N.T. 3218A DA03 - EA03. SPECIAL FEATURES OF THE F5R 740 ENGINE (including related assemblies)

Transcription

1 N.T. 3218A DA03 - EA03 SPECIAL FEATURES OF THE F5R 740 ENGINE (including related assemblies) Follow the instructions regarding cleanliness when working on this vehicle. For all parts not dealt with in this Technical Note refer to Workshop Repair Manual MR JULY 1999 Edition Anglaise "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 by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed". All copyrights reserved by Renault. Copying or translating, in part or in full, of this document or use of the service part reference numbering system is forbidden without the prior written authority of Renault. C RENAULT 1999

2 Contents Pages Pages 07 VALUES AND SETTINGS 13 FUEL SUPPLY Capacities - Grades Accessories belt tensioning Timing belt tensioning procedure Cylinder head tightening Tyres - wheels Brakes Brake compensator Underbody height Front axle angle checking values Rear axle angle checking values Specifications Supply pump Supply pressure / Pump output High pressure pump Injection rail / Injectors Pressure sensor Anti-percolation system ANTI-POLLUTION 10 ENGINE AND PERIPHERALS ASSEMBLY Oil vapours rebreathing Exhaust gas recirculation E.G.R. Fuel vapours rebreathing Identification Oil pressure Engine and transmission assembly Sump Multi-function support STARTING - CHARGING Alternator Starter TOP AND FRONT OF ENGINE Timing belt Cylinder head gasket FUEL MIXTURE Specifications Inlet manifold Exhaust manifold

3 Contents Pages Pages 17 IGNITION - INJECTION 21 MANUAL GEARBOX Static ignition General Installation Special features of direct injection Cleanliness / Safety Operation Injection fault warning light Engine immobiliser function Injection / AC strategy Idle speed correction Fuel pressure regulation Mixture regulation Adaptive mixture correction Centralised coolant temperature management Computer Wiring diagram Identification Gears Capacities - Lubricants Consumables Parts which must always be replaced Special features REAR BEARING ELEMENTS Brake hub / disc Hub / disc bearing STEERING ASSEMBLY COOLING Mechanical power steering pump Power steering unit Filling - bleeding Diagram Coolant pump Catalytic converter MECHANICAL COMPONENT CONTROLS 20 CLUTCH Master cylinder Brake servo Cover - Disc Flywheel AIR CONDITIONING General Compressor Condenser Connecting pipes

4 VALUES AND SETTINGS Capacities - Grades 07 Units Petrol engine (oil) Capacity in litres (approx.) * When draining Grade European Union countries and Turkey PETROL - 15 C - 30 C - 20 C - 10 C 0 C + 10 C + 20 C + 30 C ACEA A2/A3 15W40-15W50 ACEA A1*/A2/A3 10W30-10W40-10W50 ACEA A1*/A2/A3 0W30-5W30 ACEA A1*/A2/A3 0W40-5W40-5W50 F5R (1) ACEA A1-98 standard * Oil for fuel economy Other Countries If the lubricants specified for the European Union countries are not available, the following specifications must be taken into account: - 15 C PETROL - 30 C - 20 C - 10 C 0 C + 10 C + 20 C + 30 C API SH/SJ 15W40-15W50 API SH/SJ 10W40-10W50 API SH/SJ 10W30 API SH/SJ 5W30 API SH/SJ 5W40-5W50 Oil for fuel economy: API SJ-IL SAC GF2 standard * Adjust using a dipstick (1) Following replacement of the oil filter 07-1

5 VALUES AND SETTINGS Capacities - Grades 07 Units Capacity in litres Grade Special features JC5 gearbox 3.1 All countries: TRANSELF TRX 75 W 80 W (API GL5 or MIL-L 2105 G or D standards) F5R cooling circuit 7 Glacéol RX (type D) Protection to - 20 C ± 2 C for hot, temperate and cold climates. Protection to - 37 C ± 2 C for very cold climates. 07-2

6 VALUES AND SETTINGS Accessories belt tensioning 07 To remove the belt, turn the belt s automatic tensioner in the direction indicated below using a 13 mm offset ring ended spanner. Clamp the tensioner using a 6 mm hexagonal wrench (1). ALTERNATOR, POWER STEERING AND AIR CONDITIONING 15304R R1 WARNING: the accessories belt rests on the ridged part on the pulley (F). A B C D E F T Crankshaft Air conditioning compressor Alternator Power steering pump Coolant pump Pulley Automatic tensioner When refitting the belt, it is essential to ensure that the tooth (X) inside the pulleys (timing side) remains "free" R 07-3

7 VALUES AND SETTINGS Timing belt tensioning procedure 07 ESSENTIAL SPECIAL TOOLS Mot Tool for immobilising pinions for toothed timing belt Mot Top Dead Centre pin Mot Tool for tightening camshaft pulleys Mot Pipe wrench for removing HP pipes Mot Clip pliers for spring clips Mot Engine support tool Mot Tool for refitting camshaft covers Mot Tool for fitting the camshaft seals Mot Tool for setting the camshafts Mot Tool for immobilising the camshaft pulleys ESSENTIAL EQUIPMENT Angular tightening wrench There are two very distinct procedures for setting the timing. 1 st PROCEDURE The first procedure is applied in the event of replacement of any components in the timing face which do not require slackening of the camshaft pulley(s). Follow the instructions regarding cleanliness and safety when working on the fuel circuit. 07-4

8 VALUES AND SETTINGS Timing belt tensioning procedure 07 Setting the timing WARNING: it is essential to degrease the end of the crankshaft, the crankshaft pinion bore and the crankshaft pulley contact surfaces to prevent sliding between the timing and the crankshaft which could destroy the engine. Position the camshaft grooves using Mot as indicated in the diagram opposite. It is essential that the grooves are horizontal and offset downwards S Fit tool Mot which is secured at the end of the camshafts R 07-5

9 VALUES AND SETTINGS Timing belt tensioning procedure 07 Check that the crankshaft is at Top Dead Centre and not in the balancing hole. Correct position S Incorrect position 15163S 07-6

10 VALUES AND SETTINGS Timing belt tensioning procedure 07 The crankshaft groove (5) should be between the two marks on the engine block R The exhaust camshaft pinion mark should be opposite the cylinder position sensor securing hole. 07-7

11 VALUES AND SETTINGS Timing belt tensioning procedure 07 Fitting the belt When the timing belt is changed, it is essential to change the timing tensioners and pulleys. Check that the tensioner lug (1) is correctly positioned in the groove (2) R Refit: - the timing belt, - the pulleys (3) tightening the mounting bolts to a torque of: 5 dan.m for the M10 bolts 2.5 dan.m for the M8 bolts - the crankshaft accessories pulley bringing the bolt into position without contact with the pulley (clearance between bolt and pulley 2 to 3 mm). NOTE: - the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed 49.1 mm (otherwise change it), - do not coat a new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil R 07-8

12 VALUES AND SETTINGS Timing belt tensioning procedure 07 Align marks (6) and (7) on the tensioner using a 6 mm hexagonal wrench at (B) R Pre-tighten the tensioner nut to a torque of 0.7 dan.m. Tighten the crankshaft pulley bolt to a torque of 2 dan.m (Top Dead Centre pin Mot still in place). NOTE: do not turn the tensioner anti-clockwise. 07-9

