connecting hose bolts (2).
Tighten the bolts and nuts (3 - 4 - 5).
Remove the four bolts (6).
Remove the compressor.
NOTE: it is essential to insert plugs in the hoses and in
the compressor to prevent moisture from entering the
circuit.
REFITTING
If the compressor needs replacing, the new one is
supplied filled with oil.
Fit the drive belt and tension it.
Create a vacuum, then fill the R134a refrigerant circuit
using the filling equipment (refer to the procedure
described in the Air conditioning manual).
IMPORTANT: when replacing the compressor, it is
essential to top up the oil. It is vital to replace the
seals and lubricate them with refrigerant oil.
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AIR CONDITIONING
Condenser
62A
62A-6
Condenser
REMOVAL
Drain the R134a refrigerant circuit (refer to the
procedure described in the Air conditioning manual).
Remove:
the engine undertray.
the two indicators,
the bumper,
the two bolts securing (1) the unions to the
condenser,
the pipe bracket bolt (2),
the R134a connecting unions.
Fit protective plugs to the condenser and the unions.
If necessary, remove the intake air intercooler to move
it and access the nuts.
Remove the four condenser mounting bolts.
Remove it carefully from above the vehicle.
REFITTING
refrigerant oil.
Create a vacuum, then fill with R134a using the filling
equipment (refer to the procedure in the Air
conditioning manual).
NOTE:
Tighten to torque:
compressor
to condenser connecting union 0.8 daNm.
dehydration canister to
condenser connecting pipe 1.2 daNm.
IMPORTANT: when replacing the condenser, add
vnx.su
AIR CONDITIONING
Dehydration canister
62A
62A-7
Dehydration canister
REMOVAL
Drain the R134a refrigerant circuit using the filling
equipment (refer to the procedure described in the Air
Conditioning manual).
Remove the air filter.
Uncouple unions (1) and (2).
Loosen the bracket (3) and remove the dehydration
canister (4).
REFITTING
Check that the seals are in good condition and
lubricate them using P.A.G. SP10 oil.
Create a vacuum then fill the R134a refrigerant circuit
When changing the dehydration canister, add 20 ml of
P.A.G. SP10 oil to the circuit.
NOTE: torque tighten the unions (1) and (2) to:
1.2 daNm.
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AIR CONDITIONING
Tri-function pressure switch
62A
62A-8
Tri-function pressure switch
The pressostat (1) is located on the pressure relief
valve / dehydration filter high-pressure connecting
pipe.
NOTE: any operation on the pressostat may be carried
out without draining the refrigerant circuit; the
pressostat is secured onto a SKRADER valve.
The pressostat is fitted with a seal. Ensure the seal is
in good condition when refitting and lubricate it with
P.A.G. SP10 oil.
Tightening torque: 1 daNm.
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AIR CONDITIONING
Pressure relief valve
62A
62A-9
Pressure relief valve
REMOVAL
Drain the refrigerant circuit.
Remove:
the connecting pipes retaining bolt (1),
the two pressure relief valve retaining bolts (2) on the
evaporator.
Fit the protective plugs to the evaporator and the
unions.
REFITTING
refrigerant oil.
Refit in the reverse order to removal.
Tighten the bolts to torque:
bolt (1): 0.8 daNm,
bolt (2): 0.6 daNm.
Create a vacuum then fill the R134a refrigerant circuit
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AIR CONDITIONING
Connecting pipes
62A
62A-10
Connecting pipes
The removal-refitting procedure is a standard
procedure.
REMOVAL
Drain the refrigerant circuit.
Before dismantling, mark the routing of the hose and
the position of its mountings.
Plug the hose, condenser, evaporator, or filter
openings.
Unscrew the hose mountings.
Remove the pipe(s).
REFITTING
Observe the hose routing and mountings.
refrigerant oil.
If replacing, use an identical hose.
HOSE MOUNTINGS
1 Connection between hoses on the pressure relief
valve
2 Connection between hoses on the condenser
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AIR CONDITIONING
Connecting pipes
62A
62A-11
3 Compressor outlet hose mounting (high-pressure)
on engine
4 Pressure relief valve outlet hose mounting (low-
pressure) on radiator ring
Tighten the mountings after tightening the unions.
Create a vacuum, then fill the refrigerant circuit
IMPORTANT: when replacing an evaporator, add
If a hose splits, add 50 ml of P.A.G. SP10 oil to the
circuit.
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AIR CONDITIONING
Evaporator sensor
62A
62A-12
Evaporator sensor
REMOVAL
Remove the thermostat connectors.
From underneath the dashboard (passenger side),
remove the thermostat mounting screw (1).
Remove the thermostat.
REFITTING
Ensure that seal (3) is present.
WARNING: take care not to damage section (2) of
the sensor circulating in the evaporator.
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AIR CONDITIONING
AC thermal cut-off switch
62A
62A-13
AC thermal cut-off switch
The function of the air conditioning thermal cut-off
switch (1) is to cut-off the supply to the system in the
event of the engine overheating.
NOTE: in the case of a vehicle fitted with electronic
COMMON RAIL, fuel injection system the air
conditioning system is deactivated by the injection
system computer through the air conditioning
compressor relay.
Tightening torque: 2 daNm.
Opening temperature in C 105 + 2
Closing temperature in C 100 + 2
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AIR CONDITIONING
77 11 315 542
APRIL 2002
EDITION ANGLAISE
RENAULT 2002
Climate control
vnx.su
Air conditioning
Contents
Page
62A AIR CONDITIONING
Customer complaints 62A-1
Fault finding charts 62A-2
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AIR CONDITIONING
62A
62A-1
162A
AIR CONDITIONING
NOTES Manually-operated air conditioning.
FAULTY AIR DISTRIBUTION
FAULTY AIR DISTRIBUTION CHART 1
AIR FLOW FAULT CHART 2
POOR DE-ICING/DEMISTING PERFORMANCE CHART 3
POOR VENTILATION PERFORMANCE CHART 4
NO PASSENGER COMPARTMENT VENTILATION CHART 5
RECIRCULATION FLAP DOES NOT OPERATE CHART 6
FAULTY HEATING
HEATER PERFORMANCE POOR CHART 7
NO HOT AIR CHART 8
TOO MUCH HOT AIR CHART 9
AIR CONDITIONING PROBLEMS
INEFFICIENT AIR CONDITIONING CHART 10
NO COOL AIR CHART 11
AIR TOO COLD CHART 12
NOISY COMPRESSOR CHART 13
FAULTY CONTROL PANEL
CONTROLS STIFF (passenger compartment inconvenience) CHART 14
FAN PROBLEMS
THE ENGINE COOLING FAN DOES NOT OPERATE CORRECTLY
(when the air conditioning is switched on)
CHART 15
CLIM X24 - 1.0
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AIR CONDITIONING
62A
Change the control cable or repair the
connection of the cable (clip).
62A-2
CHART 1 Faulty air distribution
NOTES
Before carrying out any work, check that the customer is using the air conditioning
system correctly. Manually-operated air conditioning.
Switch the passenger compartment blower to
full-on, the temperature control to maximum
heat or maximum cold, and operate the air
distribution control.
Check that the air outlet is the one selected.
Is the customer complaint confirmed?
YES
Check visually or by touch, on the right-hand
side of the air distribution unit, that moving the
control moves the sprockets and the lever.
Do they move?
NO
Check the connection of the cable to the air
distribution unit and the control unit and check
the condition of the cable and its retainer.
Is the cable connected correctly?
YES
NO
YES
NO
The air distribution is correct. If
necessary, explain how the system
works to the customer again.
Check the adjustment of the air
distribution flap control cable.
In the case of a ventilation problem,
check the ventilation ducts and the
vents. Repair if necessary.
If the fault persists, remove the air
distribution unit and check the
distribution flaps. Repair if necessary.
AFTER REPAIR Check that the system is operating correctly.
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-3
CHART 1
CONTINUED
Check the condition of the moving parts
(sprockets, levers, etc) on the air distribution unit
and the control panel.
Are the moving parts correct?
YES
Remove the air distribution unit and check the
distribution flaps.
Repair or change the assembly.
NO
Repair if possible, otherwise change
the air distribution unit or the control
panel.
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-4
CHART 2 Air flow fault
NOTES
system correctly. Manually-operated air conditioning.
Is the passenger compartment fan working?
YES
Check the air intake circuit and the rain shield.
Is it correct?
YES
Check that the air recirculation flap is not stuck in the
recirculation position.
Is the flap stuck in the recirculation position?
NO
Check that the air extraction circuit is not blocked.
YES
Is it a passenger compartment air distribution problem?
NO
Remove the heater radiator.
It should be plugged, cleaned or replaced.
NO
NO
YES
NO
YES
See CHART 5.
Repair.
See CHART 6.
See CHART 1.
CLIM X24 - 1.0
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AIR CONDITIONING
62A
See CHART 7.
62A-5
CHART 3 Poor de-icing/demisting performance
NOTES
Check the windows are clean inside the vehicle.
Manually-operated air conditioning.
Check that the air extractors are not blocked up.
YES
Check that there is no ingress of water into the passenger
compartment which would significantly increase the humidity
level and reduce the effectiveness of the de-icing function.
Locate the leak and repair it.
YES
Is it an air distribution problem?
NO
Is it an air flow problem?
NO
Is it a heater performance problem?
NO
Check that the recirculation flap is not stuck in the air recirculation position (see CHART 6).
NO
NO
YES
YES
YES
See CHART 1.
See CHART 2.
AFTER REPAIR
Check that the components which were removed are connected correctly.
Check that the system is operating correctly.
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-6
CHART 4 Poor ventilation performance
NOTES
Before carrying out any work, check that the customer is operating the air conditioning
system correctly.
NO
Is it an air distribution problem?
NO
Check that the mixing flap travel is complete.
Is the flap travel complete?
NO
Readjust the cable.
YES
YES
YES
See CHART 2.
See CHART 1.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-7
CHART 5 No passenger compartment ventilation
NOTES
Special notes:
The intermediate connector (grey 2 x 6 tracks) between the dashboard harness and
the passenger compartment fan harness is located under the glove compartment. The
passenger compartment ventilation motor control module is located behind the glove
compartment.
Check that the passenger compartment fan blades have not broken or come away from their spindle.
Replace the passenger compartment fan if necessary.
Remove the control panel, disconnect its connector and switch
on the ignition. Check that there is a 12 V after ignition supply
on track B1 and an earth on track A5 of the air conditioning
control panel connector.
NO
YES
Disconnect the control panel connector and check the insulation, continuity and absence of interference
resistance of the connections:
Control panel Intermediate connector (grey
2 x 6 tracks)
6-track connector of the passenger
compartment fan electronic module
track B4 track B4 track 1
YES NO
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-8
CHART 5
CONTINUED 1
With the engine running, use a voltmeter to measure the
control voltage of the passenger compartment fan between
track B5 of the control panel and earth (control panel and fan
module connected). This voltage should vary from 0 - 12 V as
a function of the 6 speeds.
Example of measurements taken with the engine running:
Speed 0: 0 volts Speed 1: 3.47 volts
Speed 2: 4.97 volts Speed 3: 5.84 volts
Speed 4: 6.91 volts Speed 5: 8.28 volts
Speed 6: 13.34 volts (these values are given as guidelines
only as they depend on the battery charge and the vehicle's
electric consumers).
With the passenger
compartment fan electronic
control module disconnected,
use an ohmmeter to measure
between track B4 and track B5
of the control panel. The
resistance should vary from
20 10% for speed 0 to
5560 10% for speed 6.
Does the control voltage vary?
NO
Does the resistance vary?
YES YES NO
Disconnect the black 2-track connector of the passenger
compartment electronic control module. Switch on the ignition
and check for a 12 volts supply on track 1 (red wire) and an
earth on track 2 (black wire).
Replace the air conditioning
control panel.
Is the module supply correct?
YES
NO
Check that there is an earth on track A1 of the grey 2 x 6-track intermediate connector.
Check the insulation, continuity and absence of interference resistance on the following connections:
grey 2 x 6-track intermediate connector black 2-track connector of the passenger compartment fan power
module
track A1 track 2 (black wire)
track 1 (red wire)
power relay (mounted on the fan)
track 5
track 2
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-9
CHART 5
CONTINUED 2
Is there a 12 volts supply and an earth on the black 2-track connector of the passenger compartment blower
electronic control module?
NO
Check that there is a 12 volts before ignition supply on track 3 and
an after ignition supply on track 1 of the fan power relay.
Check that the fan power relay is operating correctly by performing a
test with a new relay.
YES
Disconnect the black 6-track connector from the fan electronic
module and check the insulation, continuity and absence of
interference resistance of the connections:
6-track connector of the
passenger compartment fan
electronic module
track 3 track 2 (red wire)
track 4 track 1 (black wire)
YES
NO
NO
YES
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-10
CHART 5
CONTINUED 3
Disconnect the grey 2 x 6-track intermediate connector and the black
2-track connector from the passenger compartment fan. Using
shunts, supply the fan motor directly to check that it is working :
Intermediate connector (grey
2 x 6 tracks, male side)
(shunt)
track A1 (earth) track 1 (black wire)
(shunt)
track A3 (+ 12 V battery) track 2 (red wire)
Does the fan operate at maximum speed?
YES
YES
Replace the passenger compartment fan electronic module.
NO
NO
Replace the
passenger
compartment fan.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
Using an ohmmeter, check the operation of the
air conditioning control panel buttons.
There should be continuity between track A5
and track B3 in both cases: ventilation button
on 0 or air conditioning button on maximum
position.
There should be continuity between track A5
and track A2 only when the temperature control
button is on the maximum hot position.
In all other cases, there should be insulation
between track A5 and tracks B3 and A2.
Replace the air conditioning control panel if it
does not operate as described above.
62A-11
CHART 6 Recirculation flap does not operate
NOTES
Special notes:
The intermediate connector (grey 2 x 6 tracks) between the dashboard harness and
the passenger compartment fan harness is located under the glove compartment. The
recirculation motor control module is located above and to the right of the passenger
compartment fan assembly.
NOTE:
Refer to the HELP section for details on how the recirculation motor operates.
Remove the control panel, disconnect its connector and switch on the ignition. Check that there is a 12 volts after
ignition supply on track B1 and an earth on track A5 of the air conditioning control panel connector. Repair if
necessary.
With the air conditioning control panel connector
disconnected and the ignition on, insert the shunts as
described below:
TRACKS TO BE SHUNTED RECIRCULATION FLAP
POSITION
None External air
Tracks A5 and B3 100 %
recirculation
Tracks A5 and A2 80 %
recirculation
Is the test conclusive?
NO
Disconnect the control panel connector and check the insulation, continuity and absence of interference
resistance of the connections:
Control panel Intermediate connector
(grey 2 x 6 tracks)
Recirculation motor electronic
module
track A2 track B1 track 15
With the ignition on, check that there is + 12 volts on track 1 and an earth on track 3 of the recirculation motor
electronic control module 15-track connector.
YES
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-12
CHART 6
CONTINUED
Disconnect the connector from the control module and the recirculation motor in order to check the insulation,
continuity and absence of interference resistance of the connections:
Recirculation motor electronic module Recirculation motor
track 4 track 3
track 6 track 2
track 8 track 6
track 10 track 4
track 13 track 1
YES NO
Check that the recirculation flap control sprockets are in good
condition and that the flap is not jammed.
NO
YES
Replace the recirculation flap motor and its control module.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-13
CHART 7 Poor heater performance
NOTES Manually-operated air conditioning.
Carry out a road test to observe the customer complaints.
Is the test satisfactory?
NO
Visually check that moving the control moves the mixing flap.
Does the flap move?
YES
Visually check whether the flap travel is complete.
Is the travel complete?
YES
Check the cooling circuit (correct filling and bleeding) and the
condition of the circuit (pipes, connections, conformity of the circuit,
etc).
YES
With the engine cold, remove the coolant thermostatic valve and
check that it is not stuck in the open position.
Is the valve stuck in the open position?
NO
YES
NO
NO
NO
YES
Explain to the customer
how to use the heating
correctly (e.g.: do not
switch on the passenger
compartment fan at full
speed when starting from
cold but increase its
speed progressively).
See CHART 1.
Readjust the control cable
(cable which controls the
sprockets to the right of
the air distribution unit).
Replace the thermostatic
valve
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-14
CHART 7
CONTINUED
Check that there is no unwanted intake of cold air into the
passenger compartment (seals, grommets, cables, etc).
YES
Check the air inlets and outlets. Partially blocked air inlets or
outlets reduce the flow of heated air into the passenger
compartment.
YES
The heater radiator must be blocked.
Remove the heater radiator to clean it or replace it.
NO
NO
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-15
CHART 8 No hot air
NOTES
NO
Check the coolant circuit:
Check the level of the coolant circuit (too low a level may unprime
the circuit when driving at low loads and when idling).
Check that the thermostatic valve opens at the correct
temperature.
Check the conformity of the coolant circuit (fitting an oil, water
or air cooler not specified by the Technical Department and which
is incorrectly connected may reduce and even stop the coolant
flow in the heater radiator).
YES
Do they move?
YES
Remove the heater radiator.
Clean or change it if necessary.
YES
If the vehicle is fitted with thermoplungers or additional heating,
check that these are in good working order.
YES
NO
NO
NO
See CHART 2.
See CHART 1.
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-16
CHART 9 Too much hot air
NOTES
Do they move?
YES
Check that the flap travel is complete.
Is the travel complete?
YES
Check the operation of the recirculation flap.
Is it stuck in the recirculation position?
NO
Check the operation of the coolant thermostatic valve.
Replace the thermostatic valve if necessary.
NO
NO
YES
See CHART 1.
Readjust the cable (to the
right of the air distribution
unit).
See CHART 6.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-17
CHART 10 Inefficient air conditioning
NOTES
system correctly.
With the air conditioning in the maximum position, passenger
compartment fan on speed 6 and engine idling, check that the
compressor is operating.
Does the compressor operate?
YES
Check the tension of the compressor belt, the compressor clutch air
gap and its condition.
Replace the compressor and its belt if necessary.
YES
Check the operation of the all or nothing temperature switch
(evaporator sensor): it should prevent current flow (insulation
between two tracks) for an evaporator temperature equal to or less
than: 1.3 C 0.5 C (temperature < 4 C at the dashboard vent outlet)
and it should authorise current flow for an evaporator temperature
greater than or equal to 3 C.
Replace the temperature switch if it is not operating as described.
YES
NO
NO
NO
See CHART 12,
continued 2 (section B).
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-18
CHART 10
CONTINUED 1
Check that the recirculation flap is in the recirculation position.
Is the flap in the recirculation position?
YES
Check that the mixing flap travel is complete, readjust the cable
if necessary.
YES
NO
Connect the pressure gauges and check the high and low
pressures with the engine idling and the air conditioning on
maximum.
If the high pressure is > at 27 bar, there is:
either too much refrigerant in the circuit,
or the fan is operating incorrectly,
or the engine is overheating,
or the condenser is clogged.
Is the high pressure > 7 bar?
YES
NO
NO
YES
NO
See CHART 6.
See CHART 2.
Replace the tri-function
sensor.
If the fault persists, it is
possible that humidity in
the circuit is forming a
plug of ice in the pressure
relief valve or that the
pressure relief valve is
faulty.
Replace the dehydration
canister and the pressure
relief valve then recharge
the refrigerant circuit.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-19
CHART 10
CONTINUED 2
Check that the condenser harness is clean.
Clean or change it.
Check the operation of the engine cooling fan at high speed
(ventilation and air conditioning on maximum).
The fan is:
engaged for a pressure 19 bar,
engaged for a coolant temperature 105 C.
Is operation normal?
YES
Recharge the refrigerant.
NO
See CHART 15.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-20
CHART 11 No cool air
NOTES
Special notes:
Before trying to locate an air conditioning problem, perform fault finding on the injection
system to ensure that an injection fault is not preventing the air conditioning from
operating.
Reminder::
A passenger compartment fan speed must be selected to authorise operation of the air
conditioning.
Is the passenger compartment fan working?
YES
Does the compressor clutch engage?
YES
Check the condition of the air conditioning compressor belt and
check its tension.
Is the tension correct?
YES
Check that moving the temperature control (maximum cold) does
move the mixing flap.
Do they move?
YES
Check that the condenser harness is clean.
Clean or change it.
NO
NO
NO
NO
See CHART 5.
B
Replace the belt (refer to
the repair procedures).
See CHART 1.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-21
CHART 11
CONTINUED 1
Visually check on the air distribution unit that the mixing flap travel is
complete.
Readjust if necessary.
NO
YES
With the air conditioning switched on (with a very cold setting
selected), touch the refrigerant pipe between the pressure relief
valve and the evaporator to make sure it is very cold.
Is the refrigerant pipe cold?
YES
Top up the coolant, referring to the Workshop Repair Manual.
YES NO
Change the compressor. End of fault finding.
NO
Replace the pressure
relief valve.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-22
CHART 11
CONTINUED 2
With the ignition on, set the air conditioning button to
the normal or maximum position and select a
ventilation speed.
Check (with connector connected) that there is a
12 volts supply on track A1 of the air conditioning
control panel connector.
Is there a voltage of 12 volts?
YES
Check that there is an earth on track 2 (or B
depending on compressor type) of the air
conditioning compressor clutch connector.
With the engine running and air conditioning
selected, check that there is a 12 volts supply on
track 1 (or A depending on compressor type) of the
air conditioning compressor clutch connector.
Is there a supply?
NO
NO
YES
Remove the control panel, disconnect its
connector and switch on the ignition.
Check for a 12 volts after ignition feed on
track B1 and an earth on track A5 of the
air conditioning control panel connector.
YES
Replace the air conditioning control panel.
Replace the air conditioning compressor
clutch (or the compressor if the clutch
cannot be separated).
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
Replace the compressor
relay (or relay Q for the
Master Propulsion 130)
62A-23
CHART 11
CONTINUED 3
NO
NO
Refer to reference E
(CHART 11 continued 5)
for the Master Propulsion
110 (without common
rail injection).
Refer to reference F
(CHART 11 continued 6)
for the Master Propulsion
130 (with common rail
injection).
AFTER REPAIR
CLIM X24 - 1.0
With the engine running and the passenger compartment fan on
speed setting 1, make a request of the air conditioning system
(button in normal or maximum position) in order to check that the
compressor relay is operating correctly; it is located in the
passenger compartment relay and fuse box (compressor relay for
the Master Propulsion 110, clutch compressor relay or relay Q for the
Master Propulsion 130).
Does the relay engage (listen to the relay or touch it)?
YES
Check for a 12 volts after ignition supply on track 30 of the
compressor relay: repair if necessary.
In the passenger compartment relay and fuse box, disconnect the compressor relay in
order to check the insulation, continuity and absence of interference resistance of
the connection:
Compressor relay (or relay Q for the Master Propulsion 130) Tri-function sensor
track 87 track D
With the engine running, passenger compartment fan on speed
setting 1 and a request for air conditioning made: is the 12 volts
supply present on track D of the tri-function pressure switch?
YES
Check that the tri-function pressure switch (pressure sensor) is working correctly using pressure gauges
connected to the air conditioning circuit:
The tri-function pressure switch should authorise current flow (continuity between tracks C and D) for a
refrigerant pressure equal to or greater than: 3 bar.
The tri-function pressure switch should prevent current flow (insulation between tracks C and D) for a pressure
equal to or greater than: 27 bar.
Replace the tri-function pressure switch if it is not operating as described above.
vnx.su
AIR CONDITIONING
62A
62A-24
CHART 11
CONTINUED 4
Disconnect the tri-function sensor to check the insulation, continuity and absence of
interference resistance on the connection:
Tri-function sensor Compressor clutch
track C track 1 (connector fool-proofing device side)
When all the aforementioned checks have been carried out,
reconnect all the connectors. Start the engine, set the passenger
compartment fan at speed setting 1 and the air conditioning button to
the normal or maximum position.
Does the compressor clutch engage?
NO
Replace the air conditioning compressor clutch (or the compressor if
the clutch cannot be separated).
YES
AFTER REPAIR
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AIR CONDITIONING
62A
62A-25
CHART 11
CONTINUED 5
Master Propulsion 110 (without common rail injection):
Disconnect the air conditioning control panel connector in order to check the insulation, continuity and absence
of interference resistance on the connection:
Air conditioning control panel Compressor relay (in the passenger compartment relay and
fuse box)
track A1 track 86
Check that there is an earth on track A 85 of the compressor relay.
Is there an earth?
NO
In the passenger compartment relay and fuse box, disconnect the compresor relay in
order to check the insulation, continuity and absence of interference resistance of
the connection:
Compressor relay Evaporator sensor
track 85 track 1
Check for an earth on track 2 of the evaporator sensor: repair if necessary.
Check that the evaporator sensor is operating correctly:
The temperature switch should authorise current flow (continuity between two tracks)
for a temperature equal to or greater than: 3 C (evaporator temperature).
The temperature switch should prevent current flow (insulation between two tracks)
for a temperature equal to or less than: 1.3 0.5 C (evaporator temperature).
Replace the temperature switch if it is not operating as described above.
Once the above checks have been performed, is the compressor
relay triggered when the air conditioning is requested (check for a
noise or by touching the relay)?
YES
If the air conditioning compressor is still not triggered, then continue the fault finding procedure in reference C
(CHART 11 continued 3). If the compressor engages: end of fault finding.
YES
NO
relay.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-26
CHART 11
CONTINUED 6
Master Propulsion 130 (with common rail injection):
Disconnect the air conditioning control panel connector in order to check the
insulation, continuity and absence of interference resistance on the connection:
Air conditioning control panel Compressor clutch relay
(relay Q in the relay and fuse box)
track A1 track 86
Engine injection computer connector A
(cab connector located towards the bumper)
track 6
With the engine running, check that there is an earth on track 85 of
the compressor clutch relay (relay Q).
Is there an earth?
NO
In the passenger compartment relay and fuse box, disconnect the compressor relay
(relay M) to check for the insulation, continuity and absence of interference
resistance on the following connections:
Compressor relay (relay M) Compressor clutch relay (relay Q)
track 30
track 87
track 86
track 85
track 85
Evaporator sensor
track 1
track 2 Earth
Engine injection computer connector B
(engine connector located towards the bulkhead)
track 35
track 8
YES
AFTER REPAIR
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AIR CONDITIONING
62A
62A-27
CHART 11
CONTINUED 7
Master Propulsion 130 (with common rail injection):
With the engine running and air conditioning requested, is there an earth on track 85 of
the compressor clutch relay (relay Q)?
NO
Check for an earth on track 2 of the evaporator sensor: repair if necessary.
Check that the evaporator sensor is operating correctly:
The temperature switch should authorise current flow (continuity between two tracks)
for a temperature equal to or greater than: 3 C (evaporator temperature).
The temperature switch should prevent current flow (insulation between two tracks)
for a temperature equal to or less than: 1.3 0.5 C (evaporator temperature).
Replace the temperature switch if it is not operating as described above.
Perform fault finding on the injection system, because an injection fault resulting in lower
vehicle performance could prevent the air conditioning function from operating (by
inhibiting control relay M).
If the injection fault finding procedure does not reveal any fault and the computer is
controlling relay M correctly (+ 12 volts on track 86 and earth on track 85) but it is not
triggered: replace relay M.
Once the above checks have been performed, is the compressor
clutch relay (relay Q) triggered when the air conditioning is
requested (check for a noise or by touching the relay)?
YES
If the air conditioning compressor is still not triggered, then continue the fault finding procedure in reference C
(CHART 11 continued 3).
If the air conditioning compressor clutch engages: end of fault finding.
YES
NO
clutch relay (relay Q).
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-28
CHART 12 Air too cold
NOTES
Passenger compartment fan operating correctly.
Does the compressor operate?
YES
Is the engine cooling fan still engaged?
NO
between two tracks) for an evaporator temperature equal to or
less than: 1.3 C 0.5 C .
Replace the temperature switch if it is not operating as
described.
YES
Check that the recirculation flap does not remain in the
recirculated air position. Operate the flap control and check
that the flap moves.
Is the flap stuck in the recirculation position?
NO
NO
YES
NO
YES
B
Connect the pressure gauges and
measure the pressure of the refrigerant
circuit.
The engine cooling fan is engaged at low
speed for a pressure 3 bar.
the engine cooling fan is engaged at
high speed for a pressure 19 bar.
the engine cooling fan is switched off for
a pressure 27 bar.
Replace the tri-function pressure
switch if it is not operating as described.
See CHART 6.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-29
CHART 12
CONTINUED 1
Check that operating the heater control moves the mixing flap.
Do they move?
YES
Visually check on the air distribution unit that the flap travel is
complete.
Is the flap travel complete?
YES
NO
NO
See CHART 1.
Readjust the cable.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-30
CHART 12
CONTINUED 2
Disconnect the full on - full off temperature switch (evaporator
sensor).
Does the compressor stop?
YES
between two tracks) for an evaporator temperature equal to or less
than: 1.3 C 0.5 C (temperature < 4 C at the dashboard vent
outlets).
Replace the temperature switch if it is not operating as described.
YES
Check the operation of the engine cooling fan at high speed
(ventilation and air conditioning on maximum).
The fan is:
engaged for a pressure 19 bar,
engaged for a coolant temperature 105 C.
Is operation normal?
YES
Check that the air conditioning compressor clutch only operates the compressor when controlled electrically (not
seized mechanically). If the compressor still turns over when its clutch is not being supplied electrically: replace the
air conditioning compressor.
NO
NO
NO
Check that the air
conditioning compressor
control line is not in short
circuit to + 12 volts (see
the air conditioning
diagram).
Replace the tri-function
pressure switch.
AFTER REPAIR
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AIR CONDITIONING
62A
62A-31
CHART 13 Noisy compressor
NOTES
Before starting any work, check that the noise is indeed coming from the compressor.
NOTE:
Compressor noises due to a lack of refrigerant are mostly generated by variable
displacement compressors.
Check that the compressor belt is in good condition and check its tension (for engines without automatic
tensioner).
Replace the belt if necessary.
Check that the compressor is correctly positioned.
Check the refrigerant fluid and look for leaks as the compressor may become noisy if a significant volume
of fluid is lost.
Refill if necessary.
If the problem persists, change the air conditioning compressor.
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-32
CHART 14
Controls stiff
(passenger compartment inconvenience)
NOTES
Before carrying out any work, check that the customer is operating the air conditioning
system correctly.
Check the travel of the control cable.
Remove any constraints on it:
bending,
cable clamped with plastic clips.
Change it if necessary.
YES
Unclip the cable from the side of the unit and check the stiffness of
movement of each component, control button and flap control on the
air distribution unit.
Are the control buttons or flap stiff to operate?
NO
Change the flap control cable.
NO
YES
Change the faulty part.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-33
CHART 15
The engine cooling fan does not operate correctly
(when the air conditioning is switched on)
NOTES
Special notes:
On the Master Propulsion 110, the engine cooling fan clutch is controlled by the tri-
function pressure switch or the radiator coolant temperature sensor. On the Master
Propulsion 130, the engine cooling fan clutch is controlled by the engine injection
computer or the tri-function pressure switch if the refrigerant fluid pressure is above 19
bar.
Check for a 12 volts after ignition supply on track A of the engine cooling fan clutch. Repair if necessary.
Master Propulsion 110:
Check for an earth on tracks B2 and B3 of the declutchable engine cooling fan relay (relay 980 FCA in the engine
interconnection unit). Repair if necessary.
Check for an earth on tracks 30 and 85 of the declutchable engine cooling fan relay (relay D in the passenger
compartment relay and fuse box). Repair if necessary.
In the engine interconnection unit, disconnect the declutchable engine cooling fan relay (980 FCA) to check
the insulation, continuity and absence of interference resistance on connection:
Declutchable engine cooling fan relay Engine cooling fan clutch
track B5 track B
In the passenger compartment relay and fuse box, disconnect the declutchable engine cooling fan relay (relay D)
to check for the insulation, continuity and absence of interference resistance on connection:
Declutchable engine cooling fan relay
(relay D)
Engine cooling fan clutch
track 87 track B
Declutchable engine cooling fan relay (sealed relay 713 WA located
on the bulkhead above the engine injection computer)
track 30
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
62A
62A-34
CHART 15
CONTINUED
In the engine interconnection unit, disconnect the declutchable engine cooling fan relay (980 FCA) to check
the insulation, continuity and absence of interference resistance on connection:
Declutchable engine cooling fan relay tri-function pressure switch.
track B1 track B
In the passenger compartment relay and fuse box, disconnect the declutchable engine cooling fan relay (relay D)
to check for the insulation, continuity and absence of interference resistance on connection:
Declutchable engine cooling fan relay tri-function pressure switch.
track 86 track B
Check for a 12 volts after ignition supply on track A of the tri-function pressure switch.
Check that the tri-function pressure switch (pressure sensor) is working correctly using pressure gauges
connected to the air conditioning circuit:
the tri-function pressure switch should authorise current flow (continuity between tracks A and B) for a
refrigerant pressure equal to or greater than: 19 bar.
Replace the tri-function pressure switch if it is not operating as described above.
Check that the resistance of the engine cooling fan clutch is not zero
or equal to infinity.
Replace the engine cooling fan clutch if necessary.
NO
YES
Check that the radiator coolant temperature sensor is operating correctly (see Repair
Methods).
Perform fault finding on the injection system to check that fault DF183 fan assembly is
not present or stored.
AFTER REPAIR
CLIM X24 - 1.0
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AIR CONDITIONING
Fault finding - Help
62A
62A-35
OPERATION OF THE AIR CONDITIONING CONTROL PANEL BUTTONS
HEATING
TEMPERATURE
BUTTON
POSITION
AIR CONDITIONING
BUTTON POSITION
PASS. COMP.
VENTILATION
BUTTON
POSITION
RECIRCULA-
TION FLAP PO-
SITION
AIR CONDITIONING
STATUS
ENGINE COOLING FAN
STATUS
Position <
maximum
temperature
0 0
100 %
recirculation
INACTIVE INACTIVE
Position <
maximum
temperature
0
speed from
1 to 6
EXTERNAL
AIR
INACTIVE INACTIVE
Position <
maximum
temperature
NORMAL 0
100 %
recirculation
INACTIVE INACTIVE
Position <
maximum
temperature
MAXIMUM 0
100 %
recirculation
INACTIVE INACTIVE
Position <
maximum
temperature
NORMAL
speed from
1 to 6
EXTERNAL
AIR
ACTIVE LOW SPEED
Position <
maximum
temperature
MAXIMUM
speed from
1 to 6
100 %
recirculation
ACTIVE LOW SPEED
Temperature on
maximum hot
0 0
100 %
recirculation
INACTIVE INACTIVE
Temperature on
maximum hot
NORMAL 0
100 %
recirculation
INACTIVE INACTIVE
Temperature on
maximum hot
MAXIMUM 0
100 %
recirculation
INACTIVE INACTIVE
Temperature on
maximum hot
0
speed from
1 to 6
80 %
recirculation
INACTIVE INACTIVE
Temperature on
maximum hot
NORMAL
speed from
1 to 6
80 %
recirculation
ACTIVE LOW SPEED
Temperature on
maximum hot
MAXIMUM
speed from
1 to 6
100 %
recirculation
ACTIVE LOW SPEED
CLIM X24 - 1.0
vnx.su
General Information
BATTERY
FRONT HEADLIGHTS
FUSES
IMMOBILISER
INSTRUMENT PANEL
CONTROLS & SIGNALS
WIPERS
OPENING ELEMENTS MANAGEMENT
AIRBAGS AND PRETENSIONERS
77 11 320 102
vehicles are constructed.
FEBRUARY 2003
EDITION ANGLAISE
RENAULT.
RENAULT 2002
vnx.su
Electrical
equipment
Contents
Page
80A
80B
81C
82A
83A
BATTERY
Special notes 80A-1
Safety 80A-2
Check 80A-3
FRONT HEADLIGHTS
Headlamp and direction indicator 80B-1
Beam adjustment 80B-2
FUSES
Relay and fuse box 81C-1
Engine interconnection unit 81C-4
Fan assembly fuses 81C-21
IMMOBILISER
Key engine immobiliser 82A-1
Decoder unit 82A-5
INSTRUMENT PANEL
Dashboard 83A-1
Instrument panel 83A-6
Fuel level sensor 83A-10
Page
84A
85A
87C
88C
CONTROLS & SIGNALS
Windscreen wiper stalk 84A-1
Lighting stalk 84A-2
Stalk mounting 84A-3
Rotary switch under steering wheel 84A-4
Ignition switch 84A-6
WIPERS
Windscreen wipers 85A-1
Electric windscreen washer pump 85A-3
DOORS AND BOOT MANAGEMENT
Door locking remote control 87C-1
Airbag computer 88C-2
Computer 88C-3
Pretensioner 88C-4
Airbags and seat belt pretensioner 88C-5
Destruction procedure 88C-7
vnx.su
BATTERY
Special notes
80A
80A-1
180A
BATTERY
Special notes
REMOVAL
Switch off all the consumers.
Disconnect the battery starting with the negative
terminal.
Remove the mounting clamp (1).
REFITTING
Correctly position the battery and tighten the clamp to
a torque of 0.7 daNm.
Connect the battery, starting with the positive terminal.
When the battery is refitted and after every time it has
been disconnected, a certain number of simple
programming operations, which do not require the
diagnostic tool, will have to be carried out for the
vehicle to work properly:
setting the time on the clock,
entering the four-digit radio code.
Tightening torques
mounting clamp 0.7 daNm
battery terminals 1.2 daNm
WARNING
These vehicles are equipped with a battery with low
water consumption. Topping up the electrolyte level
is therefore prohibited.
vnx.su
BATTERY
Safety
80A
80A-2
Safety
SAFETY
It should be remembered that a battery:
contains sulphuric acid, which is dangerous,
produces oxygen and hydrogen during charging. The
mixture of these two gases is an explosive gas,
hence the risk of explosion.
I - DANGER - ACID
Sulphuric acid is a highly corrosive and toxic
substance which corrodes most metals.
Also, when handling a battery, it is essential to take the
following precautions:
protect your eyes with goggles,
wear acid-proof gloves and clothing.
II - DANGER - RISK OF EXPLOSION
When a battery is charging, oxygen and hydrogen are
released. Gas production is at a maximum when the
battery is completely charged and the quantity of gas
produced is proportional to the strength of the charging
current.
Oxygen and hydrogen mix in the open air and on the
surface of the plates and form an explosive mixture.
This mixture is highly explosive.
The smallest of sparks or heat sources can cause an
explosion. The explosion is strong enough to shatter
the battery and spray the acid into the surrounding
atmosphere.
People nearby are at risk (shattered casing parts, acid
splashes). Acid splashes are harmful to the eyes, face
and hands. They also damage clothing.
Protection against the danger of explosion, which can
be caused by incorrect handling of the battery, must be
taken very seriously. Avoid all risks of sparks.
Check that all consumers are completely switched
off.
When a battery is being charged in a room, switch off
the charger before connecting or disconnecting the
battery.
Do not put any metallic items onto the battery as this
may create a short circuit across the terminals.
Never hold a naked flame, a welding gun, hot air gun,
a cigarette or a lit match near to a battery.
IMPORTANT
If acid splashes on to your clothing, rinse all
contaminated areas thoroughly in water. If your
eyes are affected, consult a doctor.
vnx.su
BATTERY
Checking
80A
80A-3
Checking
CHECKING THE BATTERY
Inspection
1. of the mounting
The battery must be mounted correctly (tightening
torque 0.7 daNm). Excessive tightening is pointless
and dangerous because it deforms, and may even
break, the battery tray. Conversely, a mounting
weakness leads to too much clearance, and there
may be wear caused by the battery tray moving and
breakage caused by impact.
2. of cleanliness
check for the absence of crystallising salts
(sulphation) on the terminals and then clean them
and grease them if necessary,
check that the nuts are correctly tightened on the
terminals. A bad connection can cause starting or
charging faults which can give rise to sparks that
could cause the battery to explode (tightening torque
1.2 daNm),
BATTERY CHARGE
Check the battery with tool El. 1593 MIDTRONICS
(see next page). For more details, see the Technical
Note entitled Systematic battery check before new
vehicle delivery.
Charger validation test reminder.
During charging, heating is much more rapid and
greater, the higher the charge. This is why it is
essential to use a direct current charger.
Test
set the maximum charge intensity adjustment
potentiometer,
Take a reading of the voltage displayed on your
charger or at the battery terminals.
If the voltage displayed is above 15 V, your charger is
not a direct current charger (use is dangerous for the
battery).
Stop the charging operation.
IMPORTANT
If acid splashes on to your clothing, rinse all
contaminated areas thoroughly in water. If your
eyes are affected, consult a doctor.
WARNING
These vehicles are equipped with a battery with
low water consumption. Topping up the
electrolyte is therefore prohibited.
vnx.su
BATTERY
Checking
80A
Has the engine been
running during the past
hour?
no
yes
Stop the engine and switch off the ignition.
Switch on the dipped headlights for two minutes.
Turn off the dipped headlights and side lights.
Wait two minutes,
Switch off all the consumers.
Adjust tool El. 1593 (Midtronics R330).
carry out the test.
80A-4
Make sure the battery is the real source of the problem.
The problem could come from:
an abnormal electrical consumer,
an alternator charging fault, etc.
no Is the battery three
years old or older?
yes
Replace the vehicle's battery
The tool displays
Battery OK +
recharge or Charge +
retest
Recharge the battery
using a direct current
charger
The tool displays Test
impossible
Is this the first
time the message
has appeared?
yes
Check the tool
connection to the
battery. Switch off all
the consumers.
The tool displays
Incorrect component
or Replace battery
no
Replace the battery
The tool displays
Battery OK
The battery is not the
cause of the problem.
Check the charge
circuit and make sure
there is no abnormal
electrical consumer.
vnx.su
FRONT HEADLIGHTS
Headlight and indicator
80B
80B-1
180B
FRONT HEADLIGHTS
Headlight and indicator
REMOVAL
Disconnect:
the battery,
the headlight and indicator bulb connectors and the
headlight beam adjustment unit.
Remove the three radiator grille mounting bolts (C).
Remove:
the indicator light,
the two radiator grille mounting bolts (C),
the four headlight mounting bolts (D).
REFITTING
ADJUSTMENT
Ensure that the vehicle is unladen, then adjust the
height using bolt (A) and the direction using bolt (B).
vnx.su
FRONT HEADLIGHTS
Beam adjustment
80B
80B-2
Beam adjustment
REMOVING THE RECEIVER
Disconnect the beam adjustment receiver connector.
Turn the receiver an eighth of a turn towards the
vehicle wing to release the headlight.
Then release the receiver ball joint and the lens unit
reflector shell to remove the receiver.
REFITTING THE RECEIVER
Remove the bulb connector protective cover at the
rear of the headlight.
Keep the reflector shell towards the rear of the
headlight by pulling the base of the bulbs and click the
ball joint into its housing.
Now refit the receiver to the headlight by turning it an
eighth of a turn.
Reconnect the connector and refit the protective bulb
cover at the rear of the headlight.
Set the height adjustment control to "0" and adjust the
headlight:
bolt (A) for the height adjustment,
bolt (B) for the direction adjustment.
vnx.su
FUSES
Fuses and relays
81C
81C-1
181C
FUSES
Fuses and relays
POSITION AND ALLOCATION
The relays are located on the fuse board under the steering wheel. To reach them, open the fuse box cover.
C Hazard warning lights relay
D Declutchable engine cooling fan relay (S9W 208 engine)
E Heated windscreen relay
F Door mirror heating resistor relays
G Heated door mirrors timer
H Lights on reminder buzzer
J Wiper timer
K After ignition supply relay
M Air conditioning compressor clutch (S9W 208 engine)
P Injection computer relay
Q Flasher unit
R Headlight washer timer
S Fuel filter heater / air conditioning compressor relay
