Renault master repair manual

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Renault 1997

77 11 195 441 AUGUST 1997 Edition Anglaise

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

The methods may be modified as a result of changes by the manufacturer in theproduction of the various component units and accessories from which his vehiclesare constructed".

All copyrights reserved by Renault.

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

C

FD0A - FD0C - UD0A - UD0C

Engine and peripherals

ENGINE AND PERIPHERALS

TOP AND FRONT OF ENGINE

TURBOCHARGING

DIESEL EQUIPMENT

STARTING - CHARGING

COOLING - EXHAUST SYSTEM

FUEL TANK - ENGINE MOUNTING



EXPLODED VIEW

PRF1006








Engine - Gearbox 10

ESSENTIAL EQUIPMENT

Suspension spring compressor

Load positioner

Wheel nuts 15.5

Lower calliper guide bolts 3

Upper calliper guide bolts 8

Drive shaft bellows screws 2.5

Steering ball joint nut 8Upper ball joint nut 9

Lower ball joint stud 8

Bolt for suspended engine mountingright-hand side 4.5

Nut for suspended gearbox mounting 8

Torque reaction arm stud 10.5

TIGHTENING TORQUES (in daN.m)

REMOVING

Place the vehicle on four axle stands (see sectionon "Lifting" to position the lifting jack correctly).

Disconnect the battery.

Drain the gearbox.

Remove :- front wheels,

- cooling assembly (see section 19),- battery,- clutch slave cylinder,- the expansion bottle and its mounting.

Disconnect:- the wiring harness for the engine interconnec-

tion unit,- the brake servo pipe,- the accelerator cable,- the diesel delivery and return lines,- the gearbox control cables,- the gearbox earthing strap,- the wiring harness for the impact sensor and

diesel filter heater,- the heating pipes,- the exhaust down pipe.

Remove the front right-hand suspension springusing a spring compressor.

12734S

NOTE: Before decompressing the spring, mark itsposition using an indelible marker on the tool.

10-2




Engine - Gearbox 10

Remove:- the front left-hand suspension spring,- the left-hand half axle by removing the ball

joint nuts for the upper arm and steering arm,

the stud for the lower arm ball joint, the brakecalliper (secure it to the body), the drive shaft bellows screws and then separate the upperand lower arms to release the half axle,

- the right-hand half axle (same operation asfor the left-hand half axle), except for thedrive shaft; the retaining flange for the inter-mediate bearing antifriction bearing must betaken out.

NOTE: Use cloths to protect the drive shafts.

Take the lower radiator mountings off the body.

Disconnect the power steering pipes from thepump.

Remove:- the power steering reservoir and secure it to

the engine,- its support,- the torque reaction arm,- the sound-damping tie bar for the suspended

engine mounting,- the bonnet.

Fit the load positioner.

Remove the right-hand suspended engine moun-ting (rubber pad plus cover).

Undo the nut for the rubber pad on the left-handsuspended mounting (but do not remove it).

Use a bronze drift to tap the stud for the rubberpin so as to separate it from the rubber pad.

NOTE: There is a risk that the engine will tilt whenthe stud and rubber pad are separated.

Remove the engine - gearbox assembly via thefront.

REFITTING

Position the engine - gearbox assembly in the bo-dy.

Fitting the suspended engine mounting

Fit the right-hand suspended mounting support,with the rubber pad fitted, on the water pump.

13447S1

10-3




Engine - Gearbox 10

Start by positioning the right-hand suspended engine mounting by tilting the enginetowards the rear of the vehicle (if necessary) and then tighten the mounting bolts forthe rubber pad to a torque of 4.5 daN.m.

Insert the left-hand suspended engine mounting stud into the rubber pad and thentighten the nut to a torque of 8 daN.m.

Fit the torque reaction arm and tighten the studs to a torque of 10.5 daN.m.

Refit in reverse order to removal.

Torque tighten the studs and nuts.

Apply Loctite FRENBLOC to the brake calliper mounting bolts before fittingand torque tighten them.

Press the brake pedal several times to bring the pistons into contact with the brakepads.

Fill and bleed the engine cooling circuit (see section 19 on filling and bleeding thesystem).

Top up the gearbox (see the general instructions in section 21 ).