13 VALUES AND SETTINGS Timing belt tensioning procedure 07 Make a mark (C) indicating the position of the camshaft pulleys in relation to the camshaft bearing cap castings R Remove camshaft setting tool Mot and Top Dead Centre pin Mot Carry out angular tightening of the crankshaft pulley bolt to 115 ± 10, while immobilising the engine flywheel using a screwdriver S 07-10

14 VALUES AND SETTINGS Timing belt tensioning procedure 07 Turn the crankshaft two revolutions clockwise (timing end). Before the end of the two revolutions (that is a half-tooth before alignment of the marks on the camshaft pulleys and the camshaft bearing cap castings), insert the Top Dead Centre pin Mot to be between the balancing hole and the pinning hole, then bring the timing to its setting point. Incorrect position 15163S Remove the Top Dead Centre pin Mot R Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not. Then tighten the nut to a torque of 2.7 dan.m. Correct position Checking the setting and the tension Checking the tension Turn the crankshaft two revolutions clockwise (timing end), then pin the crankshaft just before the end of the two revolutions aligning the camshaft pulley and camshaft bearing cap casting marks made previously. Remove the Top Dead Centre pin Mot Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not S 07-11

15 VALUES AND SETTINGS Timing belt tensioning procedure 07 Checking the setting Ensure that the tensioner marks are positioned correctly before checking the timing setting. Fit the Top Dead Centre pin Mot checking the alignment of the marks made previously. Fit (without using force) camshaft setting tool Mot (the camshaft grooves should be horizontal and offset downwards). If the tool does not engage, the timing setting and tensioning procedure must be repeated S 16077R 07-12

16 VALUES AND SETTINGS Timing belt tensioning procedure 07 The second procedure is applied in the event of replacement of any components which require slackening of the timing camshaft pulley(s). Setting the timing WARNING: it is essential to degrease the end of the crankshaft and the crankshaft pinion bore, the crankshaft pulley contact surfaces and the ends of the camshafts (timing end) and the camshaft pulley bores to prevent sliding between the timing, the crankshaft and the camshaft pulleys which could destroy the engine S Position the camshaft grooves horizontally, as indicated on the diagram above, using tool Mot It is essential that the grooves are directed downwards. This operation can be made easier by fitting the camshaft pulleys using the old nuts, tightening them to a torque of 1.5 dan.m maximum

17 VALUES AND SETTINGS Timing belt tensioning procedure 07 Fit tool Mot which is secured to the end of the camshafts. Incorrect position 16077R 15163S Remove the old pulley nuts. It is essential to replace them with new nuts. Pre-tighten the nuts, without locking them, with a clearance of 0.5 to 1 mm between the nuts and the pulleys. Check that the crankshaft is pinned at Top Dead Centre and not in the balancing hole (crankshaft groove (5) should be between the two marks (1) of the engine block). Correct position R S 07-14

18 VALUES AND SETTINGS Timing belt tensioning procedure 07 When a timing belt is changed, it is essential to change the timing tensioners and pulleys. Position the exhaust camshaft pulley mark opposite the poition sensor thread. NOTE: incorrect positioning of the exhaust camshaft pulley prevents starting of the engine. Ensure that the tensioner lug (1) is correctly positioned in the groove (2) R Refit: - the timing belt, - the pulleys (3) tightening the mounting bolts to a torque of 5 dan.m in the case of the 10 mm bolts and 2.5 dan.m in the case of the 8 mm. bolts R Fit the crankshaft accessories pulley, pre-tightening the bolt (without fully tightening the bolt, clearance of 2 to 3 mm between the bolt and the pulley). NOTE: - the crankshaft accessories pulley bolt can be re-used if the length under the head does not exceed 49.1 mm (otherwise change it), - do not coat the new bolt with oil. However, if the bolt is re-used, it is essential to coat it with oil

19 VALUES AND SETTINGS Timing belt tensioning procedure 07 Check that there is still a clearance of 0.5 to 1 mm between the camshaft nuts and pulleys. Align tensioner marks (6) and (7) using a 6 mm hexagonal wrench at (B) R Pre-tighten the tensioner nut to a torque of 0.7 dan.m. Turn the timing face through six revolutions via the exhaust camshaft pulley using tool Mot NOTE: during this operation, ensure that the pulleys do not come into contact with the nuts. If they do, reposition them from time to time

20 VALUES AND SETTINGS Timing belt tensioning procedure 07 Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not. Then tighten the nut to a torque of 2.8 dan.m. Turn the exhaust camshaft pulley to position the mark opposite the phasing sensor. Tighten the crankshaft pulley bolt to a torque of 2 dan.m (Top Dead Centre pin still in place in the crankshaft). Make a mark (C) to indicate the position of the camshaft pulleys in relation to the camshaft bearing cap castings R 07-17

21 VALUES AND SETTINGS Timing belt tensioning procedure 07 Remove the Top Dead Centre pin. Incorrect position Carry out angular tightening of the crankshaft pulley bolt to 115 ± 10, while immobilising the engine flywheel using a screwdriver S 15303S Fit camshaft pulley immobilising tool Mot and secure it using a cover bolt. Pin the crankshaft aligning the camshaft pulley and camshaft bearing cap casting marks made previously to ensure that the pin is correctly positioned in the pin hole and not in the crankshaft balancing hole. Correct position 16078R Tighten the inlet camshaft pulley nut to a torque of 3 dan.m, then turn it through an angle of S 07-18

22 VALUES AND SETTINGS Timing belt tensioning procedure 07 Tighten the exhaust camshaft pulley nut to a torque of 3 dan.m, then turn it through an angle of 45 then a second angle of 45 using tool Mot S Remove camshaft setting tool Mot. 1526, camshaft pulley immobilising tool Mot and Top Dead Centre pin Mot Checking the setting and tension Checking the tension Turn the crankshaft two revolutions clockwise (timing side), then pin the crankshaft just before the end of the two revolution aligning the camshaft pulley and camshaft bearing cap casting marks. Remove the Top Dead Centre pin Mot Check that the tensioner marks are aligned and repeat the tensioning procedure if they are not

23 VALUES AND SETTINGS Timing belt tensioning procedure 07 Checking the setting Ensure that the tensioner marks are positioned correctly before checking the timing setting. Fit the Top Dead Centre pin Mot checking that the marks made previously are aligned. Fit (without using force) camshaft setting tool Mot (the camshaft grooves should be horizontal and offset downwards). If the tool does not engage, the timing setting and tensioning procedure must be repeated S 16077R 07-20

24 VALUES AND SETTINGS Cylinder head tightening 07 CYLINDER HEAD TIGHTENING PROCEDURE The bolts can be re-used if the length under the head does not exceed mm (otherwise change all the bolts). REMINDER: to obtain correct tightening of the bolts, remove any oil from the cylinder head securing holes using a syringe. Do not coat new bolts with oil. However, if the bolts are re-used, it is essential to coat them with oil. Tighten all the bolts to 2 dan.m in the order indicated below R Check that all the bolts are correctly tightened to 2 dan.m then carry out angular tightening (bolt by bolt) of 195 ± 6 in the order of tightening. The cylinder head bolts are not re-tightened following application of this procedure

25 VALUES AND SETTINGS Tyres - Wheels 07 Vehicle Rim Tyres Tyre pressure when cold (in bar) (1) Front Rear DA J /50 R 16 V EA J /50 R 16 V (1) During motorway use with full load. Wheel nut tightening torque: 9 dan.m Rim run-out: 1.2 mm 07-22