T Air conditioning compressor clutch Common Rail relay, booster pump
U Diagnostic socket
vnx.su
FUSES
Relay and fuse box
81C
81C-2
Relay and fuse box
RELAY AND FUSE BOX (passenger compartment side)
This fuse box is located in the passenger compartment on the driver's side.
Allocation of fuses (depending on equipment level)
Symbol Rating Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
10
10
10
30
25
10
15
30
-
10
7.5
25
10
20
-
25
2
10
-
15
10
5
15
7.5
10
5
7.5
-
15
20
15
Supply available (+ before ignition)
Power take off safety unit
Supply available (+ after ignition)
ABS modulator pump relay
Fuel filter heater relay
Left-hand main beam headlight / Main beam headlight indicator light
Interior light / Chronotachograph display
Power fuse
Available
Right-hand main beam headlight
Rear fog light / Fog lights indicator light / Registration plate right-hand light
Injection computer
FLAMSTART spark plug relay / Clutch pedal position sensor / Brake lights / Fast idle
Fuel filter heater relay
Available
Central locking unit
Electronic immobiliser
Diagnostic socket
Available
Hazard warning lights switch
Supply available (+ before ignition)
ABS computer
Audible alarm (beeper)
Right-hand side light / Right-hand side strip lights / Dashboard instruments lighting
Supply available (+ after ignition)
Heated rear screen relay / Heated door mirrors and windscreen indicator light /
Heated door mirrors relay / Heated windscreen timed relay
Left-hand side light / Left-hand side strip lights / Dashboard instruments lighting / Left-
hand registration plate light / Flasher unit
Available
ABS safety relay / Heated driver's seat / Passenger seat
Preheater plugs / Exhaust gas recirculation computer / Fast idle relay
Screen wash/wipe / Screen wiper timer
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FUSES
Relay and fuse box
81C
81C-3
Allocation of fuses (depending on equipment level) (continued)
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
10
25
20
30
10
25
7.5
-
20
10
15
-
25
40
40
Right-hand dipped beam headlight / Right-hand headlight adjustment motors
Passenger electric window motor
Injection computer / FLAMSTART solenoid valve / Reversing lights
Ventilation control / Heater matrix
Left-hand dipped beam headlights / Dipped beam headlights indicator light / Left-
hand headlight adjustment motor / Headlight washer timed relay
Driver's window riser motor
After ignition supply relay
Exhaust gas recirculation diagnostic shunt
Radio / Declutchable ventilation fan / Air conditioning system
Heated door mirrors
Power fuses
Injection diagnostic shunt
Cigarette lighter
Supply available (fog light) / Lighting switch / Heater matrix
Heated rear screen / Heated door mirrors
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FUSES
Engine interconnection unit
81C
81C-4
Engine interconnection unit
ENGINE COMPARTMENT CONNECTION UNIT (engine side)
The fuse box is located on the left hand side in the engine compartment.
Allocation of fuses (depending on equipment level)
1
2
3
4
5
6
7
8
9
10
11
12
60
70
60
70
30
30
40
30
-
30
-
70
Common Rail computer / FLAMSTART solenoid valve / Reversing lights / Radio /
Declutchable ventilation fan / Air conditioning system / Common Rail diagnostic shunt
Common Rail computer / Clutch pedal position sensor / FLAMSTART igniter relay /
Brake light (S9W208)
Fuel filter heater relay (S9W208)
Headlight washer pump
COMMON RAIL computer
Fuel filter heater
Preheating unit
Not used
ABS computer
Not used
Heated windscreen
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IMMOBILISER
Coded key immobiliser system
82A
82A-1
182A
IMMOBILISER
GENERAL INFORMATION
The immobiliser is controlled by a key recognition
system (known as coded key immobiliser system).
An independently operating coded chip without a
battery is integrated into each head of the vehicle
keys.
When the ignition is switched on, an antenna ring
around the ignition switch interrogates and captures
the code from the head of the key and transmits it to
the decoder unit.
If the decoder unit recognises the code, the vehicle will
be permitted to start.
The immobiliser is activated a few seconds after the
key is withdrawn from the ignition and this is shown by
the flashing of the red immobiliser warning light on the
instrument panel.
If there is a fault with the key recognition system,
a security code can be entered using the diagnostic
tool.
This code may be communicated to the repair agent
(on his request) by the local assistance network
(depending on country, for example: Delta Assistance
on 0800.05.15.15 for France, NVSR for the UK by fax
only).
NOTES:
The immobiliser function is provided by the injection
computer.
If the vehicle is fitted with a remote control for door
locking, a single decoder unit carries out both
functions (immobiliser and remote control). The
remote control unit has no effect on the immobiliser
system (see Section 87C Doors management).
On these vehicles, the identification number of the key
heads contains eight alphanumeric characters,
beginning with the letter E or A.
WARNING
The repair agent must inform the customer that the
immobiliser system will reset itself automatically
10 minutes after the ignition is switched off.
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IMMOBILISER
82A
82A-2
DESCRIPTION
With this system, the immobiliser is activated about
10 seconds after the ignition is switched off (shown by
the red immobiliser indicator light flashing).
The system comprises:
two key heads fitted with either:
a single coded chip for controlling the immobiliser
system (A),
a coded chip (A) for controlling the immobiliser
system and the remote control unit chip (B) for
controlling the locking and unlocking of the doors
and boot (according to the vehicle equipment
level).
Opening a key head
Place the key head on a table with the metal insert
facing downwards.
Use a small screwdriver as a lever as shown below,
ensuring that the end of the screwdriver is pressing
against lower section (E) of the key head. This allows
you to slide the upper section off the lower section.
Note:
To remove the metal insert, move the retaining tab
aside before removing it. When refitting, check that
the insert is correctly clipped into position.
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IMMOBILISER
82A
82A-3
An antenna ring (C) located around the ignition
switch, fitted with a chip for transmitting the key code
to the decoder unit (D).
REMOVAL - REFITTING
Remove the half-cowlings from under the steering
wheel, release the ring from the ignition switch and
disconnect its connector.
A decoder unit (D) located behind the headlining.
This provides the following functions:
decoding the key signal from the antenna ring,
controlling the immobiliser system by sending a code
to the injection computer to authorise vehicle
starting,
controlling the red immobiliser warning light,
locking or unlocking of the doors and boot
(depending on vehicle equipment level),
timed lighting of the courtesy light (depending on
equipment level, on vehicles fitted with a door locking
remote control unit).
Note:
This aerial ring is not coded.
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IMMOBILISER
82A
82A-4
Remove the headlining to remove the decoder unit.
Remove:
the courtesy light console,
the two sun visors and their mountings,
the two windscreen pillar linings after releasing the
door seal,
the blanking pieces or grab handles (according to
vehicle equipment level).
Move the headlining as far back as possible, without
folding it, disconnect the decoder unit and remove the
two mounting bolts (E) using a small ratchet fitted with
a Torx 20 socket.
One red immobiliser indicator light on the instrument
panel used to:
indicate activation of the engine immobiliser
system,
signal a fault in the system or non-recognition of
the key,
signal entry into the door locking remote control
resynchronisation mode (depending on vehicle
equipment level).
OPERATION
When the immobiliser system is operational
(approximately 10 seconds after cutting the + after
ignition feed), the immobiliser system red indicator
light flashes (slow flashing: lights up once per second).
After switching the ignition on, the antenna ring
analyses the code from the key and transmits it to the
decoder unit.
If the code is not recognised by the decoder unit, the
red immobiliser warning light flashes (rapid flashing).
If the code is recognised by the decoder unit, it sends
a code to the injection computer and switches off the
immobiliser system red indicator light (after
approximately three seconds).
At this precise moment, one of several situations may
arise:
the injection computer has no reference code in its
memory:
the code sent to it is stored in its memory.
the injection computer has a reference code in its
memory:
the code sent to it is compared with the code in its
memory,
if the two codes match, the coded solenoid valve
allows the engine to be started. When the ignition
is switched on, the immobiliser indicator light
comes on for 3 seconds then goes out, showing
that the system is operating correctly,
if the two codes do not match, the system remains
locked to prevent the engine from being started.
Note:
To ensure that the system operates correctly, no
objects (for example: key rings) should be allowed to
come between the key and the antenna ring.
WARNING
When the vehicle battery has a low charge, the drop
in voltage caused by operating the starter could
reactivate the immobiliser. If the voltage is too low,
the engine cannot be started, even by pushing the
vehicle.
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IMMOBILISER
Decoder unit
82A
82A-5
Decoder unit
REPLACING A DECODER UNIT
A new decoder unit is not coded. Once fitted to the vehicle, it must be programmed with the code from one of the
two keys to become operational.
IMMOBILISER SYSTEM TRANSPONDER PROGRAMMING PROCEDURE:
The procedure is carried out using only one key.
Check in the Engine immobiliser field then STATES LIST that state ET045: Key programming configuration is
displayed as 1 key. If it is not, change it using the COMMAND MODE menu, then CONFIGURATION and select the
programming with one key configuration and confirm with the blue button (above and to the right of the screen),
COMMAND IN PROGRESS is displayed, then COMMAND COMPLETED.
The CLIP diagnostic tool is essential for carrying out this procedure, in order to lock the key programming.
1 Before removing the unit and replacing it, it is essential to note the configuration of the decoder unit or print the
configuration screen to program the new decoder unit with the same configuration (see Section: Decoder unit
configuration).
2 With the ignition off, remove the decoder unit.
3 Fit the new unit (ignition off).
4 Select the COMPUTER FAULT FINDING menu.
5 Select the vehicle type.
6 Select and confirm the IMMOBILISER system.
7 Choose the STATES LIST menu and check the following states:
8 Switch the ignition on using one of the keys for approximately 2 seconds (without starting the engine). Check the
following states:
Note:
When only the decoder unit is replaced, there is no operation to perform on the injection computer, as it retains the
same immobiliser code.
WARNING
When a decoder unit has been programmed with the key code, the code cannot be cleared and no other code may
be stored in its place.
ET022 KEY PROGRAMMING COMPLETE NO
ET023 KEY PROGRAMMING LOCKED NO
Note:
If Key programming locked and Key programming done are not displaying NO, replace the decoder unit (this unit
has already been used).
ET022 KEY CODE RECEIVED YES
ET023 KEY PROGRAMMING COMPLETE YES
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IMMOBILISER
Decoder unit
82A
82A-6
9 The red immobiliser warning light flashes rapidly.
10 Switch off the ignition and select the COMMAND MODE menu, then ACTUATORS and select the
CALIBRATION COMPLETED command to lock the programming, then confirm with the blue button (above and
to the right of the screen). COMMAND IN PROGRESS is displayed, followed by COMMAND COMPLETED.
11 The red indicator light should flash: slowly.
12 Check the following states in the STATES LIST menu:
13 Check that the immobiliser system is operating correctly with both keys.
With the ignition off, the immobiliser system red warning light should flash for 10 seconds after the ignition is
switched off (slow flashing).
In the STATES LIST menu, check that the state ET001: Engine immobiliser is ACTIVE.
The vehicle should not start when other keys are used.
14 Check the configuration of the new decoder unit. Select the STATES LIST menu in "Engine immobiliser and
Connection unit".
If necessary, modify the configurations. Select the COMMAND MODE menu then CONFIGURATION.
Select the COMMAND MODE menu, then ACTUATORS and select the FORCED PROTECTION MODE
command then confirm with the blue button (above and to the right of the screen). COMMAND IN PROGRESS
is displayed, followed by COMMAND COMPLETED.
In the STATES LISTmenu, check that the state ET007: Forced protection mode is ACTIVE.
Switch the ignition on, the red immobiliser warning light should flash more quickly and it should be impossible
to start the vehicle.
15 The procedure is complete. After switching the ignition off and on again (for more than 2 seconds), check that
the vehicle can be started with both keys.
ET023 KEY PROGRAMMING LOCKED YES
Note:
To simulate prevention from starting, wait for the red indicator light to flash slowly before switching the ignition on.
Note:
To program the infrared or radio frequency remote control units, after replacement of the decoder unit only:
To program the 1
st
remote control unit, follow the basic resynchronisation procedure (see procedure
Section 87C).
To program the 2
nd
remote control unit, (if fitted) follow the specific resynchronisation procedure (see
procedure Section 87C).
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IMMOBILISER
Decoder unit
82A
82A-7
DECODER UNIT CONFIGURATION
Configure the decoder unit according to the equipment level of the vehicle.
1
st
field: IMMOBILISER SYSTEM
1 Connect the CLIP diagnostic tool then select the COMPUTER FAULT FINDING menu.
4 Select the COMMAND MODE menu, then CONFIGURATION.
Programming with 1 key: Allows the decoder unit to be programmed with only one key.
Programming with 2 keys: Allows the decoder unit to be programmed with two keys.
NOTE:
To configure the decoder unit, select the configurations required then confirm.
2
nd
field: INTERCONNECTION UNIT
1 Connect the CLIP diagnostic tool then select the COMPUTER FAULT FINDING menu.
3 Select and validate the CONNECTION UNIT system.
4 Select the COMMAND MODE menu, then CONFIGURATION.
With radio frequency remote control: For vehicles fitted with radio frequency receiver.
Central door locking push button: For vehicles fitted with door locking push button.
Without timed courtesy light: For vehicles not fitted with a timed courtesy light.
Note:
The various configurations for the decoder unit are in two fields (Engine immobiliser system and Interconnection
unit).
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IMMOBILISER
Decoder unit
82A
82A-8
REPLACING A KIT
(Decoder unit plus two head keys)
If a kit is being replaced:
Program the key code into the decoder unit (supplied uncoded).
Clear the old code stored in the injection computer using the security procedure (with the number of the old kit
available from the local assistance network, refer to Technical Note 3315E).
1 Fit the metal inserts from the old keys into the new key heads.
2 Note the number of one of the old keys to obtain the security code number.
3 Before removing the unit and replacing it, it is essential to note the configuration of the decoder unit or print the
configuration screen to program the new decoder unit with the same configuration (see Sectio: Decoder unit
configuration).
4 With the ignition off, remove the decoder unit.
5 Fit the new unit (ignition off).
9 Choose the STATES LIST menu and check the following states:
10 Switch on the ignition (without starting) using one of the keys (for approximately 2 seconds). Check the following
states:
11 Switch on the ignition (without starting) using the second key (for approximately 2 seconds) and check the
following states
Scenario no.1: The 2
nd
key used belongs to the vehicle it should read:
Scenario no. 2: The 2
nd
key used does not belong to the vehicle, or the 1
st
key has been used for a second time,
it should read:
12 The red immobiliser warning light flashes rapidly.
13 Switch off the ignition and select the COMMAND MODE menu, then ACTUATORS and select the
CALIBRATION COMPLETED command to lock the programming, then confirm with the blue button (above and
to the right of the screen). COMMAND IN PROGRESS is displayed, followed by COMMAND COMPLETED.
IMPORTANT
For the old code (stored in the injection computer) to be cleared, the procedure outlined below must be followed
in order.
ET023 KEY PROGRAMMING LOCKED NO
Note:
If Key programming locked and Key programming done are not displaying NO, replace the decoder unit (this
unit has already been used).
ET002 KEY CODE RECEIVED NO
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IMMOBILISER
Decoder unit
82A
82A-9
14 The red immobiliser warning light should flash slowly.
15 Check the following states in the STATES LIST menu:
16 Switch the ignition on, the red immobiliser warning light flashes more rapidly.
17 Select the COMMAND MODE menu then ACTUATORS and select the command ENTER CODE MANUALLY.
Enter the four figure security code using the alphanumeric keypad and confirm by pressing the Enter key on the
keypad, COMMAND IN PROGRESS is displayed then COMMAND COMPLETED.
18 Switch the ignition off and on again for a few seconds without starting the engine to program the injection
computer with the immobiliser code for the new kit. The red indicator light should come on for 3 seconds then
go out. Check that the vehicle starts with both keys.
19 Check the configuration of the new decoder unit. Select the COMMAND MODE menu then STATES LIST in
Immobiliser system and Interconnection unit. If necessary, modify the configurations. Select the COMMAND
MODE menu then CONFIGURATION.
20 The procedure is complete.
ET023 KEY PROGRAMMING LOCKED YES
Note:
To program the infrared or radio frequency remote control units, after replacement of a kit:
To program the 1
st
remote control unit, follow the basic resynchronisation procedure (see procedure
page 88-1).
To program the 2
nd
remote control unit, (if fitted) follow the specific resynchronisation procedure (see
procedure page 88-1).
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IMMOBILISER
Decoder unit
82A
82A-10
PROCEDURE FOR ENTERING THE SECURITY CODE
With this immobiliser system, the procedure for entering the security code is managed by the decoder unit.
This code can only be entered using the diagnostic tool.
The security code can only be entered if the engine immobiliser system is ACTIVE. The red immobiliser warning
light should flash when the ignition is switched on (rapid flashing).
After the security code number has been determined (available from the local assistance network, refer to Technical
Note 3351E) carry out the following operations:
1 Ignition off, the red engine immobiliser warning light should flash (slow flashing).
2 Switch the ignition on, the injection warning light (petrol vehicle) comes on for approximately 3 seconds then
goes out, while the immobiliser system red indicator light should flash more rapidly.
6 Select the STATES LIST menu, then check that the state ET001: Engine immobiliser is ACTIVE.
7 Select the COMMAND MODE menu then ACTUATORS and select the command ENTER CODE MANUALLY.
Enter the security code and confirm by pressing the Enter key on the alphanumeric keypad, COMMAND IN
PROGRESS is displayed then COMMAND COMPLETED.
WARNING
You may make three attempts to enter the code.If the code is invalid, after the 3
rd
attempt, you must wait for
approximately 15 minutes before making another attempt.
When this period has expired, switch the ignition off and on again and 3 more attempts may be made.
Note:
This procedure on its own does not decode the injection computer, it only authorises the starting of the
vehicle.
Note:
Between two attempts at code entry, switch the ignition off then on.
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INSTRUMENT PANEL
Dashboard
83A
83A-1
183A
INSTRUMENT PANEL
Dashboard
REMOVAL
Unclip the steering wheel boss.
Remove:
the steering wheel bolt (replace it),
the steering wheel after marking its position in
relation to the steering column, so that it can be
refitted.
Tightening torques
flywheel bolt 4.5 daNm
airbag/steering wheel bolt 0.7 daNm
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INSTRUMENT PANEL
Dashboard
83A
83A-2
REMOVAL OF STEERING WHEEL WITH
INFLATABLE AIRBAG
Remove the driver's airbag by removing the two
mounting bolts (Torx 30) behind the steering wheel.
The inflatable airbag connector MUST be
disconnected.
Remove:
the steering wheel bolt,
straighten the wheels and then remove the steering
wheel.
If the control stalk assembly is removed, the rotary
switch connector must be disconnected on steering
wheels equipped with airbags.
REMOVING THE WINDSCREEN PILLAR LININGS
Remove:
the door seal (partially where in contact with the
lining),
the two mounting bolts (A).
Unclip the lining (two clips) and remove it from the
windscreen pillar lining.
WARNING
Pyrotechnic systems (airbags and pretensioners)
must not be handled near to a heat source or flame
as they may be triggered.
Note:
When a steering wheel is removed, the position
must be marked by immobilising the rotary switch
rotor with adhesive tape.
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INSTRUMENT PANEL
Dashboard
83A
83A-3
Partly remove the door seal at the front pillar.
Remove the two screws (A).
Remove:
the car radio and its connectors (if fitted),
the four mounting bolts from the ashtray and the
heater control panel.
Remove the two mounting bolts (F) from the heater
control unit.
Remove the two lower bolts (G).
Disconnect the cigarette lighter and hazard warning
light switch connectors.
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INSTRUMENT PANEL
Dashboard
83A
83A-4
Remove:
the lower half-cowling under the steering wheel,
the upper half-cowling,
the control stalk assembly and its connectors.
Push the two holding clips (G) of the inspection flap
below the steering column.
Remove:
the four mounting bolts (H) of the inspection flap
mounting,
the four mounting bolts (I) on the instrument panel.
Disconnect the instrument panel and remove it.
Remove the three dashboard mounting bolts on the
steering column.
WARNING
If a driver's airbag is fitted, refer to the method for
removing the rotary switch described previously.
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INSTRUMENT PANEL
Dashboard
83A
83A-5
Remove:
the three upper covers (J) with a flat-headed
screwdriver,
the three upper dashboard mounting bolts (K).
Disconnect the connectors from the speakers.
Remove the dashboard from the passenger
compartment.
SPECIAL INSTRUCTIONS ON REFITTING
Refitting the steering wheel fitted with an airbag
cushion
Ensure that the wheels are still straight and check that
the rotary switch is still immobilised before refitting.
If there is any doubt, follow the centring method
described in Section 88C entitled Driver's airbag.
Whenever the steering wheel is removed/refitted,
replace the steering wheel bolt (pre-bonded bolt).
IMPORTANT
Before reconnecting the driver's airbag, check
that the system is operating correctly (refer to
Section 88C for this procedure).
WARNING
Any failure to follow these instructions may cause a
fault in the normal operation of the system and may
even result in the airbag being triggered
inadvertently.
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INSTRUMENT PANEL
Instrument panel
83A
83A-6
Instrument panel
REMOVAL - REFITTING
Remove the four bolts (A) and the instrument panel
visor.
Remove the four bolts (B) and the instrument panel.
REMOVAL
The instrument panel MUST NOT be opened.
If it is faulty, it must be renewed.
SPECIAL NOTES FOR REFITTING
Before reconnecting the instrument panel, check the
condition of the connectors and their wiring.
Ensure the connectors are correctly connected.
Check the information given by the instrument panel is
correct.
Note:
For this operation it is not necessary to remove the
steering wheel or the half cowling.
Note:
Only the transparent plastic screen may be
replaced.
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INSTRUMENT PANEL
Instrument panel
83A
83A-7
RED CONNECTOR
GREY CONNECTOR
Track Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Not used
Interwheel differential lock indicator
light
Not used
Not used
Earth
Not used
Not used
Engine speed signal
Water in the fuel filter indicator light
Not used
Not used
Heated windscreen indicator light
Power take-off indicator light
Anti-lock braking system indicator light
Not used
Track Description
1
2
3
4
5
6
Heated rear-view mirror indicator light
Direction indicator indicator light
Trailer direction indicator indicator light
+ clock
Immobiliser system warning light
Not used
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Electronic fault warning light
Dipped beam headlights indicator light
Main beam headlights indicator light
Airbag warning light
Fog light indicator light
Not used
Fuel filter clogging indicator light
Battery charge warning light
Heated seats warning light
+ after ignition feed
Engine cooling circuit temperature
indicator light
Oil pressure warning light
Earth
Engine cooling circuit temperature signal
Engine oil sensor supply
Fuel gauge signal
Vehicle speed signal
Earth
Fuel gauge earth
Engine oil level signal
Lighting dimmer
Hand brake indicator light
Brake pad wear warning light
Brake fluid level warning light
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INSTRUMENT PANEL
Instrument panel
83A
83A-8
GENERAL INFORMATION
The instrument panel contains the following functions:
needle gauge functions
vehicle speed
rev counter
coolant temperature,
fuel level
audible function (ignition on),
indicators
"headlights on" reminder when a door is opened
warning and indicator light function
display function
oil level reading
odometer
total mileage
trip mileage
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INSTRUMENT PANEL
Instrument panel
83A
83A-9
OPERATION OF THE DISPLAY
Oil level reading
This function is displayed for approximately
30 seconds when the ignition is switched on or after
the engine is started.
If the level is between the permitted maximum and
minimum, the display shows oil OK
If during this time the "RAZ" button is pressed, the
display shows "oil ok" and then the oil level is shown
by squares. These disappear as the oil level drops and
are replaced by dashes.
If the oil level is at a minimum when the ignition is
switched on, the dashes and the word oil flash for
30 seconds. The service warning light comes on and
remains lit after the engine is started.
Note:
Under normal operating conditions, the oil level is
only measured if the ignition has been switched off
for more than one minute; otherwise the old oil level
value is displayed again.
however, when a fault in the gauge is detected, the
display switches directly to the mileometer function
when the ignition is switched on.
It is normal to find that the oil level is not always the
same: Various parameters are involved:
parking on a slope,
too short a wait after running the engine briefly
(especially when the oil is cold),
different oil temperatures.
odometer
Total mileage
The mileometer will be displayed approximately
30 seconds after the ignition is switched on (after the
oil level information). Pressing the "RAZ" reduces this
display time.
Trip mileage
The trip meter is displayed instead in the place of the
total mileage if the "RAZ" button is pressed briefly.
It is reset by pressing the RESET button.
Note:
Different instrument panels are required for a display
in kilometres or miles.
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INSTRUMENT PANEL
Fuel level sensor
83A
83A-10
Fuel level sensor
REMOVAL
To remove the gauge, it is necessary to remove the
tank (see Section 19C Tank).
Disconnect the connector on the sender unit.
Remove both fuel supply pipes and the fuel return pipe
using the special pliers for quick release unions.
Remove the sender unit nut using tool Mot. 1264-01
and remove the fuel tank sender unit.
REFITTING
Check that the seal is in good condition. If not, replace
it.
Fit the seal on the fuel tank first before fitting the
assembly.
Refit the sender unit in the fuel tank by aligning it with
the indexing arrow (F).
Tighten the sender unit mounting nut to a torque of
(6 daNm) using the tool Mot. 1264-01, holding the
sender unit to prevent it from rotating.
Ensure that the connector is correctly engaged and
that the quick-release unions are correctly clipped on.
Note:
There are three types of fueI tank sender unit:
95, 100 and 140 litres.
Mot. 1264-01 Fuel tank sender unit nut wrench
Mot. 1265-01 Pliers for quick release couplings
Tightening torques
gauge nut 6 daNm
Note:
If several hours are likely to elapse between
removing and refitting the sender unit assembly, refit
the nut to the fuel tank to prevent it from distorting.
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INSTRUMENT PANEL
Fuel level sensor
83A
83A-11
Fuel level sensor
CONNECTION
Check
Ensure that the resistance varies when the float is
moved.
Measuring height H
Place the removed sender unit on a flat surface.
H is the height measured between the sender unit float
pin and the gasket face.
Track Description
A1 Earth
A2 Fuel minimum level warning light
B1 Fuel tank sender signal
B2 Not used
C1 Not used
C2 Not used
Indication Value between terminals A1 and B1
(in )
4/4 7 7 20 4 7 7
3/4 54.5 7 40 6 54.5 7
1/2 98 10 68 10 98 10
1/4 155 16 109 15 155 16
Low fuel 275 15 137 15 275 15
Indication Height H (mm)
4/4 0 0 0
3/4 94 99.7 87.6
1/2 141 160.4 150.6
1/4 196 224.5 199.9
Low fuel 235 254.5 254.9
Note:
All the above values are given merely as an
indication.
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CONTROLS - SIGNALS
Windscreen wiper stalk
84A
84A-1
184A
CONTROLS - SIGNALS
Windscreen wiper stalk
REMOVAL - REFITTING
Remove the two half cowlings under the steering
wheel.
Release the immobiliser antenna ring or the plastic
surround from the ignition switch.
Remove the two mounting bolts (A) from the wiper
stalk.
Release the stalk from its mounting and disconnect the
connector.
CONNECTION
Note:
The steering wheel does not need to be removed.
Track Description
A1 Front timer
A2 High speed wiper
A3 Low speed wiper
A4 Windscreen wiper pump
A5 Not used
A6 Intermittent slow speed
A7 + after ignition windscreen wiper
B1 Not used
B2 Not used
B3 Not used
B4 + after ignition park position
B5 Not used
B6 Not used
B7 Not used
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CONTROLS - SIGNALS
Lights stalk
84A
84A-2
Lights stalk
REMOVAL - REFITTING
Remove:
the half cowlings under the steering wheel,
the two mounting bolts (B) from the lights stalk.
Release the stalk from its mounting and disconnect the
connector.
CONNECTION
Note:
The steering wheel does not need to be removed.
Track Description
A1 Not used
A2 Not used
A3 Rear fog lights
A4 Audible alarm (beeper)
A5 Right-hand indicators
A6 Flasher unit
A7 Left-hand indicators
B1 Side lights
B2 + before ignition
B4 Not used
B5 Dipped headlights
B7 Main beam headlight
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CONTROLS - SIGNALS
Stalk mounting
84A
84A-3
Stalk mounting
REMOVAL - REFITTING
Disconnect the battery and set the wheels straight.
Remove the steering wheel and the two half cowlings
(for vehicles with an airbag, refer to the notes on
removing the rotary switch on the following page or to
section 88C for special notes on removing the steering
wheel).
Special notes for vehicles with airbag
Before removing the assembly, it is essential to note
the position of the rotary switch under the steering
wheel by:
ensuring that the wheels are straight during removal
in order to position the tape at the centre,
immobilising the rotary switch rotor with adhesive
tape.
Slacken bolt (C) and then tap the screwdriver sharply
to release the cone.
Move the stalk mounting assembly back slightly and
disconnect the connectors.
Special notes for retting
Fit the mounting with its components, connect the
various connectors and push the assembly back
against the steering column.
Continue retting and do not lock bolt (C) until the two
half-cowlings are retted and the the stalks are aligned
with the dashboard and the instrument panel.
For vehicles tted with airbags, follow the instructions
in the "Special notes on the rotary switch under the
steering wheel" section on the following page or in
Section 88C entitled "Drivers airbag".
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CONTROLS - SIGNALS
Rotary switch under steering wheel
84A
84A-4
This makes the electrical connection between the
steering column and the steering wheel.
It consists of a strip of conductor tracks (airbag), the
length of which is designed to guarantee 2.5 steering
wheel turns (steering lock plus safety margin) on each
side.
REMOVAL - REFITTING
Remove:
the drivers airbag cushion by the two Torx T30 bolts
(tightening torque: 0.5 daNm) located behind the
steering wheel and disconnect the connector (D),
the steering wheel bolt,
the steering wheel after setting the wheels straight,
the half cowlings (5 bolts).
Disconnect the connector for the rotary switch and
remove it (clipping).
When removing the switch, its position must be noted:
by ensuring that the wheels are straight during
removal in order to position the tape at the centre,
by immobilising the rotary switch rotor with adhesive
tape.
If it is being replaced, the new part is supplied ready
centred by an adhesive label which will tear off as soon
as the steering wheel is turned for the rst time (t with
the wheels straight).
WARNING
Pyrotechnic systems (airbags and pretensioners)
must not be handled near to a heat source or a flame
as they may be triggered.
IMPORTANT
Whenever the steering wheel is removed, airbag
connector (D) must be disconnected. The airbag has
a connector which short circuits if it is disconnected
to prevent accidental triggering.
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CONTROLS - SIGNALS
84A
84A-5
Special notes for retting
Ensure that the wheels are still straight.
check that the rotary switch is still immobilised before
retting.
If this is not the case, follow the centring method
described in Section 88C entitled Drivers airbag.
Replace the steering wheel bolt whenever it is
removed (pre-bonded bolt).
Observe the correct tightening torque: 4.5 daNm.
IMPORTANT
The procedure for checking that the system is
operating correctly must be carried out before
reconnecting the driver's airbag:
Check that the airbag warning light on the
instrument panel lights up when the ignition is
switched on,
Connect a dummy ignition module to the driver's
airbag connector and check that the warning light
goes out.
Switch off the ignition, connect the airbag in place
of the dummy igniter and fix the airbag to the
steering wheel.
Switch on the ignition and check that the warning
light comes on for 3 seconds and then goes out
permanently.
If the warning light does not operate as described
above, refer to the Fault finding section and check
the system using XRBAG (part number 1288).
WARNING
If these instructions are not followed the system
may not operate normally and could even be
triggered accidentally.
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CONTROLS - SIGNALS
Ignition switch
84A
84A-6
Ignition switch
REMOVAL - REFITTING
Straighten the wheels.
Remove:
the half cowlings,
the immobiliser antenna ring or plastic surround from
the ignition switch (depending on the level of
equipment).
Disconnect star ter switch connectors (F).
Remove bolt (G) from the ignition-starter switch.
Position the ignition key in position 3 and tilt retaining
lugs (H) while releasing the switch.
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WIPERS
Windscreen wiper
85A
85A-1
185A
WIPERS
Windscreen wiper
REMOVAL OF THE WIPER MECHANISM WITH
MOTOR
Make sure that the wiper motor is in the park position.
Note the position of the wiper arms.
Open the bonnet.
Remove:
the wiper arms using tool El. 1294-01 after
disconnecting the washer pipes,
the two sections of the scuttle panel grille (eight
bolts),
the air filter and its rear mounting.
Remove the three mechanism mountings (1).
Disconnect the motor and release the assembly.
Special notes for refitting
Check that the motor is in the park position before
refitting the wiper arms.
Clean the wiper arm shaft splines with a wire brush.
Refit the wiper arms, locating the blade on the marks
made on removal.
Fit new nuts and tighten to a torque of
(2.2 daNm 15 %) using a torque wrench.
Essential special tooling
El. 1294-01 Windscreen wiper arm removing tool
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WIPERS
Windscreen wiper
85A
85A-2
REMOVING JUST THE MOTOR
Make sure that the wiper motor is in the park position.
Note the position of the wiper arms.
Open the bonnet.
Remove:
the motor shaft nut (2) and release the linkage after
noting its position,
the three motor mountings (3).
Release the motor after disconnecting it.
Special notes for refitting
Refit the linkage on the motor and refit the wiper arms
on the marks made during removal.
Ensure that the motor is in the park position before
tightening the the shaft nut.
13305R1
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WIPERS
Electric screen washer pump
85A
85A-3
Electric screen washer pump
This vehicle is fitted with an electric screen washer
pump located on the reservoir.
The reservoir does not need to be removed when the
pump is removed.
Note:
The washer reservoir is attached by three bolts.
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DOOR AND BOOT MANAGEMENT
Remote control door locking
87C
87C-1
187C
GENERAL INFORMATION
These vehicles are equipped with an infrared or radio
frequency remote control with a rolling code, which
prevents the code from being copied.
As a result, when a transmitter is replaced, it must be
resynchronised so that the transmitters are returned to
phase with the decoder unit.
This remote control is only used for locking and
unlocking the doors and boot (it has no effect on the
immobiliser).
THE TRANSMITTER
Replacing or adding a remote control with
immobiliser function without replacing the
decoder unit.
Order a spare key head using the number in the head
of one of the old keys or the label normally attached to
the keys when the vehicle is delivered (eight
alphanumeric characters).
If a key is being added or has been lost, remember to
order the insert with the key number.
WARNING
This system cannot operate with three remote
controls (the decoder unit can only manage two
different rolling codes).
Note:
It is not always necessary to resynchronise the
second remote control (if fitted to the vehicle)
when a key head is replaced.
Check that the second control operates, otherwise
resynchronise it.
If both remote controls (if fitted) are
desynchronised, two resynchronisation
procedures will have to be carried out (one for
each remote control).
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87C
87C-2
Infrared and radio frequency remote control programming procedure
1 Basic resynchronisation procedure: (Programming the 1
st
remote control unit)
This is a procedure for programming the 1
st
radio frequency remote control with the decoder unit.
This procedure is used:
When the remote control code no longer lies within the reception range of the decoder unit (over 1,000
consecutive presses on the remote control, away from the vehicle).
when replacing a decoder unit on its own (new unit).
When replacing a kit.
Ignition off:
1 Press and hold the central door locking button for a few seconds until the doors lock and unlock.
From this moment, the operator has 10 seconds to carry out the next operation.
Note:
the 10 seconds are displayed by the red immobiliser warning light being permanently on, then in the STATE LIST
menu, in the field Connection unit, check the following state:
2 Press the remote control twice (the doors lock and unlock and the red warning light goes out).
3 The procedure is complete - check that the doors lock correctly.
ET106
PROGRAMMING OR RESYNCHRONISATION.
INFRARED OR RADIO FREQUENCY REMOTE
CONTROL
ACTIVE
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87C
87C-3
2. Specific resynchronisation procedure: (Programming the 2
nd
remote control)
This procedure allows the 2
nd
infrared or radio frequency remote control to be programmed with the decoder unit
(rolling code).
3 Select and confirm the CONNECTION UNIT system.
For vehicles fitted with a radio frequency remote control, go to point 7
4 For vehicles fitted with infrared remote control. With the ignition switched off, select the COMMAND MODE
menu then ACTUATORS and select the FORCED PROTECTION MODE command, then confirm with the blue
button (above and to the right of the screen). COMMAND IN PROGRESS is displayed, followed by COMMAND
FINISHED (to display the validation of the command FORCED PROTECTION MODE go to STATE LIST and
check that state ET007: forced protection mode is ACTIVE).
5 Switch the ignition on, the red immobiliser indicator light flashes rapidly.
6 Return to the previous menu, COMMAND MODE, then ACTUATORS and select the ENTER CODE
MANUALLY command and enter the four figure code (see code entry procedure).
7 Switch off the ignition, select the COMMAND MODE menu then CONFIGURATION and select the
Programming 2
nd
infrared/radio frequency remote control key; from that moment, the operator has
10 seconds to carry out the next operation.
Note:
the 10 seconds are shown by the red immobiliser warning light coming on.
8 Press the remote control twice (the doors lock and unlock and the red warning light goes out).
Note:
It is not always necessary to resynchronise the second remote control (if fitted to the vehicle) when a key head is
replaced. Check that the second control operates, otherwise resynchronise it.
If both remote controls (if fitted) are desynchronised, two resynchronisation procedures will have to be carried out
(one for each remote control).
9 The procedure is complete - check that the doors lock correctly.
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General information
88C
88C-1
188C
General information
PRECAUTIONS DURING REPAIR
The airbags have a pyrotechnic gas generator with an
ignition module and airbag which must not be
separated.
When an airbag or pretensioner is triggered, the
computer locks permanently and switches on the
airbag fault warning light on the instrument panel. The
airbag computer must be replaced. (Some
components lose their nominal specifications after
experiencing trigger energy).
After refitting all the parts, carry out a fault finding
check using the diagnostic tool.
If everything is correct, unlock the computer, if not,
refer to the fault finding document.
Any operation, even minor, is forbidden on the
triggering lines of the pyrotechnic components.
WARNING
The computers and impact sensors contain sensitive
components, do not drop them.
Do not put covers on the front seats (except for
RENAULT products).
Do not place objects in the airbag deployment area.
When working under the vehicle (on the bodywork,
sill panel etc.), it is vital that you lock the airbag
computer using a diagnostic tool and switch off the
ignition.
For special points regarding removal and
replacement of seat trims, it is essential to read the
Bodywork section.
After an impact:
if the buckle pretensioner was triggered, the seat
frame must be replaced and also the seat belt if it
was being worn,
if the driver's front airbag has been triggered, the
steering wheel and its mounting bolt must be
replaced.
All operations on airbag and pretensioner systems
must be carried out by qualified trained personnel.
WARNING
Pyrotechnic systems (pretensioner or airbag) must
not be handled near to a heat source or flame as
they may be triggered.
IMPORTANT
Before removing a safety system component, lock
the airbag computer using a diagnostic tool. When
this function is activated all the triggering lines are
disabled and the airbag warning light on the
instrument panel lights up (ignition on).
IMPORTANT
Refer to the Destruction procedure section when
scrapping a pyrotechnic system that has not been
triggered.
IMPORTANT
It is essential that the pyrotechnic systems
(pretensioners and front airbags) are checked using
the diagnostic tools:
following an accident which did not trigger the
devices,
following theft or attempted theft of the vehicle,
before selling a used vehicle.
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Airbag computer
88C
88C-2
Airbag computer
AIRBAG COMPUTER LOCKING PROCEDURE
Lock the computer using the diagnostic tool:
1 Select and confirm the Airbag system to be checked.
2 Select the Repair menu.
3 Select the other programming command.
4 Confirm the VP006 Computer locking line.
5 In the State menu, check that the computer is locked.
The ET073 Computer locked with tool state must
be active and the airbag warning light on the
instrument panel must be on (new computers are
delivered in this state).
Note:
To unlock the airbag computer, use the same
method, by confirming the VP007 Computer
unlocking line. The ET073 Computer locked with
tool state should not be active and the airbag
warning light on the instrument panel should switch
off.
NOTE
New computers are supplied locked.
If these systems operate incorrectly during an
impact, it is possible to check that no fault was
present before the impact using the diagnostic
tools.
After locking following an impact, it is possible to
check the trigger lines supplied with the command
S0004 Reading impact contexts with the
diagnostic tool.
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Computer
88C
88C-3
Computer
REMOVAL
Remove the driver's seat.
Disconnect:
the pretensioner,
the heated seat connectors (if installed).
Remove the protective cover from the computer.
Disconnect the connector (1).
Remove the mounting bolts (2) from the computer.
Remove the computer (3).
REFITTING
Position the computer and then tighten the mounting
bolts to a torque of 0.7 daNm before reconnecting the
connector.
Make the necessary configurations then check that
there are no faults. If everything is correct, unlock the
airbag computer, if not, refer to the fault finding
document.
IMPORTANT
Before removing a safety system component, lock
the airbag computer using a diagnostic tool. When
this function is activated all the triggering lines are
inhibited and the airbag warning light on the
instrument panel lights up continuously (ignition on).
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Pretensioner
88C
88C-4
Pretensioner
SEAT BELTS
When a pretensioner has been triggered, the front seat
belt must always be replaced if it was being worn when
pretensioning took place (if there is any doubt as to
whether the belt was being worn it must be replaced).
The physical stresses exerted on the buckle are
transmitted to the inertia reel and may damage its
mechanism.
REMOVAL
Remove:
the protective trim,
the connector (1),
the pretensioner bolt (2),
the pretensioner assembly.
REFITTING
Bolt (2) must be replaced and tightened to a torque of
2.5 daNm.
Observe correct routing of the wiring and the wiring
mounting points under the seat.
REMINDER: if the pretensioners have been triggered
the computer MUST be replaced.
WARNING
pyrotechnic systems (airbags and pretensioners)
must not be handled near to a heat source or flame -
they may be triggered.
NOTE
The computer can be locked with the diagnostic tool