13450S

10-4




Accessories belt 11

ESSENTIAL SPECIAL TOOLING

Mot. 1273 Tool for checking belt tension

Drive the vehicle on to a lift (minimum of 5tonnes) or so that it is over a pit (on axle stands).


REMOVING

Remove the underbody engine guard.

Undo bolt (1) and slacken off the two bolts (2).

13458R

Remove the accessories belt.

REFITTING


Refer to section 07 on the "Accessories belt"forinformation on accessories belt tensioning proce-dure.

11-1




Timing belt 11


Mot. 910 Pin for setting injection pumptiming gear

Mot. 1054 TDC pin


Refit the crankshaft accessories pulley to make iteasier to turn the engine by hand.

Turn the engine to the timing adjustment posi-tion.

Compress the tensioner roller spring and place anM14 nut, cut to form a U-shape, at the back of thepush rod.

PRF1100



REMOVING

Remove:- the guard under the engine,- the accessories belt,

- the panel over the cylinder head cover (1),- the valve timing cover (2),- the crankshaft accessories pulley,- the lower valve timing cover (3), replace and

tighten nut (4) on the timing gear tensioner.

Crankshaft pulley bolt 20

Timing gear tensioner nut 4.5


85384-1S

11-2




Timing belt 11

Insert setting rods Mot. 910 in the injection pumptiming gear and Mot. 1054 in the gearbox casing.

85397R1

Align the mark on the camshaft with the mark onthe cylinder head, and align the mark on thecrankshaft pulley in relation to the mark on thecrankcase.

13460R

13459R

13533R

Remove the crankshaft accessories pulley.

11-3




Timing belt 11

Checking the timing gear setting

Turn the crankshaft one more time in the normaldirection of rotation and check the four timing

points, using setting rods Mot. 910 and Mot. 1054.


Tighten the bolt on the crankshaft pulley to a tor-que of 20 daN.m.

Undo the tensioner nut to release the timing belt.

REFITTING

Check that setting rods Mot. 910 and Mot. 1054are in place.

Align the mark on the camshaft sprocket with themark on the cylinder head cover.

Check that there is no play or stiffness in eitherthe tensioner rollers or the tensioner when theyare turned by hand. If any stiffness or play can bedetected, replace them .

Fit a new timing belt.

Free the timing tensioner.

Remove setting rods Mot. 910 and Mot. 1054.

Turn the engine a quarter of a turn.

Tighten the tensioner nut.

Turn the engine three quarters of a turn.

In this position, adjust the belt tension by relea-sing and retightening the tensioner.

13460R1

11-4




Cylinder head gasket 11


Emb. 880 Pin extractor

Mot. 910 Rod for setting injection pumptiming gear

Mot. 921 Tool for extracting injector holders(to be used with pin extractor Emb.880)

Mot. 1054 TDC rod


Mot. 1383 17 mm pipe wrench to remove highpressure pipes

Remove:- the retaining flange for the metal coolant

pipes,

13448S

Drive the vehicle on to a lift (minimum of 5

tonnes) or so that it is over a pit (on axle stands).


REMOVING

Remove:- the timing gear belt,- the air filter unit and the intake trunking for

the air filter unit,- the pipe for the turbo air intake,- the bracket for the air filter unit (mounted on

the scuttle panel),- the expansion bottle and its bracket,- the pipes for the turbocharger,- the upper and lower hoses for the radiator

(cylinder head side),- the pipes on the thermostat bracket.

Disconnect the various sensors and the flamestart.

Disconnect the diesel pipes which are attached on

the inlet manifold.

Remove the oil vapour rebreathing reservoir.

Bolt for crankshaft pulley 20

Nut for timing tensioner 4.5


- the lifting bracket (flywheel side),- the high pressure injection pipes, using Mot.

1383,- the injector return pipe,

11-5





- the flanged injector holders using tool Mot.921, secured using pin extractor Emb. 880.

84914R

13446S

Release the dipstick guide.

Remove:- the stay between the turbocharger and the cy-

linder block,

- the accoustic damper (tie rod),- the starter motor heat shield (if one is fitted),

13454S

- the turbocharger oil return pipe.

First take out the wastegate rod and then remove

the turbocharger oil supply pipe using Mot. 1383 .

Disconnect the exhaust down pipe from the mani-fold or the turbocharger.