26 VALUES AND SETTINGS Brakes 07 At the front At the rear Vehicle Disc thickness (in mm) Disc thickness (in mm) Drum diameter (in mm) Maximum Minimum Maximum Minimum Maximum (1) Minimum DA0 3 EA (1) Drum: maximum wear diameter (where applicable). The disc run-out is 0.07 maximum Lining thickness (in mm) Vehicle Front (including support) Rear Brake fluid New Minimum New Minimum DA0 3 EA SAE J1703 DOT

27 VALUES AND SETTINGS Brake compensator 07 BRAKING PRESSURE Vehicle Fuel level status (driver in vehicle) Check pressure (1) (in bar) Front Rear DA0 3 EA S (1) The check is carried out using two pressure gauges arranged in an X formation

28 VALUES AND SETTINGS Underbody height 07 Vehicle At the front H1 - H2 =... mm At the rear H4 - H5 =... mm Dimension X (in mm) D and G DA EA Tolerance: ± 7.5 mm The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed 5 mm, the driver s side always being the highest. Any alteration to the underbody height also requires adjustment of the brake compensator (if fitted) and of the headlights

29 VALUES AND SETTINGS Underbody height 07 MEASURING POINTS 16102R H 1 : H 2 : H 4 : H 5 : radius of tyre under load height measured between the lower surface of the sub-frame and the ground in line with the centreline of the wheel radius of rear tyre under load height measured between the centreline of the rear axle joint and the ground R 07-26

30 VALUES AND SETTINGS Front axle angle checking values 07 DA03 ANGLES VALUES POSITION OF THE FRONT AXLE SETTING CASTOR ±30 H5-H2 = 71 mm H5-H2 = 51 mm H5-H2 = 31 mm CANNOT BE ADJUSTED S Maximum right / left difference= 1 CAMBER ±30 H1-H2 H1-H2 H1-H2 = 116 mm = 124 mm = 130 mm CANNOT BE ADJUSTED S Maximum right / left difference= 1 KINGPIN INCLINATION ±30 H1-H2 H1-H2 H1-H2 = 116 mm = 124 mm = 130 mm CANNOT BE ADJUSTED S Maximum right / left difference= 1 PARALLELISM (For 2 wheels) toe out ± 10 UNLADEN Adjusted by rotating track rod sleeves 1 turn = 30 (3 mm) + 1 mm ± 1 mm S POSITION FOR TIGHTENING RUBBER BUSHES - UNLADEN S

31 VALUES AND SETTINGS Front axle angle checking values 07 EA03 ANGLES VALUES POSITION OF THE FRONT AXLE SETTING CASTOR ±30 H5-H2 = 83 mm H5-H2 = 63 mm H5-H2 = 43 mm CANNOT BE ADJUSTED S Maximum right / left difference= 1 CAMBER ±30 H1-H2 H1-H2 H1-H2 = 116 mm = 125 mm = 133 mm CANNOT BE ADJUSTED S Maximum right / left difference= 1 KINGPIN INCLINATION ±30 H1-H2 H1-H2 H1-H2 = 116 mm = 125 mm = 133 mm CANNOT BE ADJUSTED S Maximum right / left difference= 1 PARALLELISM (For 2 wheels) toe out ± 10 UNLADEN Adjusted by rotating track rod sleeves 1 turn= 30 (3 mm) + 1 mm ± 1 mm S POSITION FOR TIGHTENING RUBBER BUSHES - UNLADEN S

32 VALUES AND SETTINGS Rear axle angles checking values 07 ANGLES VALUES 4 BAR AXLE POSITION OF THE REAR AXLE SETTING CAMBER ± 15 UNLADEN CANNOT BE ADJUSTED S PARALLELISM (For 2 wheels) Toe-in ± 20-3 mm ± 2 mm UNLADEN CANNOT BE ADJUSTED S POSITION FOR TIGHTENING RUBBER BUSHES - UNLADEN S

33 ENGINE AND PERIPHERALS ASSEMBLY Identification 10 Type of vehicle Engine Gearbox Cubic capacity (cm 3 ) Bore (mm) Stroke (mm) Compression ratio DA03 EA03 F5R 740 JC /1 Manual to be consulted: Mot. F5R. 10-1

34 ENGINE AND PERIPHERALS ASSEMBLY Oil pressure 10 ESSENTIAL SPECIAL TOOLS Mot Boxed kit for measuring oil pressure ESSENTIAL EQUIPMENT Douille longue ou clé à tube de 22 mm 22 mm long socket or tube wrench CHECK The oil pressure check must be carried out while the engine is warm (approximately 80 C). Contents of boxed kit Mot R1 USE B + F Connect the pressure gauge in place of the oil pressure switch. Oil pressure Idle 1 bar (minimum) 3,000 rpm 3 bars (minimum) 10-2

35 ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly 10 ESSENTIAL SPECIAL TOOLS Mot Mot Mot Mot Mot Dummy mounting for removing/refitting engine and transmission assembly Tool for retaining the engine on the sub-frame Threaded rods for lowering the sub-frame Clip pliers for spring clips Tool for supporting the engine TIGHTENING TORQUES (In dan.m) REMOVAL Sub-frame front mounting bolt 6.2 Sub-frame rear mounting bolt 10.5 Front right suspended engine mounting cover to engine mounting bolt 6.2 Front right suspended engine mounting cover mounting nut 4.4 Rubber engine mounting to front left side member support mounting nut 6.2 Shock absorber base mounting bolts 18 Brake caliper mounting bolt 4 Steering shaft yoke mounting bolt 3 Wheel bolt 10 Three point clamp nuts 2 Sub-frame - side member tie-rod bolts 3 Place the vehicle on a two post lift. Disconnect the battery. Remove the engine undertray. Drain: - the cooling circuit via the lower radiator hose, - the gearbox and the engine (if necessary), - the refrigerant circuit using filling equipment. Follow the instructions regarding cleanliness and safety when working on the fuel circuit. 10-3

36 ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly 10 Remove: - the front wheels and the mud shields, - the sub-frame - body tie-rods, - the steering ball joints, - the brake calipers (and the ABS sensors) and attach them to the suspension springs, - the shock absorber base bolts, - the heat shield (A) and the gearbox control cable, - the protective plate (1) and unclip the fuel pipes, - the fuel supply and return pipes. Fit plugs to maintain cleanness, - the tie-rod (2) mountings, - the catalytic converter clamp (3) and attach it to the body. SPECIAL FEATURES OF VEHICLES FITTED WITH A DRIVER S AIR BAG WARNING To prevent any risk of destruction of the rotary switch under the steering wheel, follow the instructions below: Before the steering column and the rack are uncoupled, it is ESSENTIAL that the steering wheel is immobilised with the wheels straight using a "steering wheel immobiliser" tool for the entire duration of the operation. If there is any doubt about the correct centring of the rotary switch, the steering wheel must be removed and the centring procedure described in the "Air bag" section must be applied. REMINDER: in this case, only qualified, trained personnel must carry out the procedure. Remove: - the front bumper, - the air filter unit and its support, - the accelerator and clutch cables, - the brake servo vacuum pipe (manifold end). Remove the computer fasteners and fold back the assembly on the engine. - the horns, - the two power steering pipe fasteners on the sub-frame on the right-hand side, - the steering shaft yoke nut and eccentric bolt after pushing back the protector R 10-4