during the operation.
When this function is active, the trigger line is
inhibited, The airbag indicator on the instrument
panel lights up (new computers are supplied in this
state).
After carrying out the operation, perform a check
using the diagnostic tool. If everything is correct,
unlock the computer.
IMPORTANT
Before a non-triggered pretensioner is scrapped, it
MUST be destroyed (excluding parts to be returned
under warranty) refer to the Destruction procedure
operation.
IMPORTANT
After reconnecting the connector, carry out a
check using the diagnostic tool. If everything is
correct, unlock the computer.
On the pretensioner side, push the connector (C)
fully into the clips (strong clips).
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WIRING
Airbags and seat belt pretensioners
88C
88C-5
688C
WIRING
DRIVER'S AIR BAG
REMOVAL
IMPORTANT
Before removing an airbag cushion, lock the computer
using the diagnostic tool.
When this function is active, all the trigger lines are
inhibited, The airbag indicator light on the instrument
panel lights up (ignition on).
WARNING
Pyrotechnic systems (pretensioners) must not be
handled near to a heat source or flame - they may be
triggered.
IMPORTANT
Whenever the steering wheel is removed, the airbag
connector MUST be disconnected (D).
The airbag has a connector which short circuits if it
is disconnected to prevent accidental triggering.
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WIRING
88C
88C-6
Remove the airbag cushion by undoing the two Torx
bolts located behind the steering wheel and
disconnect its connector (D).
REMEMBER: If the seat belt pretensioners or airbags
have been triggered, the computer MUST be replaced
(some components loose their nominal specifications
after the trigger energy is released).
As regards the 2
nd
fitting, the computer locks
definitively and lights up the air bag indicator light on
the instrument panel.
REFITTING
Reconnect the airbag cushion and attach it to the
steering wheel (tightening torque: 0.6 daNm).
On the cushion side, push the connector (D) fully into
the clips (strong clips.
IMPORTANT
Refer to the section describing the Destruction
procedure when scrapping a driver's airbag that has
not been triggered.
IMPORTANT
After everything has been refitted, carry out a check
using the diagnostic tool. If everything is correct,
unlock the airbag computer.
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Destruction procedure
88C
88C-7
788C
In order to avoid any risk of an accident, the
pyrotechnic gas generators must be triggered before
the vehicle is scrapped or the part is scrapped.
It is essential to use tool El. 1287.
PRETENSIONERS
Destruction of part fitted to the vehicle:
Move the vehicle outside the workshop.
Connect the destruction tool El. 1287 onto the
pretensioner.
Unwind all the tool wiring so that it is far enough away
from the vehicle (approx. 10 metres) during triggering.
Connect the two supply wires on the tool to a battery.
After checking that there is no-one nearby, destroy the
pretensioner by pressing the two buttons on the tool at
the same time.
Destruction of part removed from the vehicle:
Proceed in the same way as for the front airbag, in a
stack of old tyres.
WARNING
This does not apply if local legislation requires a
specific procedure validated and circulated by
the Procedures, Fault Finding and Repair
service.
IMPORTANT
Do not reuse the pyrotechnic components as
replacement parts. The pretensioners or airbags on
a vehicle which is to be scrapped must be destroyed.
Note:
Each part is intended for a specific type of vehicle
and should not be fitted onto another vehicle under
any circumstances. The parts are not
interchangeable.
WARNING
Do not trigger pretensioners which are to be
returned under warranty because of a problem with
the seat belt catch. This makes analysis of the part
by the supplier impossible.
Return the part to the Techline in the packaging of
the new part.
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88C
88C-8
AIRBAGS
These parts can only be destroyed outside the
workshop, once they have been removed from the
vehicle.
Connect the corresponding wiring harness El. 1287.
Place the airbag cushion on two wooden shims.
Destruction is carried out in a stack of old tyres.
Make sure that deployment of the inflatable cushion
will not be hindered.
Unwind all the tool wiring so that it is far enough away
from the unit (approx. 10 metres) during triggering and
connect it to the airbag.
Connect the two supply wires on tool El. 1287 to a
battery.
After checking that there is no-one nearby, destroy the
airbag by pressing the two buttons on the tool at the
same time.
Note:
If triggering is not possible (faulty ignition module)
return the part to the Techline.
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IMMOBILISER
ELECTRICAL ASSISTANCE EQUIPMENT
AIR BAG AND PRETENSIONERS
77 11 315 562
APRIL 2002
EDITION ANGLAISE
RENAULT 2002
Electrical equipment
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Electrical equipment
Contents
Page
82A
87A
88C
IMMOBILISER
Introduction 82A-1
Interpretation of faults 82A-12
Conformity check 82A-14
Interpretation of states 82A-20
Fault finding chart 82A-22
ELECTRICAL ASSISTANCE
EQUIPMENT
Introduction 87A-1
Interpretation of faults 87A-4
Conformity check 87A-10
Interpretation of states 87A-16
Fault finding chart 87A-20
Introduction 88C-1
Interpretation of faults 88C-3
Conformity check 88C-17
Help 88C-18
Fault finding chart 88C-19
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IMMOBILISER
82A
82A-1
182A
Program no.: 56
Calibration number: 41
IMMOBILISER
GENERAL APPROACH TO FAULT FINDING
Use one of the diagnostic tools to identify the immobiliser system equipping the vehicle (to read the computer
family, the program number, the Vdiag, etc.).
Take note of information contained in the introductory sections.
DESCRIPTION OF THE FAULT FINDING STAGES
1 - CHECKING THE FAULTS
It is essential to start with this stage before any work is done on the vehicle.
Read the faults stored in the computer memory and use the Fault interpretation section of the documents.
Reminder: Each fault is interpreted for a particular type of storage (fault present, fault stored in memory, fault
present or stored). The specified checks for dealing with each fault are therefore only to be performed if the fault
declared by the diagnostic tool can be identified in the document by its type. The storage type should be considered
when using the diagnostic tool after the ignition has been switched off and switched back on.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the NOTES
box. When these conditions are not satisfied, use the fault finding procedure to check the circuit of the faulty part,
since the fault is no longer present on the vehicle. Perform the same operation when a fault is declared as stored
by the diagnostic tool but is only interpreted in the documentation as a present fault.
2 - CONFORMITY CHECK
The conformity check is designed to check the states and parameters which do not display any faults on the
diagnostic tool when they are outside the permitted tolerance values. This stage:
Diagnoses faults that are not displayed which may correspond to a customer complaint.
Checks that the immobiliser is working correctly and ensures that a fault will not reappear after repair.
This document contains fault finding features applicable to all immobiliser computers (decoder unit)
fitted to MASTER PROPULSION vehicles.
In order to implement fault finding on this system, it is essential to have the following items available:
This section of the Workshop Repair Manual.
The wiring diagram for the function on the vehicle concerned.
The Clip or NXR diagnostic tool.
decoder unit -1.0
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IMMOBILISER
82A
82A-2
Program no.: 56
This section gives the fault finding procedures for states and parameters and the conditions for checking them.
If a state is not operating normally or a parameter is outside permitted tolerance values, you should consult the
corresponding diagnostic page.
3 - RECTIFYING THE CUSTOMER COMPLAINT
If the diagnostic tool check is correct, but the customer complaint is still present, the problem should be dealt with
according to the customer complaint.
This section has fault finding charts, which suggest a series of possible causes of the problem. These lines of
investigation must only be used in the following cases:
No faults appear on the diagnostic tool.
No faults are detected during the conformity check.
The immobiliser is not working correctly.
DESCRIPTION OF THE DIFFERENT PROGRAMMING
1 - REPLACEMENT OF THE DECODER UNIT ONLY:
vehicle's two keys to become operational.
NOTE: if only the decoder unit is to be replaced, you do not need to perform any operation on the injection computer
or coded solenoid valve, as they keep the same immobiliser code.
IMPORTANT: once the key code has been stored in the decoder unit, it is not possible to clear or store another one
in its place (once the new unit has been fitted it is possible to check if its in unprogrammed, by displaying, with the
ignition off the state ET022 KEY PROGRAMMING COMPLETED; which should read: NO).
PROGRAMMING PROCEDURE FOR ENGINE IMMOBILISER TRANSPONDER:
NOTE: the diagnostic tool is required in performing this procedure, to lock the key programming.
This procedure is carried out in programming with a key mode.
1 - Before removing and replacing the unit, it is crucial to note the configuration of the decoder unit on the
vehicle, so as to be able to configure the new decoder unit as it was before replacement (with or without coded
solenoid valve, programming with a key, courtesy light timer, electric door lock button type).
2 - Remove the decoder unit (ignition off).
3 - Fit the new decoder unit (ignition off).
4 - With the diagnostic tool connected, re-establish a link with the engine immobiliser system (ignition off).
decoder unit -1.0
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IMMOBILISER
82A
82A-3
Program no.: 56
5 - Check that the decoder unit has been configured in programming with a key mode by displaying state:
ET045 KEY PROGRAMMING CONFIGURATION should read: 1 KEY
If the state displayed is: 2 KEY, configure the decoder unit in programming with a key mode (COMMAND MODE:
CONFIGURATION menu).
Configure the decoder unit according to the notes taken during stage 1.
6 - Switch on the ignition (without starting the engine) with one of the keys and check the following states:
State ET022 KEY PROGRAMMING COMPLETED should display: YES
State ET002 KEY CODE RECEIVED should display: YES,
NOTE: if these two states are not displaying as required, check the conformity of the coded line (see fault
interpretation DF015 decoder ring link). If the link is correct, there is a problem with the antenna ring or with the key
(the antenna ring being uncoded, it is necessary to carry out a test with a new ring to check that the keys are operating
correctly electronically).
7 - The red immobiliser warning light flashes rapidly.
8 - Switch off the ignition and enter the CALIBRATION FINISHED command to unlock the programming
(COMMAND MODE: ACTUATORS menu).
9 - The red warning light flashes slowly.
10 - Check that the programming was carried out correctly by displaying the following states:
State ET003 KEY CODE CONFIRMED should display: YES,
State ET023 KEY PROGRAMMING LOCKED should display: YES.
NOTE: if the vehicle is fitted with radio frequency remote controls for central locking, it is necessary to program the
remote control units. This programming procedure is described in the introductory section on the connection unit.
IMMOBILISER SYSTEM TEST:
When the immobiliser transponder has been programmed, it is possible to test that the engine immobiliser system is
working properly with the two keys using the following procedure:
1 - With the ignition off, the red immobiliser warning light should flash for 10 seconds after the ignition is switched
off (slow flashing).
2 - With the diagnostic tool connected, re-establish communication with the immobiliser system and check the
following states: ET001 IMMOBILISER should be: YES
3 - With the ignition off and the immobiliser warning light flashing slowly, enter the FORCED PROTECTION MODE
command (ACTUATOR COMMANDS menu).
4 - Switch on the ignition; The immobiliser warning light will flash more rapidly and it should be impossible to start
the vehicle.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-4
Program no.: 56
5 - The procedure is complete. After switching the ignition off and on again (for more than 2 seconds), check that
the vehicle can be started with both keys.
NOTE: the engine may appear to start (in spite of the FORCED PROTECTION MODE command) due to the fuel left
in the injection pump. To confirm that it does not really start, repeat the procedure.
2 - REPLACING A KIT (decoder unit + the two key heads):
SPECIAL NOTES: in the event that one of the keys is lost, both the keys and the decoder unit must be replaced,
If a kit is replaced it will be necessary to:
Program key codes in the decoder unit (supplied uncoded).
Replace the old code stored in the injection computer or in the coded solenoid valve by using the security procedure
(with the number of the old kit which should be requested from the local assistance network, refer to Technical
Note 3315E).
IMPORTANT: once the key code has been stored in the decoder unit, it is not possible to clear or store another one
in its place (once the new unit has been fitted it is possible to check if its in unprogrammed, by displaying, with the
ignition off the state ET022 KEY PROGRAMMING COMPLETED; which should read: NO).
IMPORTANT: to replace the old code (stored in the injection computer or coded solenoid valve unit), the procedure
described below must be followed in the correct order.
1 - Before removing and replacing the unit, it is crucial to note the configuration of the decoder unit on the
vehicle, so as to be able to configure the new decoder unit as it was before replacement (with or without coded
solenoid valve, programming with two keys, courtesy timer light electric door lock button type).
2 - Fit the metal inserts from the old keys into the new key heads.
3 - Note the number of one of the old key heads to obtain the fault finding code number.
4 - Remove the decoder unit (ignition off).
5 - Fit the new decoder unit (ignition off).
6 - With the diagnostic tool connected, re-establish a link with the engine immobiliser system (ignition off).
7 - Configure the decoder unit according to the notes taken during stage 1.
8 - Switch on the ignition (without starting the engine) with one of the keys and check the following states:
State ET022 KEY PROGRAMMING COMPLETED should display: NO (for the state to display YES the second
key must be programmed).
9 - Switch on the ignition (without starting the engine) with the second key and check the following states:
NOTE: if these two states are not displaying as required, it is because the key inserted does not belong to the vehicle
or because it is the first key that was used in step 8.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-5
Program no.: 56
10 - The red immobiliser warning light flashes rapidly.
11 - Switch off the ignition and enter the CALIBRATION FINISHED command to unlock the programming
(COMMAND MODE: ACTUATORS menu).
12 - The red warning light flashes slowly.
13 - Check that the programming was carried out correctly by displaying the following states:
State ET003 KEY CODE CONFIRMED should display: YES,
State ET023 KEY PROGRAMMING LOCKED should display: YES.
14 - With the ignition off, enter the FORCED PROTECTION MODE command to check that the immobiliser is
ACTIVE (COMMAND MODE: ACTUATORS menu).
15 - Switch the ignition on, the red immobiliser indicator light will flash more quickly.
16 - Enter the MANUAL CODE ENTRY command (COMMAND MODE: ACTUATORS menu).
17 - Enter the four-figure fault finding code using the alphanumeric keyboard and CONFIRM (number given by the
local assistance network depending on the number of the old kit).
18 - Switch the ignition off and on again for a few seconds without starting the engine to program the immobiliser code
for the new kit in the injection computer or coded solenoid valve. The red indicator light should come on for 3
seconds then go out.
19 - The procedure is finished, check that the vehicle starts with both keys.
NOTE: if the vehicle is fitted with radio frequency remote controls for central locking, it is necessary to program the
remote control units. This programming procedure is described in the introductory section on the connection unit.
3 - PROCEDURE FOR ENTERING THE FAULT FINDING CODE:
With this immobiliser system, the procedure for entering the fault finding code is managed by the decoder unit.
The fault finding code can only be entered if the engine immobiliser system is ACTIVE. The red immobiliser
indicator light should flash when the ignition is switched on (rapid flashing).
NOTE: this procedure on its own does not decode the injection computer or coded solenoid valve (depending on
the engine), it only authorises vehicle starting (for fault finding purposes).
After the fault finding code number has been determined (request from the local assistance network, refer to
Technical Note 3315E) carry out the following operations:
1 - With the ignition off, the red engine immobiliser indicator light should flash, slowly.
2 - Switch the ignition on, the injection warning light comes on for approximately 3 seconds then goes out, while the
red immobiliser indicator light should flash more quickly.
3 - Connect the diagnostic tool and re-establish communication with the engine immobiliser system.
4 - Check that the immobiliser is ACTIVE by displaying state ET001.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-6
Program no.: 56
5 - Enter the MANUAL CODE ENTRY command (COMMAND MODE: ACTUATORS menu).
6 - Enter the four-figure fault finding code using the alphanumeric keyboard and CONFIRM (number given by the
local assistance network depending on the number of the old kit).
IMPORTANT: You may make three attempts to enter the code. If the code is invalid, after the third attempt, you must
wait for approximately 15 minutes before making another attempt.
When this period has expired, switch the ignition off and on again and three more attempts may be made.
REMINDER: The ignition must be switched off and on again between attempts to enter the code.
4 - PROGRAMMING PROCEDURE FOR INFRARED AND RADIO FREQUENCY REMOTE CONTROLS:
This procedure is set out in the Introduction section on the CONNECTION UNIT (the states and commands
corresponding to the radio frequency remote control are in the fault finding procedure for the connection unit).
GLOSSARY:
CDL electric door lock button.
Infrared transmitter.
Radio frequency transmitter.
RAID: automatic door locking when driving.
LED: instrument panel diode (immobiliser indicator light).
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-7
Program no.: 56
DF006
PRESENT
OR
STORED
DIESEL SOLENOID VALVE ACKNOWLEDGEMENT CIRCUIT
NOTES
Priority for dealing with a combination of faults:
Deal with fault DF014 coded line circuit first if it is present or stored.
Conditions for applying the fault finding procedure to stored faults:
The fault is declared present after the ignition has been switched on for 5 seconds.
Special notes:
If the decoder unit has been changed, check that it has been correctly configured by
displaying the coded diesel solenoid valve configuration state ET042. This state must
be ACTIVE in the case of a diesel engine with coded solenoid valve and INACTIVE in
the case of a diesel engine without coded solenoid valve. If necessary, configure the
decoder unit according to the vehicle engine (configuration menu).
Check the connection and condition of coded solenoid valve connector (black 3-track connector).
Disconnect the decoder unit (under the steering column) and check, with the ignition off, the insulation
(against + 12 volts and earth), the continuity and absence of interference resistance of the connection:
decoder unit trackA6 track 1 coded solenoid valve
Check for the presence of earth on track 3 and +12 volts after ignition supply on track 2 on the coded solenoid
valve connector (see vehicle wiring diagram).
AFTER REPAIR
Follow the instructions to confirm repair.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-8
Program no.: 56
DF006
CONT'D 1
Reconnect the solenoid valve and the decoder unit, turn on the ignition and, using the diagnostic tool, display
state ET006 rereading acknowledgement of the diesel solenoid valve (on the state screen).
If the connection previously checked is not faulty and the solenoid valve is correctly supplied, state ET006
should be ACTIVE (problem solved).
If the previous tests did not solve the problem (state ET006 remains INACTIVE), replace the coded diesel
solenoid valve.
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-9
Program no.: 56
Vehicles fitted with a coded solenoid valve (not DCI):
DF014
PRESENT
OR
STORED
CODED LINE CIRCUIT
NOTES
Conditions for applying the fault finding procedure to stored faults:
The fault is declared present after the ignition has been switched on for 20 seconds.
Special notes:
If the decoder unit has been changed, check that it has been correctly configured by
displaying the coded diesel solenoid valve configuration state ET042. This state must
be ACTIVE in the case of a diesel engine with coded solenoid valve and INACTIVE in
the case of a diesel engine without coded solenoid valve. If necessary, configure the
decoder unit according to the vehicle engine (configuration menu).
Check the connection and condition of coded solenoid valve connector (black 3-track connector).
decoder unit track A6 track 1 coded solenoid valve
Check for the presence of earth on track 3 and a +12 volts after ignition supply on track 2 on the coded
solenoid valve connector (see vehicle wiring diagram).
Reconnect the solenoid valve and the decoder unit, turn on the ignition and, using the diagnostic tool, display
state ET006 rereading acknowledgement of the diesel solenoid valve (on the state screen).
If the connection previously checked is not faulty and the solenoid valve is correctly supplied, state ET006
should be ACTIVE (problem solved).
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-10
Program no.: 56
Vehicles without coded solenoid valves (DCI):
DF014
CONT'D 1
If the previous tests did not resolve the problem (state ET006 remains INACTIVE), check that the decoder unit
is sending a signal to the solenoid valve by measuring between track 1 of the solenoid valve and earth (with
the decoder unit and coded solenoid valve electrically connected).
With the ignition off, there is no voltage.
With the ignition on, it should be possible to measure an average of around 5 volts with a multimeter set to
the a.c. voltage measurement position (the decoder unit sends out a permanent signal).
NOTE: for a more accurate measurement, the signal can be checked using an oscilloscope by measuring
between track 1 of the solenoid valve and earth (5 volt per scale division / 50 ms time base). It should display
a permanent square wave signal.
If the signal measured previously is not present, replace the decoder unit.
If the signal is present but the problem persists, replace the coded diesel solenoid valve.
Disconnect the decoder unit (under the steering column) and check, with the ignition off, insulation against
+12 volts and earth), the continuity and absence of interference resistance of the connection:
decoder unit track A6 Diesel injection computer
(see diagrams of injection system fitted on the vehicle).
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-11
Program no.: 56
DF014
CONT'D 2
If the previous check does not resolve the problem, check that the decoder unit is sending a correct signal to
the computer by measuring between track A6 of the decoder unit and earth (decoder unit and diesel injection
computer electrically connected).
With the ignition of no voltage should be present.
With the ignition on, it should be possible to measure an average of around 5 volts with a multimeter set to
the a.c. voltage measurement position (the decoder unit sends out a permanent signal).
NOTE: for a more precise measurement, the signal can be tested using an oscilloscope to measure between
track A6 of the decoder unit and earth (5 volts per scale division and 50 ms time base). It should display a
permanent square wave signal.
If the signal measured previously is not present, replace the decoder unit.
If the signal is present but the problem persists, replace the diesel injection computer.
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-12
Program no.: 56
DF015
PRESENT
OR
STORED
RING DECODER LINK
CO.0 : OPEN CIRCUIT OR SHORT CIRCUIT TO EARTH
CC.1 : SHORT CIRCUIT ON + 12 V
NOTES
Conditions for applying the fault finding procedure to the stored fault:
The fault is declared present when the ignition is switched on (when the ignition is
switched off, the fault is stored even if it is still present).
NOTE: the voltage described in the last check below is not a supply voltage but a high
state signal (12 volts) consisting of a pulse sent when the engine immobiliser indicator
light switches off (coded signal).
Remove the half-cowling under the steering wheel, and check that the antenna ring connector (on the ignition
switch) is connected and in working order.
Disconnect the decoder unit (under the steering column) and check, with the ignition off the insulation
(against +12 volts and to earth), the continuity and absence of interference resistance of the connection:
decoder unit track A2 track 4 of the antenna ring
Check for the presence of an earth on track 2 and +12 volts before ignition on track 3 of the antenna ring.
If the previous tests have not solved the problem, turn on the ignition and check for the presence of a 12 volt
signal on track A2 of the decoder unit connector (ring and decoder unit connected).
NOTE: for a more precise measurement, the signal can be tested using an oscilloscope to measure between
track A2 of the decoder unit and earth (2.5 volts per scale division and 50 ms time base). A voltage of 12 volts
with a pulse of 100 ms (signal variation) should be displayed when the indicator is switched off (as the pulse
is fast, do several tests or activate the oscilloscope pre-release function).
If the signal is not present, replace the antenna ring.
If the signal is present, replace the decoder unit.
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-13
Program no.: 56
DF065
PRESENT
COMPUTER
NOTES None.
The computer fault indicates an internal memory fault. Try to clear the fault, by switching the ignition off and
on again.
If the fault reappears, check the connection and condition of the decoder unit connector.
Disconnect the decoder unit (under the steering column) and, with the ignition off, check the conformity of
its supply (it should be equal to the battery voltage with the ignition on 0.5 volts) by checking the connections:
decoder unit track A7 + after ignition
decoder unit track A8 earth
decoder unit track A9 + before ignition
If the previous checks did not clear the fault, replace the decoder unit.
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
Fault finding - Conformity check
82A
82A-14
Program no.: 56
NOTES
Only carry out this conformity check after a complete check with the diagnostic tool
(no faults should be present).
Checking application conditions: Ignition switched off and immobiliser ACTIVE.
Order Function
Parameter or state
Check or action
Display and notes Fault finding
1 Supplies
ET005: +12 volts after
ignition
INACTIVE
If there is a fault check, the
conformity of the decoder
unit supplies. If the fault
persists, carry out a fault
finding test on the charge
circuit.
PR002: Computer supply
voltage
10 V < x < 12.5 V
2 Immobiliser
ET001: Immobiliser ACTIVE
If the state is INACTIVE
(when the ignition has been
switched off for more than
15 seconds), the decoder unit
supplies are correct and the
keys have been correctly
programmed, replace the
decoder unit.
ET007: Forced protection
mode
INACTIVE
This state should only
become ACTIVE after the
forced protection mode
control has been switched on.
This command is used to test
the engine immobiliser
(impossible to start the
engine). If the state is
ACTIVE switch on the
ignition, switch off, then
switch on again.
3 Ignition key
ET002: Key code received NO
None. ET003: valid key code NO
ET008: key present NO
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-15
Program no.: 56
NOTES
Order Function
Parameter or state
Check or action
4 Key programming
ET020: Programming the
first key
INACTIVE
Changes to ACTIVE state
once the first key is
programmed.
ET022: Key has been
programmed
YES
If these states are indicated
as NO, you must program the
keys.
For further information refer
to the programming
procedure in the introduction.
locked key.
YES
ET045: Key programming
configuration
1 KEY
or
2 KEYS
1 or 2 KEYS according to the
configuration carried out.
5
Coded diesel
solenoid valve
ET042: Configuration:
coded diesel solenoid
valve
ACTIVE
or
INACTIVE
The state should be ACTIVE
if the diesel engine is fitted
with a coded solenoid valve
and INACTIVE if it is not
(DCI).
If the state does not conform
with the vehicle's engine the
decoder unit needs to be
reconfigured.
ET006: Diesel solenoid
valve acknowledgement
rereading
INACTIVE None.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-16
Program no.: 56
NOTES
Order Function
Parameter or state
Check or action
6
Immobiliser fault
finding code
ET142: Fault finding
code entry timed block
INACTIVE
ACTIVE after 3 incorrect fault
finding codes have been
entered. This state becomes
INACTIVE once the correct
code has been entered.
NOTE: If the state is ACTIVE,
you need to wait 15 minutes,
with the ignition on, before
entering a new fault code.
7
Immobiliser
indicator light
PR005: LED warning
light
0 or 1
The state is at 0 if the
indicator light is off and at 1
when the indicator light is on.
8 Equipment level PR014: Equipment level 1, 2, 3, 4, 5 or 6 None.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-17
Program no.56:
NOTES
Checking application conditions: Ignition switched on and immobiliser INACTIVE.
Order Function
Parameter or state
Check or action
1 Supplies
ignition
ACTIVE
If there is a problem check,
the conformity of the
decoder unit supplies. If the
problem persists, carry out a
fault finding test on the
charging circuit.
PR002: Computer supply
voltage
10 V < x < 14.4 V
2 Immobiliser
ET001: Immobiliser INACTIVE
If the state is ACTIVE, check
that the decoder unit is
correctly configured and that
the keys have been
programmed. If the fault
persists, refer to CHART 2.
ET007: Forced protection
mode
INACTIVE
This state should only
become ACTIVE after the
forced protection mode
control has been switched on.
This command is used to test
the engine immobiliser
(impossible to start the
engine). If the state is
ACTIVE switch on the
ignition, switch off, then
switch on again.
3 Ignition key
ET002: key code received YES
If one of these states is
identified as NO refer to state
interpretation.
ET003: valid key code YES
ET008: key present YES
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-18
Program no.: 56
NOTES
Order Function
Parameter or state
Check or action
4 Key programming
first key
INACTIVE
Changes to ACTIVE state
once the first key is
programmed.
ET022: Key has been
programmed
YES
If these states are indicated
as NO, you must program the
keys.
For further information refer
to the key programming
procedures in the
introduction.
locked
YES
configuration
1 KEY
or
2 KEYS
1 or 2 KEYS according to the
configuration carried out.
5
Coded diesel
solenoid valve
ET042: Configuration:
coded diesel solenoid
valve
ACTIVE
or
INACTIVE
The state should be ACTIVE
if the engine is fitted with a
coded solenoid valve and
INACTIVE if it is not fitted
with a coded solenoid valve
(DCI).
If the state display does not
conform with the vehicle
engine, the decoder unit must
be reconfigured.
ET006: Diesel solenoid
valve acknowledgement
rereading
ACTIVE
If the state is INACTIVE,
replace the coded diesel
solenoid valve.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-19
Program no.: 56
NOTES
Order Function
Parameter or state
Check or action
6
Immobiliser fault
finding code
ET142: Fault finding code
entry timed block
INACTIVE
ACTIVE after 3 incorrect fault
finding codes have been
entered. This state becomes
INACTIVE once the correct
code has been entered.
NOTE: If the state is ACTIVE,
you need to wait 15 minutes,
ignition off, before entering a
new fault code.
7
Immobiliser
indicator light
PR005: LED warning light 0 or 1
The state is at 0 if the
indicator light is off and at 1
when the indicator light is on.
decoder unit -1.0
vnx.su
IMMOBILISER
Fault finding - Interpretation of states
82A
82A-20
Program no.: 56
ET002
ET003
ET008
KEY CODE RECEIVED
KEY CODE VALIDATED
KEY PRESENT
NOTES
Special notes:
Before searching for any possible problem in these states, check that the keys have
been correctly programmed by displaying states ET022 Key programming complete,
and ET023 Key programming locked. These two states should read YES, if this is not
the case refer to the introduction to carry out the key programming.
IGNITION OFF, IMMOBILISER ACTIVE: The three states display NO.
IGNITION ON, IMMOBILISER INACTIVE: The three states should display YES.
If this is not the case, three types of digits can be displayed:
ET008 KEY PRESENT: NO The key's electronic components no longer work.
or
The ring is not receiving the signal.
To find out which component is not operating, a test needs to be performed with a new ring (uncoded). If the
problem is solved, the receptor ring needs to be replaced, otherwise the key's electronic components need to
be replaced.
ET002 KEY CODE RECEIVED: NO The ring / decoder unit is faulty and in this scenario the
fault finding procedure DF015) needs to be carried out.
or
The ring is faulty and it needs to be replaced.
ET003 KEY CODE VALID: NO The key's electronic components no longer operate.
or
The key's electronic components do not match the code
programmed in the decoder unit.
In both cases, the key's electronics will have to be replaced.
AFTER REPAIR Repeat the conformity check.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-21
Program no.: 56
NOTES Only refer to this customer complaint after a complete check with the diagnostic tool.
NO DIALOGUE WITH THE COMPUTER CHART 1
THE VEHICLE DOES NOT START (with the ignition on and the immobiliser indicator
light flashing continually).
CHART 2
THE VEHICLE DOES NOT START (when the ignition is turned on, the immobiliser
indicator light comes on for 3 seconds and then goes out).
CHART 3
THE IMMOBILISER INDICATOR LIGHT STAYS LIT CHART 4
THE IMMOBILISER INDICATOR LIGHT DOES NOT COME ON (even when the
immobiliser is active).
CHART 5
decoder unit -1.0
vnx.su
IMMOBILISER
Fault finding - Fault finding charts
82A
82A-22
Program no.:56
CHART 1 No dialogue with the computer
NOTES
None.
Check that the vehicle battery is correctly charged.
Charge the battery if required.
Try the diagnostic tool on another vehicle (to find out if the tool is faulty).
Check:
the connection between the diagnostic tool and the diagnostic socket (lead in good condition),
the injection, engine and passenger compartment fuses.
Check for the presence of + 12 volts before ignition on track 16, + 12 volts after ignition on track 1 and an
earth on tracks 4 and 5 of the diagnostic socket.
Make sure that the decoder unit is correctly fed and correctly connected to the diagnostic socket by checking
the insulation, continuity and absence of interference resistance of the following connections:
decoder unit track A9 before ignition (passenger compartment fuse box )
decoder unit track A7 + after ignition (passenger compartment fuse box)
decoder unit track A4 track 15 of the diagnostic socket (line L)
decoder unit track A3 track 7 of the diagnostic socket (line K)
If the above checks have not cleared the fault, replace the decoder unit.
AFTER REPAIR
Perform a complete check using the diagnostic tool.
If the decoder unit has been changed, reprogram and reconfigure it with reference to
the introductory section.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-23
Program no.: 56
CHART 2
The vehicle does not start (ignition on, the immobiliser indicator
light flashes continuously).
NOTES
Only refer to this customer complaint when you have carried out a complete check
with the diagnostic tool (there should be no fault present in the immobiliser and
injection fault finding procedures).
Special notes:
Before carrying out this fault finding procedure, check that the decoder unit has been
programmed and configured by displaying states ET022, ET023 and ET042.
To find out if these states are correct you need to refer to section conformity checks;
if these states do not have the correct display refer to the introductory section to find
out the key programming procedure.
Check for the presence of a before ignition supply on track 3 and an earth on track 2 of the antenna ring
connector. Repair if necessary (see the vehicle wiring diagram).
Switch on the ignition and check the states in the state
menu:
ET008 KEY PRESENT.
ET002 KEY CODE RECEIVED.
Are these states identified as: YES?
YES
Turn on the ignition and in the states menu, check the
state:
ET003 KEY CODE VALID.
Does the state display: YES?
YES NO
Replace the decoder unit. Replace the key head chips.
NO
NO
Carry out a test with the
second key.
Is the fault solved?
YES
The head chip of the first
key is faulty and must be
replaced.
Replace the transponder ring.
AFTER REPAIR
the Introductory section.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-24
Program no.: 56
CHART 3
The vehicle does not start (when starting, the immobiliser
indicator light comes on for three seconds then goes out).
NOTES
Only refer to this customer complaint when you have carried out a complete check
with the diagnostic tool (there should be no fault present in the immobiliser and
injection fault finding procedures).
Special notes:
Before carrying out this fault finding procedure, check that the decoder unit has been
programmed and configured, particularly the manual entry of the code if the decoder
unit has been changed (so that the new code can be programmed into the injection
computer or coded solenoid valve).
When the diagnostic tool is connected, carry out a
mechanical check of the solenoid valve (listening test):
With the ignition switched off, activate the DIESEL
SOLENOID VALVE control, then switch on the ignition (as
soon as the control has been initiated). The solenoid valve
should open and close for 30 seconds.
Can you hear the solenoid valve operating?
YES
Refer to the fault finding charts (for starting problems) included in the diesel injection technical note. This
customer complaint is a reference point concerning the major causes of the vehicle not starting: immobiliser
problems, battery voltage, engine water sensor pre-heating, speed sensor, fuel and air supply circuits, exhaust
pipe and the general condition of the engine (oil level, compression, etc).
NO
Replace the coded diesel
solenoid valve.
AFTER REPAIR Perform a complete check using the diagnostic tool.
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-25
Program no.: 56
CHART 4 The immobiliser indicator light stays lit
NOTES
Do not refer to this customer complaint until you have performed a complete check
with the diagnostic tool (no fault should be present in the immobiliser diagnostic,
the injection diagnostic and the connection unit diagnostic).
Special notes:
When there is a fault with the acknowledgment from the diesel solenoid valve or there
is a problem with the coded line, the immobiliser indicator light is on continuously. You
must therefore check in the engine immobiliser diagnostic to see if these faults are
present or stored.
Turn on the ignition and check the state in the state menu:
ET006 REREADING THE ACKNOWLEDGEMENT
FROM THE DIESEL SOLENOID VALVE.
Does this state read: ACTIVE?
YES
Disconnect the decoder unit (under the steering column).
Has the indicator light gone out?
NO
With the decoder unit disconnected and ignition switched off, check
the insulation (against earth), the continuity and the absence of
interference resistance of the connection:
decoder unit grey 30-track connector on the instrument panel
track A5 track 5
Has the indicator light gone out?
NO
NO
YES
Apply the fault finding
procedure DF057
ACKNOWLEDGMENT
FROM DIESEL SOLENOID
VALVE CIRCUIT.
Replace the decoder unit.
YES
End of fault
finding.
Carry out the fault finding procedure for the instrument panel (refer
to the corresponding Technical Note).
AFTER REPAIR
decoder unit -1.0
vnx.su
IMMOBILISER
82A
82A-26
Program no.: 56
CHART 5
The immobiliser indicator light does not come on (even when its
active).
NOTES
Only refer to the customer complaint after a complete check with the diagnostic tool
(no faults should be present in the immobiliser fault finding and the injection fault
finding).
With the decoder unit disconnected and ignition switched off, check
the insulation (against + 12 volts), the continuity and the absence of
interference resistance of the connection:
decoder unit grey 30-track instrument panel connector
track A5 track 5
When the decoder unit connector is reconnected, does the indicator
light come on?
NO
Disconnect the decoder unit (under the steering column)
and connect track A5 of the decoder unit connector to a
vehicle earth.
Does the indicator light come on?
NO
Check the conformity of supplies and the instrument panel earths (see the instrument panel diagram).
If the supplies and earths are correct, carry out a fault finding procedure on the instrument panel (refer to the
relevant Technical Note).
YES
End of fault
finding.
YES
AFTER REPAIR
decoder unit -1.0
vnx.su
CONNECTION UNIT
87B
87B-1
187B
Program no.: 66
CONNECTION UNIT
GENERAL APPROACH TO FAULT FINDING
Use one of the diagnostic tools to identify the immobiliser system fitted to vehicle (to read the computer family, the
program number, the Vdiag, etc.).
Take note of information contained in the introductory sections.
DESCRIPTION OF THE FAULT FINDING STAGES
1 - CHECKING THE FAULTS
It is essential to start with this stage before any work is done on the vehicle.
Read the faults stored in the computer memory and use the Fault interpretation section of the documents.
Reminder: Each fault is interpreted for a particular type of storage (fault present, fault stored in memory, fault
present or stored). The specified checks for dealing with each fault are therefore only to be performed if the fault
declared by the diagnostic tool can be identified in the document by its type. The storage type should be
considered when using the diagnostic tool after the ignition has been switched off and switched back on.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the NOTES
box. When these conditions are not satisfied, use the fault finding procedure to check the circuit of the faulty part,
since the fault is no longer present on the vehicle. Perform the same operation when a fault is declared as stored
by the diagnostic tool but is only interpreted in the documentation as a present fault.
2 - CONFORMITY CHECK
The conformity check is designed to check the states and parameters which do not display any faults on the
diagnostic tool when they are outside the permitted tolerance values. This stage:
diagnoses faults that do not have a fault display, and which may correspond to a customer complaint.
checks that the immobiliser is working correctly and ensures that a fault will not reappear after repair.
This section gives the fault finding procedures for states and parameters and the conditions for checking them.
If a state is not operating normally or a parameter is outside permitted tolerance values, you should consult the
corresponding diagnostic page.
This document contains special notes on fault finding applicable to all immobiliser computers fitted to
MASTER PROPULSION vehicles.
In order to implement fault finding on this system, it is essential to have the following items available:
This section of the Workshop Repair Manual.
The wiring diagram for the function on the vehicle concerned.
The Clip or NXR diagnostic tool.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-2
Program no.: 66
3 - RECTIFYING THE CUSTOMER COMPLAINT
If the diagnostic tool check is correct, but the customer complaint is still present, the problem should be dealt with
according to the customer complaint.
This section has fault finding charts, which suggest a series of possible causes of the problem. These lines of
investigation must only be used in the following cases:
No faults appear on the diagnostic tool.
No faults are detected during the conformity check.
The immobiliser and door locking are not working properly.
PROGRAMMING DESCRIPTION FOR RADIO FREQUENCY REMOTE CONTROLS
1 - PROGRAMMING PROCEDURE FOR INFRARED/ RADIO FREQUENCY REMOTE CONTROLS:
Basic resynchronisation procedure: (Programming the 1
st
remote control).
st
This procedure is used:
when the remote control code no longer lies within the reception range of the decoder unit (over 1,000 consecutive
presses on the remote control, away from the vehicle),
when replacing a decoder unit alone (new decoder unit),
when replacing a kit (keys + decoder unit).
(Carry out this procedure when the ignition is switched off).
1 - Press and hold the central door locking button for a few seconds until the doors lock and unlock.
From this time, the operator has 10 seconds to carry out step 2.
NOTE: the 10 seconds will be indicated by the red immobiliser warning light being continuously lit or by the
following appearing on the states menu:
State ET106 PROGRAMMING OR RESYNCHRO. INFRARED/RADIO FREQUENCY REMOTE CONTROL
should be displayed as: ACTIVE.
2 - Press the remote control twice (the doors lock and unlock and the red warning light goes out).
3 - The procedure is complete, check that the doors lock correctly.
Specific resynchronisation procedure: (Programming the 2
nd
remote control)
nd
Select the COMPUTER FAULT FINDING menu.
1 - Connect the diagnostic tool and, with the ignition switched off, re-establish dialogue with the decoder unit.
2 - Activate the command programming 2
nd
infrared/radio frequency remote control unit (in the COMMAND
MODE: ACTUATORS menu), from this time, the operator has 10 seconds to carry out operation no. 3.
NOTE: The 10 seconds are indicated by the red immobiliser warning light being lit continuously.
3 - Press the remote control twice (the doors lock and unlock and the red warning light goes out).
4 - The procedure is complete, check that the doors lock correctly.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-3
Program no.: 66
2 - PROGRAMMING PROCEDURE FOR THE IMMOBILISER TRANSPONDER:
vehicle's two keys to become operational.
The immobiliser transponder must be programmed in the following situations:
The decoder unit only is replaced.
A kit (decoder unit + both key heads) is replaced.
A key head is replaced.
The IMMOBILISER TRANSPONDER PROGRAMMING procedures are listed in the introduction to the section
dealing with the immobiliser system (82A). There are also two other procedures in the immobiliser section.
There are also two other procedures in the immobiliser section:
IMMOBILISER SYSTEM TEST.
PROCEDURE FOR ENTERING THE SECURITY CODE.
NOTES:
KEY TO ABBREVIATIONS
RAID: automatic door locking when driving.
TIR: infrared transmitter.
TRF: radio frequency remote control.
CPE: external central door locking (switch).
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-4
Program no.: 66
DF003
PRESENT
OR
STORED
ELECTRIC DOOR LOCKING CIRCUIT
NOTES