Remove:- cylinder head cover,- cylinder head bolts,- cylinder head.

84592S

11-6





NOTE : Two studs are used to centre the cylinderhead on the cylinder block (A). Do not pivot thecylinder head: lift it up to release it. (No risk of li-ners becoming detached as they are force-fitted.)

85077R

Checking the gasket face

83179S

First remove the pre-combustion chambers. Thenuse a straight edge and a set of shims to check forgasket face bow.

Maximum bow : 0.05 mmMaximum regrinding : 0.4 mm

After the cylinder head has been ground, thevalves must be recessed according to the amount

ground from the cylinder head.

Stripping down cylinder head(see S engine workshop repair manual)

Check the cylinder head for cracks.

Fit a new cylinder head gasket and refit the cylin-der head.

Tighten the cylinder head bolts (see section 07).


See section 11 for information on refitting the ti-ming gear.

Fill up and bleed the cooling system (see sectionon"Filling and bleeding cooling system").

CLEANING

It is very important not to scratch the gasket facesof aluminium parts.

Use Décapjoint to dissolve any parts of the gasketremaining on the metal.

Apply the product on the area to be cleaned; waitapproximately 10 minutes then remove using awooden spatula.

Gloves should be worn during this operation.

Do not allow this agent to drip on to the paint-work.

Remember that this operation should be carriedout with extreme care to avoid the risk of foreignbodies being introduced into the oilways brin-ging oil under pressure to the camshaft.

11-7



TURBOCHARGING

Turbocharger 12


Mot. 1383 Pipe wrench for high pressure

diesel pipes

Turbocharger nuts onexhaust manifold 2.5

Nuts, turbine outlet elbow 2.5

Oil inlet pipe 1.2

Screws for oil return pipe 1.2

Bracket mounting bolt forwastegate on compressor 1.5


REMOVING

Drive the vehicle on to a lift (minimum 5 tonnes)or so that it is over a pit (on axle stands).


Working from underneath the vehicle, remove- the guard under the engine,- the exhaust down pipe,- the turbocharger oil return pipe.

Working from above the vehicle remove:- the air filter unit assembly with the trunking,- the air inlet pipe for the turbocharger,- the starter motor protection plate,- the oil delivery pipe on the turbocharger

using tool Mot. 1383 (to do this, disconnect

the wastegate control rod (1)),- the wastegate assembly with its bracket (2),- the stay holding the turbocharger (3),

13446-1R

S9W engine

- the four nuts securing the turbocharger to themanifold.

Remove the turbocharger, taking it out under-neath the vehicle.

12-1



TURBOCHARGING

Turbocharger 12

Special precautions

• Before refitting, make sure that the lubrica-tion is correct for the turbocharger bearings.To do this, first disconnect the diesel pump co-ded solenoid valve (to stop the engine startingup) and then operate the starter.

Plenty of oil should be supplied by the oil sup-ply pipe. (Place a container underneath tocatch the oil.) If this is not the case, change thelubrication pipe.

• Ensure that no foreign bodies enter the turbine or compressor during the refitting opera-tion.

• If there has been a fault in the turbocharger,check that the air-air exchanger is not full of

oil.

If the air-air exchanger is full of oil, it must beremoved, flushed with a cleaning agent andthen left to drain properly.

• Check that the turbocharger oil return pipe isnot partially or completely blocked by scale.Also check that it is absolutely leak-tight(crimping). If it is not, replace it.

IMPORTANT :

Before starting the engine, ensure the connectorfor the solenoid valve on the diesel injection

pump is still disconnected.

Activate the starter motor until the oil pressurewarning light extinguishes. (Keep operating it forseveral seconds.)

Reconnect the diesel pump solenoid valve. Waitfor the warning light to extinguish and start theengine.

Run the engine at idling speed and check thatthere are no leaks at the connections for oil andwater.

REFITTING - Special points

Proceed in reverse order to removal. When refit-ting the turbocharger, ensure that the self-locking

nuts securing the turbocharger on the exhaustmanifold and the nuts for the turbine outlet elbow are replaced with new nuts.

12-2



TURBOCHARGING

Wastegate 12


Mot. 1014 Kit for checking and adjustingturbo pressure

Mot. 1079-02 Dial gauge

Mot. 1311-01 Pressure gauge and connectorsfor measuring oil pressure

Checking calibration pressure

Fit on vehicle.