37 ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly 10 Remove: - the heating radiator hose using tool Mot. 1448, - the expansion bottle fasteners and move it aside, - the relay board and the electrical connector of the engine connection unit, NOTE: it is essential to fit plugs on the pipes and the pressure relief valve to prevent the introduction of moisture into the circuit and on the fuel pipes to keep them clean. Fit engine retaining tool Mot ensuring that the strap is positioned correctly. Remove the suspended engine mountings cover and the engine tie-bar. Place a shim between the gearbox and the subframe. Remove nut (1), then, using a copper hammer, tap to detach the stud from the suspended engine mountings fastener R - the earth strap on the bulkhead, - the air conditioning pipe fasteners on the pressure relief valve, - the starter supply wire R R 10-5

38 ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly 10 Fit the two tools Mot as indicated below. Secure tool Mot under the sub-frame R R2 Lower the lift until the tool comes into contact with the ground. Remove the sub-frame mounting bolts and remove the engine and transmission assembly by lifting the body. When starting to lift the body, be sure to remove the catalytic converter and to extract the radiator from its upper fasteners (then place it on the subframe again) R NOTE: in the case of an operation which requires separation of the engine/gearbox/sub-frame assembly, take care to mark the position of the tools Mot on the sub-frame. 10-6

39 ENGINE AND PERIPHERALS ASSEMBLY Engine and transmission assembly 10 REFITTING The alignment of the sub-frame with the body will be made easier by positioning two threaded rods Mot in the two front fasteners of the body sub-frame. Be sure to reposition the catalytic converter on lowering the body onto the engine and transmission assembly. Tighten the sub-frame mounting bolts to a torque of: dan.m at the front, dan.m at the rear. Refit in the reverse order to removal. Fit the heat shields correctly. Fit the caliper mounting bolts with Loctite FRENBLOC and tighten them to the specified torque. Press the brake pedal several times to bring the pistons into contact with the pads. Carry out the following operations: - fill the engine and gearbox with oil (if necessary), - fill and bleed the cooling circuit (see section 19 "Filling - Bleeding"). Fill the refrigerant circuit using the filling equipment. 10-7

40 ENGINE AND PERIPHERALS ASSEMBLY Sump 10 ESSENTIAL SPECIAL TOOLS T.Av Tool for working on the subframe - axle TIGHTENING TORQUES (in dan.m) Pre-tightening of sump bolts 0.8 Tightening of sump bolts 1.35 ± 0.15 REMOVAL Place the vehicle on a two post lift. Disconnect the battery. Remove the steering shaft yoke nut R2 10-8

41 ENGINE AND PERIPHERALS ASSEMBLY Sump 10 Remove the sub-frame tie-rods mounting bolts and lower the sub-frame by approximately 100 mm R2 Drain and remove the sump. 10-9

42 ENGINE AND PERIPHERALS ASSEMBLY Sump 10 REFITTING Apply a spot of RHODORSEAL 5661 at (A) on either side of bearing n 1, and at (B) at the intersection of the crankshaft closing plate and the cylinder block R Refit the sump with a new seal pre-tightening it to a torque of 0.8 dan.m, then carry out a final tightening of 1.35 dan.m in the order shown R 10-10

43 ENGINE AND PERIPHERALS ASSEMBLY Multi-function support 10 TIGHTENING TORQUE (in dan.m) Multi-function support bolts and stud 4.4 ± 0.4 REMOVAL Place the vehicle on a two post lift. Disconnect the battery. Remove: - the alternator (see section 16 "Alternator"). - the air conditioning compressor fasteners and attach it to the upper crossmember, - the multi-function support removing the stud (A) R REFITTING Refit the support tightening the bolts and the stud to a torque of 4.4 dan.m. Refer to section 07 "Accessories belt tensioning" for the tensioning procedure. Refit in the reverse order to removal

44 TOP AND FRONT OF ENGINE Timing belt 11 ESSENTIAL SPECIAL TOOLS Mot Tool for immobilising pinions for toothed timing belt Mot Top dead centre pin Mot Tool for tightening camshaft pulleys Mot Pipe wrench for removing HP pipes Mot Engine support Mot Tool for refitting camshaft covers Mot Tool for fitting the camshaft seals Mot Tool for setting the camshafts Mot Tool for immobilising camshaft pulleys ESSENTIAL EQUIPMENT Angular tightening wrench TIGHTENING TORQUES (in dan.m or/and ) Wheel bolt 10 Pulley bolt: - M10: 5 - M8: 2.5 Tensioner nut 2.8 Crankshaft pulley bolt ± 10 Mounting bolt on suspended mounting 6.2 Intermediate timing cover bolt 2 High pressure pump mounting bolt 1 High pressure pipe union 2.5 REMOVAL Place the vehicle on a two post lift. Disconnect the battery. Remove: - the front right wheel, - the front right wheel arch and the engine undertray. Fit the engine support Mot Follow the instructions regarding cleanliness and safety when working on the fuel circuit R2 11-1

45 TOP AND FRONT OF ENGINE Timing belt 11 Remove : - the suspended engine mountings cover and movement limiter assembly, - the bolt (A) and slacken engine tie-bar bolt (B). Remove: - the Top Dead Centre pin plug, Raise the engine S - the air resonator (1), - the ignition coil and harness (2), 15424R3 Lock the accessories belt tensioner. To do this, turn the tensioner towards the right and immobilise it using a 6 mm hexagonal wrench (see section 07 "Accessories belt tensioning") R - the inlet manifold (3) (see section 12 "Inlet manifold"), S 11-2

46 TOP AND FRONT OF ENGINE Timing belt 11 - the exhaust camshaft sealing plug (4), - the high pressure fuel pipe using tool Mot (5). For this operation, support the unions using open wrenches. Fit blanking pieces to maintain cleanness. Remove: - the high pressure fuel pump (6), - the timing cover mounting bolts then remove the covers (7) R R 11-3

47 TOP AND FRONT OF ENGINE Timing belt 11 Setting the timing Position the exhaust camshaft pulley mark (1) one tooth before the phase sensor fastener (2). The camshaft grooves must be towards the bottom and almost horizontal as indicated below R S 11-4

48 TOP AND FRONT OF ENGINE Timing belt 11 Insert pin Mot to be between the balancing hole and the setting groove of the crankshaft. Correct position S S Incorrect position Turn the engine slightly, in the same direction, engaging pin Mot at the setting point S 11-5

49 TOP AND FRONT OF ENGINE Timing belt 11 Remove the timing pulley immobilising the engine flywheel using a screwdriver S Slacken the timing belt using the tensioner. Remove the belt and the pulley. Take care not to let the crankshaft pinion fall as it does not have a key. WARNING: it is essential to degrease the end of the crankshaft, the crankshaft pinion bore and the contact surfaces of the crankshaft pulley to prevent sliding between the timing and the crankshaft which could destroy the engine S 11-6

50 TOP AND FRONT OF ENGINE Timing belt 11 REFITTING When the timing belt is changed, it is essential to change the timing tensioners and pulleys. Refit: - the timing belt (it is essential to follow the procedure described in section 07 "Timing belt tensioning procedure"), - the accessories belt (see section 07 "Accessories belt tensioning procedure"), - the Top Dead Centre pin plug applying a spot of RHODORSEAL 5661 to the thread, - the new exhaust camshaft sealing plug using tool Mot. 1488, - the high pressure fuel pump and pipe (refer to the procedure described in section 13 "High pressure pump"), Replace the shim (1), 16127R Refit the inlet manifold (refer to the procedure described in section 12 "Inlet manifold"), 15615S - the air resonator and air intake pipe, - the right-hand suspended engine mounting tightening the bolts to the specified torque S 11-7