The fault is declared present after the ignition has been switched on.
Special notes:
When there is a short circuit in the electric door locking connection (between the CDL
button and the decoder unit), the immobiliser warning light comes on when the ignition
is switched off and the doors are unlocked.
Display state: ET038 central door locking /unlocking, this should display INACTIVE.
If this state is ACTIVE, remove the interior lighting console and check the electric door lock button:
When the button is not depressed, there should be no continuity between track B2 and tracks B3 and A1.
When the button is depressed (on the side of the door opening symbol):
Continuity between track B2 and track A1 (unlocking instruction).
When the button is depressed (on the side without a symbol):
Continuity between track B2 and track B3 (locking instruction).
Replace the central locking button if it is not operating as described above.
(against + 12 volts and earth), continuity and absence of interference resistance of the connection:
locking button track B3 track B2 of the decoder unit
If the checks above have not cleared the fault, replace the decoder unit.
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-5
Program no.: 66
DF005
PRESENT
OR
STORED
OIL PRESSURE SENSOR CIRCUIT
NOTES None.
This fault is not active on this vehicle (multi-timer unit fault only).
AFTER REPAIR None.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-6
Program no.: 66
DF009
PRESENT
IMPACT SIGNAL CONNECTION
NOTES

Special notes: The fault is present 10 seconds after the ignition is switched on and
disappears when the ignition is switched off.
If the vehicle is not fitted with the impact connection (no wire on track B7), the
fault is PERMANENT. It should therefore be disregarded.
NOTE:
If the fault is present, the door locking function while driving is prevented from working.
air bag computer track 27 track B7 of the decoder unit
If the checks above have not cleared the fault, carry out a fault finding check on the air bag.
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-7
Program no.: 66
DF025
PRESENT
OR
STORED
RELAY (indicator lighting relay)
NOTES