Use a dial gauge with a magnetic holder (1) which

is positioned at the end of the wastegate rod.

13494R

S9W engine

The pressure applied to the wastegate is variedusing pressure gauge Mot. 1014.

Calibration pressure values

Pressures(mbar)

Rod movement(mm)

1100 ± 33 1

1220 ± 66 4

12-3



TURBOCHARGING

Wastegate 12

Fitting on the vehicle

When checking the calibration pressure it may benecessary to adjust the wastegate rod length (A)

(if it is not within tolerance).

This adjustment is made with the turbocharger inplace.

13446R

S9W engine

To do this, release clip (1) and regulator arm rod(A).

The rod at the wastegate end (2) must be held in avice.

Next undo the lock nut and then slacken off or

tighten the threaded end.

Work half a turn at a time. (Tighten to increase ca-libration pressure. )

NOTE : The operation to replace the threadedend on the regulator arm (A) will be easier if toolMot. 1014 is used and if the pressure applied is in-creased.

REMOVING

Remove:- the pneumatic pipe (1) on the wastegate,

- the circlip (2) on the wastegate; release therod on the wastegate arm,

- the two mounting screws for the wastegateassembly with its bracket (3).

Take out the wastegate.

13446R1

REFITTING

Refit the wastegate assembly, together with its bracket, in reverse order to removal.

NOTE: Apply LOCTITE FRENBLOC to the wastegate bracket mounting screws before refitting.Tightening torque: 1.5 daN.m.

12-4





TURBOCHARGING

Exhaust manifold 12


Mot. 1383 Pipe wrench for high pressure

diesel pipes

Mounting nuts for exhaustmanifold 2.5

Union for oil delivery pipe 1.2

Mounting studs 1


The turbocharger and the inlet manifold do nothave to be taken out to remove the exhaust mani-fold. REMOVING



Working from underneath the vehicle, remove:- the guard under the engine,- the exhaust down pipe,- the turbocharger oil return pipe.

Working from above the vehicle remove:- the air filter unit assembly with the trunking,- the air inlet pipe for the turbocharger,- the starter motor protection plate,- the oil delivery pipe on the turbocharger

using tool Mot. 1383 (to do this, disconnectthe wastegate control rod (1)),

- the stay holding the turbocharger (2),- the heat shield on the manifold (3),- the exhaust manifold mounting bolts and

take out the manifold from underneath thevehicle (exhaust manifold/turbocharger as-sembly not separated).

13446-1R1

S9W engine

13451R

REFITTING


COMMENT: When refitting, always replace allseals and gaskets for the manifold and for the turbocharger oil return pipe with new ones.

12-6





TURBOCHARGING

Inlet manifold 12

Inlet manifold mounting nuts 2.5

Mounting studs 1Fuel supply pipe for fuel on Flamestartsolenoid valve 1

Flamstart on inlet manifold 3.5


REMOVING


Working from above the vehicle remove:- the air filter assembly with trunking,- the connector for the flamstart solenoid valve,- the fuel supply connection for the flamstart,- the manifold pressure information connec-

tion,- the air inlet tube on the turbocharger,- the mounting nuts for the inlet manifold.

Remove the inlet manifold (1) from underneath

the vehicle.

PRF1201

S9W engine

REFITTING

Refit in reverse order to removal. (Always replaceseals and gaskets (2) on the inlet manifold with

new ones.)

NOTE: When refitting, make sure that all theconnections are correctly aligned and check thecondition of the copper seals.

12-8





DIESEL EQUIPMENT

Fuel cut-off on impact 13

AIM

The aim of this function is to avoid a fire after anaccident due to a fuel leak. To accomplish this, all

components which pump fuel from the fuel tankmay only be started again by a reset procedureperformed by the driver or repair mechanic.

DESCRIPTION

The system consists of an inertia switch (whichmay be reset) which :- detects the impact (1),- cuts the electrical circuit.

13484R

It is fitted between the + feed and the fuel shutoff solenoid valve (or the coded solenoid valve if the vehicle is fitted with an engine immobiliser).

OPERATION

During the impact, the inertia switch ball leaves itsseat and breaks the electrical current at the +feed to the fuel shut off or the coded solenoidvalve .