51 TOP AND FRONT OF ENGINE Cylinder head gasket 11 ESSENTIAL SPECIAL EQUIPMENT Mot Top Dead Centre pin Mot Engine support tool Mot Tool for tightening camshaft pulleys Mot Pipe wrench for removing HP pipes Mot Clip pliers for spring clips Mot Engine support tool Mot Tool for refitting camshaft covers Mot Tool for fitting the camshaft seals Mot Tool for setting the camshafts Mot Tool for removing injectors Mot Tool for removing the high pressure rail Mot Tool for fitting injector seals Mot Tool for immobilising camshaft pulleys ESSENTIAL EQUIPMENT Cylinder head testing equipment Angular tightening wrench TIGHTENING TORQUES (in dan.m or/and ) Wheel bolt 10 Pulley bolt: - M10: 5 - M8: 2.5 Tensioner nut 2.8 Crankshaft pulley bolt ± 10 Mounting bolt on suspended mounting 6.2 Intermediate timing cover bolt 2 Camshaft bearing cap casting bolt 1.2 Oil separator bolt 1.3 Injection rail mounting bolt 1.5 High pressure pump mounting bolt 1 High pressure pipe union 2.5 Follow the instructions regarding cleanliness and safety when working on the fuel circuit. 11-8

52 TOP AND FRONT OF ENGINE Cylinder head gasket 11 REMOVAL Place the vehicle on a two post lift. Disconnect the battery. Remove: - the front right wheel, - the front right wheel arch and the engine undertray. Drain the cooling circuit (via the lower radiator hose). Fit the engine support tool Mot Remove: - the air intake pipe and resonator, - the ignition coil and harness, - the inlet manifold (see section 12 "Inlet manifold"), - the high pressure fuel pipe using tool Mot supporting the unions using open wrenches. Fit blanking pieces to maintain cleanness. Remove: - the high pressure fuel pipe (see section 13 "High pressure pump"), - the suspended engine mountings, - the exhaust camshaft sealing plug, - the accessories belt (see section 11 "Accessories belt"). Position the engine at Top Dead Centre using the pin Mot Remove the timing belt (see section 11 "Timing belt"). Fit tool Mot positioning the timing cover bolt in hole (1), and remove the camshaft pulleys R R R 11-9

53 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Remove the injection rail mounting bolts (fit the sealing plugs). Fit the injection rail extraction tool Mot (the dowels and the threaded rods). Remove: - the clips between the injectors and the rail, - the injectors using tool Mot To do this, turn the injector slightly to break the carbon deposit. Extract the injector and position the plugs to maintain cleanness R Extract the injection rail. The injector retaining clips remain in place and may allow the injection rail to escape on removal R Fit blanking pieces to maintain cleanness

54 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Remove: - the oil separator, 15612S - the EGR valve/manifold connecting pipe, - the EGR valve support, - the camshaft bearing cap bolts S 11-11

55 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Vertically detach the camshaft bearing cap casting by tapping on the lugs (2) using a mallet and at the same time, slide a screwdriver under the lug R Remove: - the camshafts, 15656S 11-12

56 TOP AND FRONT OF ENGINE Cylinder head gasket 11 - the earth strap, - the catalytic converter/ manifold connecting bolts, - the exhaust manifold strut, - the harness supports, - the coolant pipes on the plenum chamber, - the tabs and the hydraulic stops, 15657S - the aluminium timing cover (1) R 11-13

57 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Remove the cylinder head S Cleaning It is very important that the mating surfaces of the aluminium parts are not scratched. Use the product Décapjoint to dissolve the part of the gasket which remains attached. Apply the product to the section to be cleaned; wait approximately ten minutes, then remove it using a wooden spatula. CHECKING THE MATING SURFACE Check whether the mating surface is deformed using a ruler and a set of feeler gauges. Maximum deformation Grinding of the cylinder head is prohibited. Test the cylinder head to detect any cracks mm It is advisable to wear gloves during this operation. Do not allow the product to fall onto the paintwork. Your attention is drawn to the care which must be taken when carrying out this operation to prevent the introduction of foreign bodies into the pressurised oil feed pipes leading to the camshafts (pipes located both in the cylinder block and in the cylinder head)

58 TOP AND FRONT OF ENGINE Cylinder head gasket 11 REFITTING When removing-refitting the cylinder head, observe the following points: - It is essential to reprime the hydraulic stops as they risk becoming empty after a very prolonged time. To check whether it is necessary to reprime them, press the top of the stop at (A) with the thumb. If the stop piston lowers, immerse it in a container full of diesel. Refit: - the tabs, - the camshaft lubricating the bearings. WARNING: do not apply oil to the cylinder head cover mating surface. NOTE: the camshafts are identified by a mark (A) R 15658R Details of mark (A) : - mark B is only used by the supplier, - mark C identifies the camshafts: A = Inlet, E = Exhaust, - mark D indicates the type of engine For example: F5RE D C B 11-15

59 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Position the camshaft grooves as indicated on the diagram below (the grooves must be horizontal and offset downwards) S NOTE: the mating surfaces must be clean, dry and not greasy (avoid finger prints). Using a roller (uneven) apply Loctite 518 to the camshaft bearing cap casting mating surface until it is reddish S 11-16

60 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Refit: - the camshafts S - the camshaft bearing cap castings. Tighten them to a torque of 1.2 dan.m following the order and the procedure indicated R 11-17

61 TOP AND FRONT OF ENGINE Cylinder head gasket 11 - the EGR valve support, - the oil separator. Using a roller (uneven) apply Loctite 518 to the mating surfaces until they are reddish S Tighten the oil separator to a torque of 1.3 dan.m in the order indicated R 11-18

62 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Refit: - the camshaft seals using tool Mot the coolant pipes on the plenum chamber, - the harness supports, - the earth strap, - the catalytic converter/manifold connecting bolts, - the exhaust manifold strut, - the EGR valve/manifold connecting pipes, - the EGR valve support R 11-19

63 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Refit the injector seals using tool Mot (refer to the procedure described in section 13 "Injection rail/injectors"). Refit the injectors and the clips on the rail observing their positions S Refit the injection rail (see section 13 "Injection rail/injectors")

64 TOP AND FRONT OF ENGINE Cylinder head gasket 11 Setting the timing WARNING: it is essential to degrease the end of the crankshaft, the crankshaft pinion bore and the contact surfaces of the crankshaft pulley to prevent sliding between the timing and the crankshaft which could destroy the engine. Refit: - the timing belt (it is essential to follow the procedure described in section 07 "Timing belt tensioning procedure", - the high pressure pump refitting the shim (1) (see section 13 "High pressure pump"), 16127R - the exhaust camshaft sealing plug using tool Mot. 1488, - the inlet manifold (see section 12 "Inlet manifold"), - the accessories belt (refer to the procedure described in section 07 "Accessories belt"), - the right-hand suspended engine mounting and the engine tie-bar. Before starting the engine, switch on the ignition several times to run the petrol pump and prime the fuel circuit. IMPORTANT: if the exhaust manifold fastening studs have been removed, change them and seal using "LOCTITE FRENBLOC BLEUE"