The fault is declared present if: when the ignition is switched off and the doors are
locked, the fault appears after an unlocking or locking command from the radio
frequency remote control.
Special notes:
This fault is not indicated by the immobiliser warning light being continuously lit.
This faults prevents the indicators from being lit when the doors are unlocked or locked
by the radio frequency remote control.
Check the condition of the clips on the infrared remote control relay on the passenger compartment fuse/
relay plate.
Replace the clips if necessary.
Check for the presence of + 12 volts before ignition on track 86 and on track 30 of the infrared remote control
relay.
indicator lighting relay (infrared remote control relay) track 85 track B3 of the decoder unit
Check the resistance value of the relay by measuring between:
Track 85 and track 86 of the infrared remote control relay.
Replace the relay if the value is not approximately: 85 5 at 25C.
If the fault persists, replace the infrared remote control relay.
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-8
Program no.: 66
DF026
PRESENT
OR
STORED
ELECTRIC DOOR UNLOCKING CIRCUIT
NOTES

The fault is declared present after the ignition has been switched on.
Special notes:
When there is a short circuit in the electric door unlocking connection (between the
door central locking button and the decoder unit), the immobiliser warning light comes
on continuously when the ignition is switched off and the doors are unlocked.
Display state: ET038 central door locking/unlocking, this should display INACTIVE.
If this state is ACTIVE, remove the interior lighting console and check the door central locking button:
When the button is not depressed, there should be no continuity between track B2 and tracks B3 and A1.
When the button is depressed (on the side of the door opening symbol):
Continuity between track B2 and track A1 (unlocking instruction).
When the button is depressed (on the side without a symbol):
Continuity between track B2 and track B3 (locking instruction).
Replace the central locking button if it is not operating as described above.
unlocking button track A1 track B5 of the decoder unit
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-9
Program no.: 66
DF127
PRESENT
COMPUTER
NOTES None.
The computer fault indicates an internal memory fault. Try to clear the fault, by switching the ignition off and
on again.
If the fault reappears, check the connection and condition of the decoder unit connector.
Disconnect the decoder unit (under the steering column) and, with the ignition on, check that the supply is
correct (it should be equal to the battery voltage 0.5 volts) by checking the following connections:
decoder unit track A7 + after ignition
decoder unit track A9 + before ignition
If the previous checks did not clear the fault, replace the decoder unit.
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-10
Program no.: 66
NOTES
Only carry out this conformity check after a complete check using the diagnostic tool
Test conditions: Ignition switched off and immobiliser ACTIVE.
Order Function
Parameter or state
Check or action
1 Supplies
ignition
INACTIVE
circuit.
2
Radio frequency
remote control
programming
ET106: Infrared/radio
frequency remote control
programming or
resynchronisation
INACTIVE
ACTIVE if programming or
resynchronisation is in
progress.
key programmed
ACTIVE
If the state is INACTIVE, the
remote control units must be
programmed (se the
introductory section).
3
Decoder unit
configurations
ET081: Radio frequency
function configuration
ACTIVE
The state is usually ACTIVE
because the infrared remote
controls are no longer fitted
on the vehicle (however, the
infrared remote control unit
configuration still exists).
ET048: Configuration with
courtesy light timer
ACTIVE
or
INACTIVE
The state is ACTIVE or
INACTIVE depending on the
configuration of the decoder
unit.
ET216: CDL button
STATE 1: One touch
central door locking
If the state is not correct for
the type of electric door lock
button fitted to the vehicle,
the decoder unit must be
reconfigured.
STATE 2: rocker
switch central door
locking
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-11
Program no.: 66
NOTES
Order Function
Parameter or state
Check or action
4 Switches
ET038: Central Locking/
Unlocking button
INACTIVE
Switches to ACTIVE state
when the central door locking
button is pressed for 3
seconds.
ET205: Door opening
contacts
ACTIVE: Doors open This state is ACTIVE when
any of the doors are opened.
If this is not the case, the
switch on the door concerned
is faulty and should be
checked along with its
connections (see vehicle
diagram).
INACTIVE Doors
closed
5 Door control
ET012: Source of last
opening element
command
CDL: Locking /
unlocking switch
CDL switch or radio
depending on the last
unlocking or locking
command.
RF: Radio frequency
remote control
ET105: Last opening
element command
UNLOCK
or
LOCK
(depending on the last
command)
None.
ET208: Action of motors
The state is ACTIVE
for three seconds after
an unlocking or locking
command then it goes
back to INACTIVE.
None.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-12
Program no.: 66
NOTES
(no faults should be present ).
Order Function
Parameter or state
Check or action
6
Radio frequency
remote control
signal information: signal
received
YES
or
NO
After a door unlocking or
locking command with the
remote control, state ET061
should display: YES and
state ET062 should display:
ACTIVE. If this is not the
case, refer to the
interpretation of these states.
working
ACTIVE
or
INACTIVE
7
Automatic door
locking when
driving function
ET018: RAID function
authorisation by fault
finding
ACTIVE
or
INACTIVE
ACTIVE if the decoder unit
has been configured with the
RAID function and INACTIVE
if it has not.
For more information, refer to
the interpretation of states.
NOTE: The RAID function is
only available on vehicles
fitted with an impact signal
connection (track B7).
authorisation using the
CDL switch
ACTIVE
or
INACTIVE
8 Impact signal ET238: Impact signal INACTIVE
If the state is ACTIVE the air
bag computer has detected
an impact.
A fault finding procedure
must be carried out on the air
bag and then the necessary
repairs.
9 Vehicle speed PR001: Vehicle speed X = 0 mph None.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-13
Program no.: 66
NOTES
Order Function
Parameter or state
Check or action
1 Supplies
ignition
ACTIVE
circuit.
2
Radio frequency
remote control
programming
programming or
resynchronisation
INACTIVE
ACTIVE if programming or
resynchronisation is in
progress.
key programmed
ACTIVE
If the state is INACTIVE, the
remote control units must be
programmed (se the
introductory section).
3
Decoder unit
configurations
ET081: Radio frequency
function configuration
ACTIVE
The state is usually ACTIVE
because the infrared remote
controls are no longer fitted
on the vehicle (however, the
infrared remote control unit
configuration still exists).
ET048: Configuration with
courtesy light timer
ACTIVE
or
INACTIVE
The state is ACTIVE or
INACTIVE depending on the
configuration of the decoder
unit.
ET216: CDL button
STATE 1: One touch
central door locking
If the state is not correct for
the type of electric door lock
button fitted to the vehicle,
the decoder unit must be
reconfigured.
STATE 2 : rocker
switch central door
locking
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-14
Program no.: 66
NOTES
Order Function
Parameter or state
Check or action
4 Switches
ET038: Central Locking/
Unlocking button
INACTIVE
Switches to ACTIVE state
when the central door locking
button is pressed for
3 seconds.
ET205: Door opening
contacts
ACTIVE: Doors open This state is ACTIVE when
any of the doors are opened.
If this is not the case, the
switch on the door concerned
is faulty and should be
checked along with its
connections (see vehicle
diagram).
INACTIVE: Doors
closed
5 Door control
ET012: Source of last
opening element
command
CDL: Locking /
unlocking switch
CDL switch or radio
depending on the last
unlocking or locking
command.
RF: Radio frequency
remote control
ET105: Last opening
element command
UNLOCK
or
LOCK
(depending on the last
command)
None.
ET208: Action of motors
The state is ACTIVE
for three seconds after
an unlocking or locking
command then it goes
back to INACTIVE.
None.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-15
Program no.: 66
NOTES
Order Function
Parameter or state
Check or action
6
Radio frequency
remote control
received
YES
or
NO
After a door unlocking or
locking command with the
remote control, state ET061
should display: YES and
state ET062 should display:
ACTIVE. If this is not the
case, refer to the
interpretation of these states.
working
ACTIVE
or
INACTIVE
7
Automatic door
locking when
driving function
authorisation by fault
finding
ACTIVE
or
INACTIVE
ACTIVE if the decoder unit
has been configured with the
RAID function and INACTIVE
if it has not.
For more information, refer to
the interpretation of states.
NOTE: The RAID function is
only available on vehicles
fitted with an impact signal
connection (track B7).
authorisation using the
CDL switch
ACTIVE
or
INACTIVE
8 Impact signal ET238: Impact signal INACTIVE
If the state is ACTIVE the air
bag computer has detected
an impact.
A fault finding procedure
must be carried out on the air
bag and then the necessary
repairs.
9 Vehicle speed PR001: Vehicle speed
X = 0 mph
if the vehicle is
stationary and
X = vehicle speed
if the vehicle is moving
This parameter applies
only to vehicles with
equipment level No.4.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-16
Program no.: 66
ET061
ET062
INFRARED/RADIO FREQUENCY REMOTE CONTROL SIGNAL
INFORMATION: SIGNAL RECEIVED
Infrared/radio frequency remote control signal information: signal
working
NOTES