The pump can no longer draw fuel. Any risk of fire from the high pressure diesel spray over theengine is removed.

RESETTING THE SWITCH AND SWITCH

OPERATION

To reset the inertia switch, press the top to reposi-tion the ball in its seat.

13-1



DIESEL EQUIPMENT

Specifications 13

Vehicles Gearbox

Engine

Type SuffixBore

(mm)

Stroke

(mm)

Capacity

(cc)

Compression

ratio

Catalytic

converter

Depollutionstandard

XD0C PF1 S9W 702 94.4 100 2799 19/1 C83 EU95

ENGINE SPEED (rpm)

Idling speed Max. - no load Max. - with load

SMOKE DENSITY

Homologation value Legal maximum

800 ± 25 4000 ± 100 3600 ± 100 1.52 m -1 (46 %) 3 m -1 (71 %)

DESIGNATION MAKE/TYPE SPECIAL NOTES

Injection pump BOSCHVE 4/12 F1800 R721

VE 4/12 F1800 R713-1

Rotary pump with cold start solenoidincorporating thermo switch (KSB).

Pump timing obtained by 8 mmdiameter TDC pin (Mot. 1054) - Pump piston lift: 1.1 ± 0.02 mm.

Injector holders KBEL 110 P 140 Tightening torque of injector nut to injectorholder :4.5 daN.m.Tightening torque of injector holder to cylinderhead:4 daN.m.

Injectors BOSCHDSLA 134 P604

Checking: 240 bars

Max.variation in pressure: 8 bars

Fuel filter-

Separate priming pump.The filter is fitted with an electric fuel heater.

Fuel pipes - Internal diameter: 1.85 mmLength: 470 mm

Cold start solenoid (KSB) - Resistance: 5 Ω Waxstat format

FLAMESTART cold start system(with solenoid valve control) -

Igniter coil resistance: 0.2 Ω

Solenoid valve resistance: 8 Ω

Turbocharger "GARETT" GT 17 Calibration:1100 ± 33 mbar for a rod travel of

1±

0.02 mm1220 ± 66 mbar for a rod travel of 4 ± 0.02 mm

+8- 5

13-2



DESCRIPTION MAKE/TYPE SPECIAL NOTES

Injection pump BOSCHVE 4/10 F2100 R717-1VE 4/10 F2100 R725-1

Rotary pump with:

- a cold start solenoid with thermo switch (KSB),- a postheating cut-off microswitch.

Pump timing obtained by 8 mmdiameter TDC pin (Mot. 1054) -

Pump piston lift: 0.97 ± 0.02 mm.

Injector holders KBE 5858 Tightening torque for injector nut to holder:8 daN.m.Tightening torque for injector to cylinder head:4 daN.m.

Injectors BOSCHDNOSD 301

Checking : 120 bars

Max. variation in pressure : 8 bars

Fuel filter-

Separate priming pump.The filter is equipped with an electrical fuelheater.

Fuel pipes-

Internal diameter: 2 mmLength: 520 mm cylinders 1 and 4

460 mm cylinders 2 and 3

Preheating unit - With pre-postheating function and advance

solenoid valve control.Plugs BERU Resistance: 0.2 Ω

Tightening torque: 2.5 daN.m

Cold start solenoid (KSB) - Resistance: 5 Ω Waxstat format

DIESEL EQUIPMENT

Specifications 13

Vehicles Gearbox

Engine

Type SuffixBore

(mm)

Stroke

(mm)

Capacity

(cc)

Compression

ratio

Catalytic

converter

Depollutionstandard

XD0A PF1 S8U 770 93 92 2499 22/1 217 (1) EU95

ENGINE SPEED (rpm)

Idling speed Max. - no load Max. - with load

SMOKE DENSITY

Homologation value Legal maximum

800 ± 25 4600 ± 100 4200 ± 100 1.60 m -1 (48 %) 2.5 m -1 (64 %)

+8- 5

(1) Non-impregnated catalytic converter

13-3



DIESEL EQUIPMENT

BOSCH coded solenoid valve 13

The operation to remove the screening whichgives access to the coded solenoid valve and thefuel shut off device must be performed with thepump in situ on the engine


Mot. 1372 Kit for removing self-shearing boltson coded solenoid valve

REMOVING

Remove:- air filter,- air duct,

- sound-deadening material on engine,- high-pressure diesel pipes (use tool Mot.