65 FUEL MIXTURE Specifications 12 Engine Vehicle Gearbox Type Index Bore (mm) Stroke (mm) Cubic capacity (cm 3 ) Compression ratio Catalytic converter Emission control standard Type of injection DA0 3 EA0 3 JC5 F5R /1 C110 C77 EU 96 Multipoint direct Static ignition Temperature in C Air sensor NTC type resistance in Ohms 8525 to to to Coolant sensor NTC type resistance in Ohms to to to to 117 Idle speed (rpm) Checks carried out at idle * Emissions of pollutants** CO (%) (1) C02 (%) HC (ppm) Lambda (λ) Fuel *** (minimum octane rating) 750 ± maximum 14.5 minimum 100 maximum 0.97 < λ < 1.03 Super unleaded (IO 95) (1) at 2,500 rpm the CO should be 0.3 maximum. * At a coolant temperature greater than 80 C and after a constant engine speed of 2,500 rpm for approximately 30 seconds. ** For the legislative values, refer to the specifications for the country concerned. *** Compatible IO 91 unleaded. 12-1

66 FUEL MIXTURE Specifications 12 DESCRIPTION BRAND/TYPE SPECIAL NOTES Injection and ignition computer Injectors control computer SIEMENS "SIRIUS 3H" SIEMENS "Driver" 90 tracks 55 tracks Injection - Direct multipoint sequential Ignition - Static with monobloc coil Idle stepper motor PHILIPS Resistance : 53 ± 5 Ω at 25 C Throttle potentiometer Magnetic sensor (TDC and engine speed) CTS - MAGNETI MARELLI ELECTRIFIL Incorporated in the throttle housing Resistance of track : 1,200 ± 240 Ω Resistance of cursor < 1,050 Ω Variable reluctance type Resistance = 200 to 270 Ω Camshaft position sensor SAGEM Hall Effect sensor Canister solenoid valve SAGEM Incorporated in the canister Resistance : 26 ± 4 Ω to 23 C Resistance of sensor track 5 KΩ Resistance of valve 6 KΩ Track 1 : sensor signal Track 2 : sensor earth Track 3 : sensor supply Track 4 : valve earth Track 6 : valve supply EGR solenoid valve SIEMENS Injector SIEMENS 4 6 Resistance 1.78 ± 5 C Operation under high pressure Fuel pressure sensor SIEMENS Resistance 3,8 Ω Fuel pressure regulator SIEMENS Resistance between tracks 2 and 3 2,084 Ω Manifold pressure sensor DELCO Resistance 50 KΩ Knock sensor SAGEM Piezo-electric type. Tightening to 2 dan.m 12-2

67 FUEL MIXTURE Specifications 12 DESCRIPTION BRAND/TYPE SPECIAL NOTES Upstream oxygen sensor Downstream oxygen sensor Ignition coils BOSCH BOSCH SAGEM Heating resistance: 9 ± 1 Ω at 23 C Rich mixture > 750 ± 240 mv Lean mixture < 150 ± 50 mv Heating resistance : 3.4 ± 0.7 Ω at 23 C Rich mixture > 750 ± 70 mv Lean mixture < 150 ± 50 mv Monobloc coil with four outputs Primary resistance 0.5 Ω Secondary resistance : 11 ± 1 KΩ A : cylinder 1 and 4 coil supply B : cylinders 2 and 3 coil supply C : supply D : common wire A B C D Spark plugs CHAMPION REC 14 PYC WARNING: long thread Tightening : 2.5 to 3 dan.m Idle manifold pressure ± 40 mbars Exhaust counter-pressure upstream of the pre-catalytic converter 1,500 rpm 59 3,000 rpm 176 4,500 rpm 409 5,500 rpm 520 Scavenge pump BOSCH Pressure : 4.5 ± 0.06 bars 12-3

68 FUEL MIXTURE Inlet manifold 12 TIGHTENING TORQUES (in dan.m) Inlet manifold 8 mounting bolt 2.5 Inlet manifold 6 mounting bolt 1 Side mounting bolt 2.5 Throttle housing bolt 1 REMOVAL Disconnect the battery. Remove: - the air intake pipe, - the air resonator (1), - the pressure sensor (2) and air temperature sensor (3) connectors, - the ignition coil, - the ignition harness, 15616R1 - the manifold side bolt (4), - the inlet manifold mounting bolts and nuts R 12-4

69 FUEL MIXTURE Inlet manifold 12 REFITTING Replace the manifold seal and the EGR valve. Refit: - the inlet manifold replacing the seals and observing the tightening torque of the 6 mm and 8 mm bolts and nuts R1 - the manifold side bolt, - the coil (3) and the ignition harness (4), - the air resonator and air intake pipe. In the case of removal of the throttle housing, refer to the procedure described in section 12 "Throttle housing"). 12-5

70 FUEL MIXTURE Exhaust manifold 12 ESSENTIAL SPECIAL TOOLS Mot Tool for removing the oxygen sensor TIGHTENING TORQUES (in dan.m) Catalytic converter/manifold connecting nuts 1.2 Exhaust manifold mounting nuts 1.8 Engine tie-bar 6.2 Oxygen sensor 4.5 Shock absorber lower bolts 17 Lower ball joint 6 REMOVAL Place the vehicle on a two post lift. Disconnect the battery. Remove: - the idle regulation solenoid valve (1), - the EGR pipe (2), 16080R - the front right wheel, - the front right mud shield, - the ABS sensor connector, - the front right brake caliper, - the right lower ball joint mounting bolt, - the lower shock absorber mounting bolts, - the front right driveshaft, - the oxygen sensor (3) using tool Mot. 1495, 12-6

71 FUEL MIXTURE Exhaust manifold 12 - the exhaust strut (1), - the manifold heat shields, - the engine tie-bar, - the manifold to catalytic converter connection mounting bolts. Slacken the catalytic converter / exhaust line connection clamp to move the catalytic converter back a few centimetres. Remove the exhaust manifold nuts. Tilt the engine and detach the manifold from underneath R REFITTING Replace all the seals removed and the EGR pipe clamps. It is essential to tighten all the bolts to the specified torque. Refit the heat shield. IMPORTANT: in the case of removal of the exhaust manifold mounting studs, replace them and seal using "LOCTITE FRENETANCH BLEUE" S 12-7

72 FUEL SUPPLY Specifications 13 The fuel supply circuit is composed of: - the low pressure supply pump (placed in the gauge/pump assembly in the tank (1), - a fuel filter located at the front of the tank (2), - a high pressure mechanical pump located at the end of the camshaft (3), - an injection rail (high pressure) fitted with the pressure sensor and regulator (which cannot be removed) (4), - four electromagnetic injectors opening directly into the combustion chamber (5) R Removal of the interior of the high pressure pump and the injectors is prohibited. The pressure regulator cannot be separated from the injection rail, it is essential to replace the assembly. OBSERVE THE RULES REGARDING CLEANLINESS DESCRIBED IN THIS DOCUMENT (SECTION 17) STRICTLY WHEN WORKING ON THE FUEL SUPPLY SYSTEM. 13-1

73 FUEL SUPPLY Supply pump 13 The low pressure supply pump is immersed in the fuel tank. It is installed on the pump/gauge assembly and has a low pressure regulator (4) R For the removal of the low pressure supply pump, refer to the procedure described in section 19 "Pump - gauge" of Workshop Repair Manual MR