Special notes:
Before searching for any possible problem in these states, check that the radio
frequency remote control units have been programmed correctly by displaying state:
ET011 Infrared / radio frequency remote control programmed. This state should
display ACTIVE, if not, refer to the introductory section for information on programming
remote controls.
UNDER NORMAL OPERATION:
RADIO FREQUENCY REMOTE CONTROL NOT USED:
ET061: INFRARED/RADIO FREQUENCY REMOTE CONTROL SIGNAL INFORMATION:
SIGNAL RECEIVED NO
CORRECT SIGNAL INACTIVE
RADIO FREQUENCY REMOTE CONTROL UNLOCKING OR LOCKING COMMAND:
SIGNAL RECEIVED YES
CORRECT SIGNAL ACTIVE
If these two states do not function as above, there are two possible scenarios:
SIGNAL RECEIVED YES
The chip in the key is functioning correctly and the radio frequency receiver is receiving the signal and sending
it to the decoder unit, but the signal is not correct:
The key used is not from the vehicle,
or
The remote control must be resynchronised (refer to the programming procedure in the introduction).
If resynchronisation does not rectify the fault, the key head chip must be replaced.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-17
Program no.: 66
ET061
ET062
CONTINUED
SIGNAL RECEIVED NO
The fault has four possible causes:
The key head chip does not work,
The radio frequency receiver is not working,
The connection between the radio frequency receiver and the decoder unit is faulty,
The decoder unit does not work.
To locate the faulty part, refer to fault finding chart No.3 (CHART 3 radio frequency remote control door
locking/unlocking fault).
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-18
Program no.: 66
ET018
ET019
RAID FUNCTION AUTHORISATION BY FAULT FINDING
RAID FUNCTION AUTHORISATION USING THE CDL SWITCH
NOTES

REMINDER:
The RAID function enables the doors to be automatically locked above 5 mph (8 Km/h).
NOTE:
If the RAID function is deactivated by the diagnostic tool, it cannot be activated by the
CDL button.
CONFIGURATION WITHOUT RAID FUNCTION (with the diagnostic tool):
To cancel the RAID function: Choose the CONFIGURATION service in the COMMAND MODE and enter
command CANCEL RAID FUNCTION.
After the decoder unit has been configured without the RAID function, the state screen should read:
ET019: RAID FUNCTION AUTHORISED
THROUGH CENTRAL DOOR LOCKING INACTIVE
ET018: FUNCTION AUTHORISED
BY DIAGNOSTIC TOOL INACTIVE
CONFIGURATION WITH RAID FUNCTION (by the diagnostic tool):
To activate the RAID function: Choose the CONFIGURATION service in the COMMAND MODE and enter
command AUTHORISE RAID FUNCTION.
After the decoder unit has been configured with the RAID function, the state screen should read:
THROUGH CENTRAL DOOR LOCKING ACTIVE
BY DIAGNOSTIC TOOL ACTIVE
CONFIGURATION WITHOUT RAID FUNCTION (with the electric door lock button):
To cancel the RAID function: press the door central locking button down for 5 seconds with the ignition on:
After the decoder unit has been configured without the RAID function using the CDL button, the state screen
should read:
THROUGH CENTRAL DOOR LOCKING INACTIVE
BY DIAGNOSTIC TOOL ACTIVE
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-19
Program no.: 66
NOTES Only refer to this customer complaint after a complete check with the diagnostic tool.
NO DIALOGUE WITH THE COMPUTER CHART 1
PROBLEM LOCKING AND UNLOCKING DOORS WITH THE CDL BUTTON CHART 2
PROBLEM LOCKING AND UNLOCKING DOORS WITH RADIO FREQUENCY
REMOTE CONTROL
CHART 3
INDICATOR LIGHTING FAULT WHEN LOCKING AND UNLOCKING CHART 4
COURTESY LIGHT FAULT CHART 5
THE RAID FUNCTION DOES NOT WORK
(RAID: automatic door locking when driving)
CHART 6
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-20
Program no.: 66
CHART 1 No dialogue with the computer
NOTES None.
Check that the vehicle battery is correctly charged.
Charge the battery if required.
Try the diagnostic tool on another vehicle (to find out if the tool is faulty).
Check:
the connection between the diagnostic tool and the diagnostic socket (lead in good condition),
the injection, engine and passenger compartment fuses.
Check for the presence of + 12 volts before ignition on track 16, + 12 volts after ignition on track 1 and an
earth on tracks 4 and 5 of the diagnostic socket.
Make sure that the decoder unit is correctly fed and correctly connected to the diagnostic socket by checking
the insulation, continuity and absence of interference resistance of the following connections:
decoder unit track A9 before ignition (passenger compartment fuse box)
decoder unit track A7 + after ignition (passenger compartment fuse box)
decoder unit track A4 track 15 of the diagnostic socket (line L)
decoder unit track A3 track 7 of the diagnostic socket (line K)
AFTER REPAIR
If the decoder unit has been replaced, reprogram and reconfigure it with reference to
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-21
Program no.: 66
CHART 2
Problem locking / unlocking doors with the central door locking
button
NOTES

Only refer to this customer complaint after a complete check with the diagnostic
tool (no faults should be present).
Special notes:
Before carrying out this fault finding procedure, check that the configuration of the
central door locking button matches the button on the vehicle by displaying state
ET216 Central door locking BUTTON.
Reconfigure the decoder unit if necessary (if the configuration is not correct the system
will not work properly).
Using the diagnostic tool, issue the unlocking and locking commands (Command mode: Actuator menu)
Do the doors lock and unlock?
YES NO
Check that the central door locking button is
working correctly:
When the button is not depressed, there should
be no continuity between track B2 and
tracks B3 and A1.
When the button is depressed (on the side of the
door opening symbol):
Continuity between track B2 and track A1
(opening instruction).
When the button is depressed (on the side
without a symbol):
Continuity between track B2 and track B3
(closing instruction).
Replace the central locking button if it is not
operating as described above.
Test the centralisation power circuits referring to the
vehicle diagram (the number of centralisation
motors depends on the number of doors on the
vehicle).
To carry out this test, disconnect the decoder unit
and, with the ignition off, check the insulation,
continuity and absence of interference
resistance of the following connections:
Decoder unit track B8 track 1 of the
motors
(unlocking command).
Decoder unit track B9 track 3 of the
motors
(locking command).
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-22
Program no.: 66
CHART 2
CONTINUED
Check for an earth on track B2 of the central door locking button.
(against + 12 volts and earth), continuity and absence of interference resistance of the following
connections:
locking button track B3 track B2 of the decoder unit
locking button track A1 track B5 of the decoder unit
If the central door locking button and the connections tested previously match but the fault persists, check that
none of the door motors have short circuited by disconnecting them all and measuring, with the connectors
disconnected, between track 1 and track 3: their resistance should not be negligible nor infinite (this
resistance should average between 2.5 and 10 depending on the type of motor fitted to the vehicle).
Replace the faulty motor(s).
Check that the motors are working properly:
Disconnect all the motor connectors,
Remove the faults using the diagnostic tool,
Switch on the ignition.
Connect the connector of one of the motors,
Test locking or unlocking with the central door locking button,
If the motor is not working, replace it,
If you hear the motor running but the door does not lock properly, check the mechanical locking part
(linkage),
Repeat the procedure for each motor.
AFTER REPAIR
If the decoder unit has been replaced, reprogram and reconfigure it referring to the
introductory section.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-23
Program no.: 66
CHART 3
Problem locking / unlocking
doors using the radio frequency remote control
NOTES

Special notes:
Before carrying out this fault finding procedure, check that the configuration of the
remote control is correct by displaying state ET081 RADIO FREQUENCY
CONFIGURATION FUNCTION, which should be ACTIVE. Reconfigure the decoder
unit if necessary.
Also check that the remote control unit(s) have been programmed by displaying state
ET011 INFRARED / RADIO FREQUENCY REMOTE CONTROL UNIT
PROGRAMMED, which should be ACTIVE. Reprogram if necessary (refer to the
introductory section for this procedure).
With the diagnostic tool connected, refer to the states screen and check that they are working as below:
RADIO FREQUENCY REMOTE CONTROL NOT USED:
ET061: INFRARED/RADIO FREQUENCY REMOTE
CONTROL SIGNAL INFORMATION: SIGNAL RECEIVED NO
CONTROL SIGNAL INFORMATION: CORRECT SIGNAL INACTIVE
CONTROL SIGNAL INFORMATION: SIGNAL RECEIVED YES
CONTROL SIGNAL INFORMATION: CORRECT SIGNAL ACTIVE
If these two states do not function as above, there are two possible scenarios:
CONTROL SIGNAL INFORMATION: SIGNAL RECEIVED YES
The chip in the key is functioning correctly and the radio frequency receiver is receiving the signal and sending
it to the decoder unit, but the signal is not correct:
The key used is not from the vehicle,
or
The remote control must be resynchronised (refer to the programming procedure in the
introduction).
If resynchronisation does not rectify the fault, the key head chip must be replaced.
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-24
Program no.: 66
CHART 3
CONTINUED
CONTROL SIGNAL INFORMATION: SIGNAL RECEIVED NO
Check that the remote control battery is in working order, replace it if necessary.
Check for an earth on track 5 and +12 volts before ignition on track 2 of the remote control receiver (located
behind the glove compartment): Repair if necessary.
Disconnect the remote control receiver connector and, with ignition off, check the insulation (from to
+12 volts and earth), continuity and absence of interference resistance of the connection:
decoder unit track B1 track 1 of the radio frequency receiver
YES NO
Perform a test with a new radio frequency receiver.
If the fault is rectified, replace the remote control receiver.
If the fault persists, replace the remote control.
If the fault persists, replace the decoder unit.
AFTER REPAIR
If the decoder unit or radio frequency remote control have been replaced, reprogram
and reconfigure them referring to the introductory section.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-25
Program no.: 66
CHART 4 Indicator lighting fault when locking and unlocking
NOTES
Only investigate this customer complaint after a full check with the diagnostic tool
(there should be no faults present).
Check that the indicators and hazard warning light circuit are working.
Repair if necessary (refer to the relevant vehicle wiring diagram).
decoder unit track B3 track 85 of the infrared remote control (in the passenger
compartment fuse box)
Check that there is a + 12 volts supply on tracks 30 and 86 of the infrared transmitter relay.
Check that the infrared remote control relay has not short-circuited by measuring its resistance between
tracks 85 and 86.
Replace the relay if its resistance is not equal to 85 5 .
With the decoder unit disconnected and the infrared
transmitter relay reconnected, earth track B3.
Can the relay be heard operating?
YES
Track B3 shunted to the earth, do the indicators light up
continuously?
NO
Replace the infrared remote control relay.
NO
Replace the infrared remote
control relay.
YES
AFTER REPAIR
introductory section.
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-26
Program no.: 66
CHART 5 Courtesy light fault
NOTES
Move the interior lighting console switch to permanent
lighting (press on the side with the symbol).
Does the interior courtesy light come on?
YES
With the decoder unit disconnected and the ignition off, check the insulation, the continuity and
absence of interference resistance of the connection: decoder unit track A1 track 2 of the
interior light
When the decoder unit connector and courtesy light connector are reconnected, does the courtesy
light come on when the door is open (courtesy light switch in the central position)?
NO YES
Disconnect the decoder unit connector then open the
doors, one after another. When each of the doors is
opened track B4 of the decoder unit should receive an
earth; if not, check the continuity of the faulty connection
and ensure that the door switch involved is sound and that
there is an earth to the second track of the switch.
Is the problem still present?
NO
Check for an earth on track 3
and +12 volts before ignition on
track 1 of the interior light switch
and check that the interior light
bulb is sound.
NO
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
87B-27
Program no.: 66
CHART 5
CONTINUED
Disconnect the decoder unit (under the steering column)
and connect track A1 of the decoder unit connector to a
vehicle earth (interior lights switch set to the centre
position).
Does the courtesy light come on?
NO
Replace the interior courtesy light.
YES
AFTER REPAIR
decoder unit 1.1
vnx.su
CONNECTION UNIT
87B
Program no.: 66
CHART 6
The RAID function does not work
(RAID: automatic locking when driving)
NOTES