74 FUEL SUPPLY Supply pressure / Pump output 13 ESSENTIAL SPECIAL TOOLS Mot Fuel pressure checking kit with pressure gauge and adapters ESSENTIAL EQUIPMENT 2,000 ml graduated receptacle SUPPLY PRESSURE CHECK Disconnect the fuel supply union (1) on the high pressure pump and fit in its place a "T" union fitted with the checking pressure gauge Mot Start the engine to run the low pressure fuel pump. Pressure measured: 4.5 ± 0.06 bars Maximum pressure: 6 bars SUPPLY PUMP OUTPUT CHECK Disconnect the supply union (R) located after the fuel filter and place it in the graduated receptacle. Run the supply pump shunting the control relay or using the diagnostic equipment. Minimum output measured: 165 litres/hour R 15755R1 WARNING: THE PRESSURE READ UNDER THE "FUEL PRESSURE" PARAMETER ON THE DIAGNOSTIC EQUIPMENT CANNOT BE MEASURED USING A PRESSURE GAUGE. NO ATTEMPT MUST BE MADE TO READ IT IN ANY CIRCUMSTANCES. 13-3

75 FUEL SUPPLY High pressure pump 13 ESSENTIAL SPECIAL EQUIPMENT Mot Tool for removing high pressure unions TIGHTENING TORQUES (in dan.m) High pressure pump mounting bolt 1 High pressure pipe union 2.5 The high pressure pump is a mechanical pump located at the end of the inlet camshaft. Removal of the interior of the high pressure pump is prohibited, it is sold complete. Disconnect the low pressure fuel supply and return unions (1). Fit appropriate plugs to maintain cleanness. Remove: - the inlet manifold (refer to the procedure described in section 12 "Inlet manifold"), WARNING: when removing the injectors, the rail or the high or low pressure pumps, be aware of the quantity of the fuel in the unions. Protect areas susceptible to damage. REMOVAL WARNING: Before carrying out any work, connect the after sales service diagnostic equipment, enter into dialogue with the injection computer and check that the pressure in the rail is below 5 bars. Be aware of the fuel temperature. Place the vehicle on a two post lift. Disconnect the battery. THE RULES REGARDING CLEANLINESS MUST BE OBSERVED STRICTLY R3 - the high pressure pipe (2) using tool Mot To do this, support the pump s intermediate steel union during slackening (3) and the rail union (4), - the pump mounting bolts (5), - the intermediate shim between the pump and the cylinder head and clean its mating surface. 13-4

76 FUEL SUPPLY High pressure pump 13 REFITTING Replace the intermediate shim between the pump and the cylinder head S Fit: - the pump on its support and tighten the bolts to the specified torque, - the pipe and tighten the unions to the specified torque using tool Mot To do this, support the intermediate steel unions of the pump and the rail. WARNING: After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan assembly cuts in, then accelerate several times while stationary. Check that there are no leaks. 13-5

77 FUEL SUPPLY Injection rail / Injectors 13 ESSENTIAL SPECIAL TOOLS Mot Tool for removing high pressure unions Mot Tool for extracting injectors Mot Tool for removing the injection rail Mot Tool for replacing injector seals TIGHTENING TORQUES (in dan.m) Rail mounting bolt 1.5 ± 0.2 High pressure pipe union 2.5 ± 0.3 Pressure sensor 2 ± 0.2 NOTE: removal of the intermediate union located between the rail and the high pressure pipe and removal of the pressure regulator is prohibited. In this case, replace the injection rail. The injectors are secured to the injection rail by means of clips. They open directly into the cylinder head combustion chamber. 13-6

78 FUEL SUPPLY Injection rail / Injectors 13 REMOVAL WARNING: Before carrying out any work, connect the after sales service diagnostic equipment, enter into dialogue with the injection computer and check that the pressure in the rail is below 5 bars. Beware of the fuel temperature. Disconnect the battery. THE RULES REGARDING CLEANLINESS MUST BE OBSERVED STRICTLY. Disconnect the injection rail and injector connectors. Remove the inlet manifold (see section 12 "Inlet manifold"). WARNING: when removing the injectors, the rail or the high or low pressure pumps, be aware of the quantity of the fuel in the unions. Protect areas susceptible to damage S 13-7

79 FUEL SUPPLY Injection rail / Injectors 13 Remove the high pressure union using tool Mot supporting the unions on the rail and on the pump (1). Fit blanking pieces to maintain cleanness. NOTE: the injectors are secured to the rail by retaining clips. It is not necessary to remove them to extract the injection rail. Remove the injector clips Fit blanking pieces to maintain cleanness. Fit extraction tool Mot Rotate to break the carbon deposit on the injector nozzle R4 Remove the fuel return pipe (low pressure). Fit blanking pieces to maintain cleanness. Remove the rail mounting bolts. Extract the rail using tool Mot Remove the injectors. Fit blanking pieces to maintain cleanness R 16126R 13-8

80 FUEL SUPPLY Injection rail / Injectors 13 REPLACEMENT OF THE INJECTOR NOZZLE SEAL the seal on the cone and fit it slowly by hand, It is essential to replace the Teflon injector seals. To do this: - clean the injector soaking it in a suitable, clean thinner. The use of a metal brush, sandpaper, or an ultrasound cleaner is prohibited, - wipe the injector nozzle using a lint-free wipe, - cut the seal carefully using circlip pliers taking care not to mark the injector, clean the injector again S - remove the cone and retract the seal from the injector using the body of tool Mot pushing it to its limit. - place: the cone of tool Mot on the injector, 16373S 16376R 16374R 13-9

81 FUEL SUPPLY Injection rail / Injectors 13 REFITTING Change: - the O-rings, - the clips, - the injector Teflon seals. Position the injectors on the injection rail. Fit the injector retaining clips taking care to position them correctly S Fit: - the injection rail, - the pipe and tighten it to the specified torque using tool Mot taking care not to place it under stress. Refit the connectors. WARNING: After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan assembly cuts in, then accelerate several times while stationary. Check that there are no leaks

82 FUEL SUPPLY Pressure sensor 13 ESSENTIAL SPECIAL TOOLS Mot Socket for removing the pressure sensor TIGHTENING TORQUES (in dan.m) Injection rail pressure sensor 2 ± 0.2 REMOVAL WARNING: Before carrying out any work, connect the after sales service diagnostic equipment, enter into dialogue with the injection computer and check that the pressure in the rail is below 5 bars. Be aware of the fuel temperature. Disconnect the battery. THE RULES REGARDING CLEANLINESS MUST BE OBSERVED STRICTLY. Disconnect the injection rail connectors. WARNING: when removing the injectors, the rail or the high or low pressure pumps, be aware of the quantity of the fuel in the unions. Protect areas susceptible to damage

83 FUEL SUPPLY Pressure sensor 13 Disconnect the pressure sensor (1) and unscrew it. Fit a blanking piece to maintain cleanness R REFITTING Change the seal. Fit the sensor then tighten it to the specified torque. Refit the connector. WARNING: After all work, check that there are no leaks on the fuel circuit. Run the engine at idle until the cooling fan assembly cuts in, then accelerate several times while stationary. Check that there are no leaks. WARNING: removal of the fuel pressure regulator is strictly prohibited

84 FUEL SUPPLY Anti-percolation system 13 PRINCIPLE OF OPERATION The anti-percolation system is controlled directly by the injection computer. The coolant temperature information is taken from the injection coolant temperature sensor (see section 17 "CCTM"). When the ignition is switched off, the injection computer changes to monitoring mode. If the engine coolant temperature exceeds the threshold of 100 C during the two minutes which follow switching off of the engine, the fan low speed relay is supplied. If the temperature again falls below 96 C, the fan assembly relay is cut off (operation of the fan assembly cannot exceed a duration of 10 minutes)

85 ANTI-POLLUTION Oil vapours rebreathing 14 BASIC DIAGRAM OF THE CIRCUIT 1 Engine 2 Oil separator 3 Air filter housing 4 Inlet manifold 13042R CHECK To ensure correct operation of the anti-pollution system, the oil vapours rebreathing circuit must be kept clean and in good condition S 14-1

86 ANTI-POLLUTION Exhaust gas recirculation E.G.R. 14 PRESENTATION OF CIRCUIT 3 Inlet manifold 4 Exhaust manifold 5 EGR valve 16080R1 14-2

87 ANTI-POLLUTION Exhaust gas recirculation E.G.R. 14 TIGHTENING TORQUES (in dan.m) EGR valve mounting bolt 2.7 EGR valve support 1 REMOVAL OF THE VALVE Remove: - the lower gas recirculation clip (pipe/valve), - the mounting bolts, - if necessary, the valve support (1). PRINCIPLE OF OPERATION The valve is controlled by an RCO signal emitted by the injection computer. The RCO signal permits modulation of the opening of the valve, and consequently, the quantity of exhaust gas directed back towards the inlet manifold. The computer continuously carries out a test to detect the position of the EGR valve flap. OPERATING CONDITIONS The parameters which determine the activation of the EGR solenoid valve are as follows: - air temperature, - coolant temperature, - atmospheric pressure, - accelerator pedal position, - engine speed, - vehicle speed, - battery voltage. EGR is authorised if: - the air temperature is greater than 10 C, - the coolant temperature is greater than 70 C, - the manifold pressure is between 300 and 650 mbars, - the engine speed is between 1,700 and 3,800 rpm, - a map (torque/engine speed/load potentiometer) is above a given threshold R5 REFITTING It is essential to change the valve seal. PURPOSE OF THE EGR SYSTEM The computer controls the EGR except in the following cases: - in the case of a fault on one of the following: coolant temperature sensor, air temperature sensor, pressure sensor, vehicle speed information, EGR valve. The recirculation of the exhaust gas is used to reduce the nitrogen oxide (NOx) content of the exhaust gas. Passage of the gas is authorised by the control of an electromagnetic valve by the injection computer. Programming conditions: - engine speed 2,800 ± 100 rpm, - manifold pressure of 630 ± 150 mbars, - for a duration of approximately 30 seconds. 14-3

88 ANTI-POLLUTION Fuel vapours rebreathing 14 BASIC DIAGRAM OF THE CIRCUIT CANISTER PURGE CONDITION The canister purge solenoid valve is controlled by track 4 of the computer when: - the coolant temperature is greater than 70 C, - the air temperature is greater than 10 C, - the throttle position potentiometer is not at no-load and is outside idle regulation. It is possible to display the canister purge solenoid valve opening cyclic ratio using the diagnostic equipment by consulting the parameter "Canister purge solenoid valve RCO". The solenoid valve is closed if the value is below 1.5 % (minimum value). CANISTER PURGE OPERATION CHECK R1 1 Inlet manifold 2 Incorporated canister purge solenoid valve 3 Fuel vapours absorber (canister) with solenoid valve 4 Tank M Breather A system malfunction may result in an unstable idle or stalling of the engine. Check the conformity of the circuit (refer to the basic diagram) and the condition of the pipes to the tank (refer to Workshop Repair Manual MR 312). 14-4

89 STARTING - CHARGING Alternator 16 IDENTIFICATION Vehicle Engine Alternator Intensity DA0 3 EA0 3 F5R 740 BOSCH 14 V A 100 A CHECK After 15 minutes of warming up under a voltage of 13.5 volts. RPM 100 Amperes 2, A 3, A 4, A 16-1

90 STARTING - CHARGING Alternator 16 REMOVAL Place the vehicle on a two post lift. Lock the accessories belt tensioner using a 8 mm pin, then remove the belt (see section 07 "Accessories belt tensioning"). Disconnect the battery. Remove: - the wiring and computer fasteners and fold it back onto the engine, - the front right wheel, - the front right wheel arch S Remove the power steering reservoir support fasteners and unclip the power steering reservoir S Move aside the power steering reservoir and support assembly to allow access to the alternator. Remove: - the power steering pump pulley, S 16-2

91 STARTING - CHARGING Alternator 16 - the power steering pump. REFITTING Refit in the reverse order to removal. NOTE: on refitting, use the upper alternator and power steering support mounting bolt to position the alternator. Take care not to crush the wiring between the compressor and the power steering support. Refer to section 07 "Accessories belt tensioning" for the tensioning procedure S Disconnect the alternator. Remove the alternator mounting bolts S Remove the alternator from above. 16-3

92 16-4 STARTING - CHARGING Starter 16 IDENTIFICATION Vehicle Engine Starter DA0 3 EA0 3 F5R BOSCH REMOVAL Place the vehicle on a two post lift. Disconnect the battery. From above Disconnect the starter energising connector. Remove the starter mounting bolts. From below Remove: - the manifold/catalytic converter connecting rod, - the pre-catalytic converter lower heat shield, - the right-hand lower wishbone ball joint mounting bolt, - the shock absorber strut upper bolt, - the starter supply wire. Detach the ball joint and tilt the shock absorber strut to uncouple the right-hand driveshaft. Remove the air intake pipe and the resonator S Remove the starter. To do this: - tilt the starter downwards, - free the fastener on the engine block side. REFITTING Refit in the reverse order to removal S

93 IGNITION Static ignition 17 TIGHTENING TORQUES (in dan.m) Ignition coil bolts 1 to 1.5 Spark plugs 2.5 to 3 DESCRIPTION The ignition system is of the static type supplied with signals from the engine speed and exhaust camshaft position sensors. The power module is incorporated in the injection computer S WARNING: the spark plugs fitted to the F5R engine are specific and have a long thread. 17-1

94 INJECTION General 17 SPECIAL FEATURES OF THE MULTIPOINT DIRECT INJECTION FITTED TO THE F5R ENGINE SIEMENS "SIRIUS 3H" 90-way computer controlling the injection and the ignition. 55-way computer controlling the opening of the injectors. Multipoint direct injection operating in sequential mode from the time the engine is started. Injection warning light on the instrument panel. Use of the engine overheating warning light in the event a major fault on the high pressure circuit. Special precautions relating to the engine immobiliser. Adoption of a 2 nd generation type engine immobiliser making a special computer replacement procedure necessary. High pressure fuel circuit with an electric scavenge pump (low pressure) and a mechanical high pressure pump. Idle speed - nominal idle when warm rpm Idle speeds corrected in line with: - air conditioning, - power steering, - coolant temperature, - electrical balance. Maximum engine speeds: - maximum engine speed when the coolant temperature is below 75 C ,900 rpm - maximum engine speed for T > 75 C ,500 rpm Canister purge solenoid valve controlled by opening cyclic ratio (RCO). Electric exhaust gas recirculation (E.G.R.) valve controlled by opening cyclic ratio (RCO). Use of two oxygen sensors placed upstream and downstream of the catalytic converters. Automatic configuration for AC operation by exchange of signals between computers. Control of the fan assemblies and of the coolant temperature warning light on the instrument panel by the injection computer (CCTM). 17-2

95 INJECTION Installation Fuel vapours absorber with solenoid valve 2 Injection computer 3 Pressure regulator 4 Manifold pressure sensor 5 Fuel pressure sensor 6 Idle stepper motor 7 Electric E.G.R. valve 8 Throttle position potentiometer 9 High pressure pump 10 Engine speed sensor 11 Ignition coil 12 Air temperature sensor 13 Knock sensor 14 Power steering pressure switch 15 Injectors control computer 17-3