Special notes:
The RAID function (automatic door locking when driving) is only available on vehicles
fitted with an impact signal connection (track B7).
If the impact signal connection fault is present, the RAID function is prevented
from working.
Check that the RAID function is correctly configured using the state screen (see interpretation of states ET018
and ET019). Reconfigure the decoder unit if necessary.
Check that the doors can be locked with the central
door locking button.
Does it lock?
YES
Check that the door switches are working by
displaying state ET205 DOOR OPENING
SWITCHES on the state screen. When the doors
are closed, this state should be inactive.
Is the state inactive when the doors are closed?
YES
NO
Check CHART 2.
NO
Test all the door switches: there should
be no continuity between the two tracks
when the switch is depressed.
Replace it or the faulty switches if
necessary.
Is the state inactive when the doors
are closed?
YES NO
With the decoder unit disconnected and the doors closed, check
the insulation (from earth), continuity and the absence of
interference resistance of the connections:
decoder unit door switches
track B4 track B (or track 3 depending on the
switch model)
AFTER REPAIR
technical note for programming.
decoder unit 1.1
87B-28
vnx.su
CONNECTION UNIT
87B
Program no.: 66
CHART 6
CONTINUED
With the decoder unit disconnected and the ignition off, check the insulation (from +12 volts and earth),
continuity and absence of interference resistance of the following connection:
decoder unit track B6 track B1 of the vehicle speed sensor (or track 3 depending on the
sensor model).
Check that there is an earth on track B2 (or track 2) and +12 volts after ignition on track A (or track 1
depending on the sensor model). Repair if necessary.
Reconnect the decoder unit and the vehicle speed sensor to confirm that the sensor is sending a vehicle speed
signal to the decoder unit. To do this, you must carry out a road test or lift the front of the vehicle and turn the
wheels above 5 mph (engine running at idle speed, first gear engaged). There are two ways of measuring it:
With a voltmeter (set to direct current measuring position), measuring between track B6 of the decoder unit
and the earth, a direct current of around 7 volts should be measured.
With an oscilloscope (part of the diagnostic tool), measuring between track B6 of the decoder unit and the
earth (the oscilloscope time base should be set to 100 m/s divisions with a gauge of 5 volt divisions). A
square wave signal should be obtained (with a high state equivalent to the battery voltage) whose frequency
varies with the vehicle speed.
If no signal is sent out by the vehicle speed sensor to the decoder unit: replace the vehicle speed sensor.
YES NO
AFTER REPAIR
technical note for programming.
decoder unit 1.1
87B-29
vnx.su
88C
88C-1
188C
CONDITIONS FOR APPLICATION OF THE TESTS DEFINED IN THIS FAULT FINDING DOCUMENT
The tests defined in this fault finding should only be applied to vehicles not fitted with side air bags but fitted with
2
nd
generation air bag computers.
These new computers can be identified by the heading AC4 Ph 2 on the fault finding tools.
The tests defined in this fault finding should only be applied if the fault is present on the vehicle at the time of
checking.
Only the computer fault leads to replacement of the computer, whether the fault is present or simply stored.
If the fault is not present but simply stored, the application of checks recommended in the fault finding will not allow
location of the origin of the fault stored. In this case only, the wiring and the faulty component connections should be
checked (it is possible to access the wiring concerned in fault finding mode to try to display the passage from stored
fault to present fault).
TOOLING REQUIRED FOR OPERATIONS ON THE AIR BAG AND SEAT BELT PRETENSIONER SYSTEMS:
Diagnostic tools (except XR 25).
Adapter and bornier kit to be used for the Air bag and pretensioner wiring harness check function on the CLIP and
NXR tools or the XRBAG unit
Multimeter.
REMINDER:
During operations on the air bag/seat belt pretensioner systems it is vital that you lock the computer using the
diagnostic tool to prevent any risk of accidental triggering (all the trigger lines will be inhibited). The locked mode is
signalled when the instrument panel warning light comes on.
Without the diagnostic tool, switch off the ignition and remove the supply fuse from the system, then wait at least
2 seconds for the power reserve capacity to discharge.
Never measure the air bag or pretensioner trigger lines with any device other than the XRBAG or by the Air bag and
pretensioner wiring harness check function on the CLIP and NXR tools.
Before using a dummy ignition module, ensure that its resistance is between 1.8 and 2.5 ohms.
Ensure during the operation that the voltage supply to the computer does not drop below 10 volts.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-2
SYSTEM CONFIGURATION FAULT FINDING - DATA SHEET
Pretensioners, passenger and driver's front air bags
Correct insulation value: display 100.h or 9999 flashing.
A
B
C
D
E
G
Central unit
Drivers seat
Passenger seat(s)
Pretensioner
Driver's air bag ignition module
Passenger air bag ignition module
CT
A1
A2
A3
B1
B2
Rotary switch
+ 12 volts
Warning light
Earth
Diagnostic lines
AIR BAGS
Measuring point Correct value
Driver C0, C2 and C4 2 to 9.4 ohms
Passenger C0 and C4 1.6 to 4.6 ohms
SIDE AIR BAGS AND PRETENSIONERS
Measuring point Correct value
C0, C1 and C3 1.6 to 4.6 ohms
AC4PIIX70 MASC 1.0
)
vnx.su
88C
88C-3
DF001
PRESENT
OR
STORED
COMPUTER
1.DEF: Internal electronical fault.
2.DEF: Impact detected
NOTES Special notes: None.
Replace the air bag computer (refer to the Help section for this operation).
AFTER REPAIR None.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-4
DF002
PRESENT
COMPUTER SUPPLY VOLTAGE
1.DEF: Too many micro-cutoffs
2.DEF: Voltage not within permitted limits
NOTES Use the 30-track B40 adaptor to work on the computer connector.
1.DEF - 2.DEF NOTES None.
Carry out the operations necessary to obtain the correct computer voltage:
10.5 volts 0.1 <correct voltage < 16 volts 0.1.
Check the battery charge.
Check the charge circuit.
Check the tightening and the condition of the battery terminals.
Check the computer earth.
Check the condition of the computer and that it is locked.
AFTER REPAIR
Deal with any faults detected by the diagnostic tool.
Clear the computer memory.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-5
DF003
PRESENT
DRIVER'S FRONT AIR BAG CIRCUIT
CC : Short circuit
CO : Open circuit
CC.1 : Short circuit to 12 volts
NOTES
Special notes: never carry out measuring operations on trigger lines using any tool
other than CLIP, NXR or XRBAG.
Use the 30-track B40 adaptor to work on the computer connector.
CO - CC NOTES None.
Lock the computer using the command on the diagnostic tool.
Switch off the ignition and remove the two mounting bolts from the steering wheel cushion.
Check that it is correctly connected.
Disconnect the air bag cushion and connect a dummy ignition module to the ignition module connector.
Switch on the ignition and carry out a check using the diagnostic tool.
Replace the air bag if the fault is now stored (fault no longer declared present).
With the ignition switched off, disconnect and reconnect the rotary switch connector under the steering wheel.
Repair the wiring if the fault is now stored (fault declared as present).
The CLIP, NXR or XRBAG tools MUST be used for checking resistance at point C2 of the driver's front air
bag circuit.
If the value obtained is incorrect, replace the rotary switch under the steering wheel.
Reconnect the rotary switch under the steering wheel, disconnect the computer connector and fit the 30-track
B40 adaptor.
The CLIP, NXR or XRBAG tools MUST be used for checking resistance on the wire marked A on the adapter.
If the value obtained is not correct, check the 30-track connector connections (tracks 10 and 11) and replace
the wiring if necessary.
If the checks carried out did not show the presence of a fault, check on
the base of the air bag computer for the presence of 5 pins which open the 30-track connector shunts.
Check the condition of the computer connections.
Check the condition of the 30-track connector (locking system, etc).
AFTER REPAIR
Clear the computer memory then switch off the ignition.
Carry out the check again using the diagnostic tool and, if there are no faults, unlock
the computer.
Destroy the air bag cushion if it has been replaced (tool El. 1287).
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-6
DF003
PRESENT
CONTINUED
CC.1 - CC.0 NOTES None.
Switch off the ignition and remove the two mounting bolts from the steering wheel cushion.
Check the condition of the trigger wire.
The CLIP, NXR or XRBAG tools MUST be used for measuring insulation appropriate to the type of fault at
point C2 of the driver's front air bag circuit.
If the value obtained is incorrect, replace the rotary switch under the steering wheel.
Reconnect the rotary switch under the steering wheel, disconnect the computer connector and fit the B40
30-track adaptor.
The CLIP, NXR or XRBAG tools MUST be used for measuring the insulation suited to the fault type on the
wire marked A of the adaptator.
AFTER REPAIR
the computer.
Destroy the air bag cushion if it has been replaced (tool El. 1287).
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-7
DF004
PRESENT
PASSENGER FRONT AIR BAG CIRCUIT
CC : Short circuit
CO : Open circuit
NOTES
CO - CC NOTES None.
Switch off the ignition, disconnect the computer connector and fit the B40 30-track adaptor.
The CLIP, NXR or XRBAG tool MUST be used for measuring the resistance on the wire marked B of the adaptor.
Is the value obtained correct?
YES
NO
If the value obtained is correct on wire B of the adaptor, check on the base of the air
bag computer for the presence of the 5 shunt opening pins of the 30-track
connector. Check the condition of the computer connections.
Check the condition of the 30-track connector (locking system, connections, etc).
If the value obtained is not correct on wire B of the adapter, check the connections
on the 30-track connector (tracks 13 and 14).
If the value remains incorrect, switch off the ignition and remove the components
necessary to gain access to the wiring of the passenger air bag module.
Disconnect the passenger airbag ignition module, connect a dummy ignition module
to the ignition module connector then measure the resistance on the wire marked B
of the adapter again.
If the value obtained is correct, replace the passenger air bag module.
If the value obtained is not correct, replace the air bag wiring.
AFTER REPAIR
Reconnect the computer and the ignition module of the passenger's air bag module,
then switch on the ignition again.
the computer.
Destroy the passenger air bag module if it has been replaced (tool El. 1287).
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-8
DF004
PRESENT
CONTINUED
Lock the computer.
Switch off the ignition, disconnect the computer connector and fit the B40 30-track adaptor.
The CLIP, NXR or XRBAG tool MUST be used to take a measurement of the insulation appropriate to the type of
fault on the wire marked B on the adaptor.
Is the value obtained correct?
YES
NO
If the value obtained is correct on wire B of the adapter, check the condition of the
connections on computer.
If the value obtained is not correct on wire B of the adaptor, check the connections
on the 30-track connector (tracks 13 / 14).
If the value remains incorrect, replace the air bag wiring.
AFTER REPAIR
Reconnect the computer and the ignition module of the passenger's air bag module,
then switch on the ignition again.
the computer.
Destroy the passenger air bag module if it has been replaced (tool El. 1287).
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-9
DF010
PRESENT
AIR BAG FAULT WARNING LIGHT CIRCUIT
NOTES
CC.1 NOTES None.
Check the condition of the warning light bulb.
Ensure the insulation against 12 volts on the connection between the warning light and track 7 of the
30-track connector.
CO.0 NOTES None.
Warning light goes out after ignition
Check the condition of the warning light bulb.
Ensure the continuity of the connection between the warning light and track 7 of the 30-track connector.
Ensure that 12 volts are present at the warning light.
If the checks carried out did not show the presence of a fault, disconnect the computer connector and fit the
30-track B40 adaptor. Use the CLIP, NXR or XRBAG tool to test the operation of the instrument panel
warning light from the grey wire marked 1 on the adaptor.
If it is possible to light up the warning light using the tool, replace the air bag computer (refer to the Help section
for this operation).
If it is impossible to operate the warning light, repeat the preceding checks.
Warning light comes on after ignition
Disconnect the airbag computer and check the presence, on the base, of the 5 pins which open the connector
shunts.
Ensure the insulation to earth of the connection between the warning light and track 7 of the 30-track
connector.
AFTER REPAIR
the computer.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-10
DF016
PRESENT
COMPUTER CONFIGURATION
NOTES
Special notes: this fault may appear after using the passenger air bag locking control,
by not observing the procedure described in the Technical Note (this control allows a
child seat to be fitted on the passenger seat).
It is vital that you do not use this passenger air bag locking command before a
Technical Note dealing with the subject has been distributed for this vehicle.
This fault indicates an inconsistency between the computer configuration and the vehicle equipment detected
by the computer. The computer has detected the presence of an element additional to its configuration.
Modify the computer configuration using the Configuration command on the diagnostic tools.
AFTER REPAIR
Check again using the diagnostic tool.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-11
DF029
PRESENT
DRIVER'S PRETENSIONER CIRCUIT
CC : Short circuit
CO : Open circuit
NOTES
CO - CC NOTES None.
Switch off the ignition and check that the driver's pretensioner ignition module is connected correctly.
Disconnect the ignition module of the driver's pretensioner and connect a dummy ignition module to the ignition
module connector.
Replace the driver's pretensioner if the fault is now stored (fault no longer declared as present).
The CLIP, NXR or XRBAG tools MUST be used for measuring the resistance at point C1 (seat connector) on
the driver's pretensioner line.
If the value obtained is not correct, replace the wiring between points C1 and C3 (seat wiring).
Disconnect the computer connector and fit the B40 30-track adaptor.
The CLIP, NXR or XRBAG tools MUST be used for checking resistance on the wire marked D on the adapter.
If the value obtained is not correct, check the connections to the 30-track connector (tracks 1 and 2) and
replace the wiring if necessary.
If the checks carried out have not shown the presence of a fault, check on the base of the air bag computer for
the presence of the 5 shunt opening pins 30-track connector.
AFTER REPAIR
Reconnect the computer and the pretensioner ignition module, then switch on the
ignition again.
the computer.
Destroy the pretensioner if it has been replaced (tool El. 1287).
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-12
DF029
PRESENT
CONTINUED
Disconnect the driver's pretensioner ignition module and connect a dummy ignition module to the ignition
module connector.
If the fault is now stored (fault no longer declared as present), check the condition of the seat wiring.
Replace the driver's pretensioner if the wiring is not faulty.
the driver's pretensioner line.
The CLIP, NXR or XRBAG tools MUST be used for checking resistance on the wire marked Don the adapter.
If the value obtained is not correct, check the connections to the 30-track connector (tracks 1 and 2) and
If the checks carried out have not shown the presence of a fault on the passenger pretensioner circuits, check
on the base of the air bag computer for the presence of the 5 shunt opening pins for the 30-track connector.
AFTER REPAIR
ignition again.
the computer.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-13
DF030
PRESENT
PASSENGER PRETENSIONER CIRCUIT
CC : Short circuit
CO : Open circuit
NOTES
Vehicle with 1 passenger pretensioner only
CO - CC NOTES None.
Switch off the ignition and check that the driver's pretensioner ignition module is connected correctly.
Disconnect the ignition module of the driver's pretensioner and connect a dummy ignition module to the ignition
module connector.
Replace the passenger's pretensioner if the fault has been stored (fault no longer declared).
the passenger's pretensioner line.
The CLIP, NXR or XRBAG tool MUST be used for checking resistance on the wire marked C on the adaptor.
AFTER REPAIR
ignition again.
the computer.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-14
DF030
CONTINUED 1
Vehicle with 2 passenger pretensioners
CO - CC NOTES None.
Switch off the ignition and check that the two passenger pretensioner ignition modules are connected correctly.
Disconnect the ignition module from the passenger pretensioners and connect a dummy ignition module to
each ignition module connector.
If the fault has become stored (fault no longer declared present), the CLIP, NXR or XRBAG tool MUST be used
to measure the direct resistance on each passenger pretensioner (point C3).
Replace the faulty passenger's pretensioner.
The CLIP, NXR or XRBAG tool MUST be used to measure the resistance at point C1 (passenger seat
connector) on the passenger pretensioner line.
Disconnect the computer connector and fit the 30-track adaptor. The CLIP, NXR or XRBAG tool MUST be
used for checking resistance on the wire marked C on the adapter.
If the value obtained is not correct, check the connections of the 30-track connector (tracks 3 and 4) and
AFTER REPAIR
ignition again.
the computer.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-15
DF030
PRESENT
CONTINUED 2
Disconnect the passenger's pretensioner ignition module and connect a dummy ignition module to the ignition
module connector.
If the fault is now stored (fault no longer declared as present), check the condition of the seat wiring.
Replace the passenger's pretensioner if the wiring is not faulty.
The CLIP, NXR or XRBAG tools MUST be used to measure the insulation appropriate to the type of fault at
point C1 (seat connector) on the passenger's pretensioner line.
The CLIP, NXR or XRBAG tools MUST be used for measuring the insulation appropriate to the type of fault
on the wires marked C on the adapter.
If the value obtained is not correct, check the connections of the 30-track connector (tracks 3 and 4) and
If the checks carried out have not shown the presence of a fault on the passenger pretensioner circuits, check
on the base of the air bag computer for the presence of the 5 shunt opening pins for the 30-track connector.
AFTER REPAIR
ignition again.
the computer.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-16
DF034
PRESENT
COMPUTER LOCKED
1.DEF: Locking after impact
2.DEF: Locking with diagnostic tool
NOTES None.
This fault is used to display the locked status of the computer.
When it occurs, all the trigger lines are inhibited, preventing triggering of the air bags and seat belt
pretensioners.
1.DEF NOTES None.
This fault is declared present after the seat belt pretensioners have been triggered with or without triggering of
the front air bags.
Replacement of the computer and the components which were operational at the time of impact is compulsory.
2.DEF NOTES None.
This fault normally occurs in two cases:
The computer is new (it is sold locked).
The computer locking command using the diagnostic tool was used during an operation on the
vehicle.
Unlocking: Clear the computer memory then switch off the ignition.
Carry out the check again using the diagnostic tool and, if there are no faults, unlock the computer
(Parameters section).
AFTER REPAIR
the computer.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-17
AC4PIIX70 MASC 1.0
NOTES Only perform this conformity check after a complete check with the diagnostic tool.
Order Function
Parameter or state
Check or action
Display and notes
Fault
finding
1
Diagnostic tool
dialogue
- Air bag AC4 Ph2 CHART 1
2
Computer
conformity
Vehicle type parameter Master Propulsion 32 None
3
Computer
configuration
Using the Reading configuration
command
Ensure that the computer
configuration defined in the
Current column corresponds to
the vehicle equipment.
None
4
Warning light
operation
Computer
initialisation
check
Switch on the ignition
The warning light comes on for
3 seconds when the ignition is
switched on.
None
vnx.su
88C
88C-18
REPLACING THE AIR BAG COMPUTER
The air bag computers are sold in locked mode to avoid all risk of accidental triggering (all trigger lines are inhibited).
The locked mode is indicated by the air bag fault warning light on the instrument panel lighting up.
Follow this procedure when replacing an air bag computer:
Ensure that the ignition is switched off.
Replace the computer.
Carry out a check using the diagnostic tool.
If necessary modify the computer configuration using the Configuration command.
Unlock the computer only if no faults are indicated by the diagnostic tool.
AC4PIIX70 MASC 1.0
vnx.su
88C
88C-19
CHART 1 Absence of dialogue with the air bag computer
NOTES None.
Try to establish dialogue with a computer on another vehicle to make sure that the diagnostic tool is not faulty.
If the tool is not the cause of the fault and dialogue cannot be established with any other computer on the same
vehicle, it may be that a faulty computer is disrupting diagnostic lines K and L. Disconnect the computers one
at a time to locate the fault.
Check the battery voltage and carry out the necessary operations to obtain a correct voltage
(10.5 volts < battery voltage < 16 volts).
Check the presence and condition of the air bag computer supply voltage fuse.
Check that the computer connector is properly connected and check the condition of its wiring.
Check that the computer is correctly supplied:
Disconnect the air bag computer and fit the B40 30-track adaptor.
Check and ensure the presence of + after ignition feed between the terminals marked earth and + after
ignition feed.
Check that the diagnostic socket is correctly supplied:
+ before ignition on track 16.
Earth on track 5.
Check the continuity and insulation of the diagnostic socket / air bag computer connection lines:
Between the terminal marked L and track 15 of the diagnostic socket.
Between the terminal marked K and track 7 of the diagnostic socket.
If dialogue is still not established after these various checks, replace the air bag computer (refer to the Help
section for this operation).
AFTER REPAIR When dialogue is established, deal with any displayed faults.
AC4PIIX70 MASC 1.0
vnx.su

VNX - Su Master Propulsion 2003

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General Information

MECHANICAL SPECIFICATIONS FOR THE

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+ Before ignition supply

Front left-hand exhaust solenoid valve

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