1383),- oil decanter.

10578R

13-4



DIESEL EQUIPMENT


99780G3

Remove coded solenoid valve (16). To do this:- Fit drilling tube (17).- Drill the two bolts using a 4 mm dia. bit (9) from kit Mot. 1372 (drilling depth approximately 4 mm).

We recommend that you lubricate the drill bit lightly to make the drilling operation easier:- Use extractor (10) and the corresponding handle to remove the bolts.- Remove the coded solenoid valve unit (16).

13-5



DIESEL EQUIPMENT


REFITTING

Tighten the nut securing the electric wire on the fuel shut off solenoid valve to a torque of 0.2 daN.m.

Take care to remember to replace the plastic cover on the solenoid valve nut.

Use self-shearing bolts to replace the bolts you have drilled out (can be obtained from the Parts Department).

Tighten the self-shearing bolts until the heads shear off.

Carry out other refitting operations in reverse order to removal.

IMPORTANT: The coded solenoid valve electronics are supplied uncoded. It is therefore necessary to programthe solenoid valve with the engine immobiliser code when it is installed.

To do this, carry out the following operations:

• Switch on the ignition using the coded vehicle key for a few seconds.

• Switch off the ignition. Programming of the engine immobiliser function will be complete after approxi-mately 10 seconds. (The engine immobiliser warning light will flash.)

NOTE: It is possible to check the engine immobilisation function by using the XR25 (code D56) :

- With the ignition switched off, wait for the red warning light to move to a slow flashing mode. Entercommand G04* with the ignition still switched off. (The passive protection mode bar graph will illumi-nate.)

- Switch on the ignition. The red engine immobiliser warning light will flash more rapidly and it should beimpossible to start the vehicle.

13-6





DIESEL EQUIPMENT

Cold start device (KSB) 13

OPERATION OF S9W ENGINE

Ignition off

The Waxstat is not energised and therefore notreleased.

The cold advance is active.

When the ignition is switched on

If the coolant temperature is greater than 6°C, theWaxstat is energised.

If the temperature is below 6°C, the Waxstat is notenergised from the time the ignition is switchedon to the end of the starting phase (disappea-rance of starter information).

Once the starting phase is complete, the Waxstatis not energised for a maximum of 10 minutes; af-ter this time it is energised.

If the coolant temperature exceeds 6°C before10 minutes have elapsed, the Waxstat is suppliedwith power directly.

When the Waxstat is energised, it heats the waxand progressively reduces the advance over seve-ral minutes. (The heat from the engine adds to theprocess).

When the ignition is switched off

The Waxstat is not electrically energised. It is stillreleased advance lever in hot position). It returnsto its initial position as a function of the decreasein engine temperature.

NOTE :

- If the coolant temperature information isincorrect, the Waxstat is energised 10 minutesafter completion of the starting phase.

- If the starter information is incorrect, theWaxstat is energised 1 hour after + after igni-tion appears.

13-8



DIESEL EQUIPMENT

Cold start device (KSB) 13

ADJUSTING the Waxstat operating link

The cold start device is matched to the pump. If any work has beenperformed on the pump, check that the lever (1) rests on the plastic ring

(2).

13478R

13-9





DIESEL EQUIPMENT

Cold start device (KSB) 13Warm up the engine or provide a 1+12V feed to the Waxstat for10 minutes.

Check:- that lever (1) makes contact with stop (4),

- that clearance (Y) between tube holder (5) and lever (1) is between 1and 3 mm.

13478-1R

13-11



DIESEL EQUIPMENT

Heating the inlet air 13

Igniter coil resistance : 0.2 Ω

Solenoid valve resistance : 8 Ω

13483R

SYSTEM FOR HEATING THE INLET AIR

(FLAMSTART)

The device consists of:

- a diesel solenoid valve (1),- a diesel igniter (2),- a coolant temperature sensor (3),- a preheating unit (4),- a warning light on the instrument panel.

LOCATION OF COMPONENTS

13486R

S9W engine

13487R

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

Air temperature sensorCTN typeResistance en ohms

7470to

11970

3060to

4045

1315to

1600

300to

370

210to

270

13-12



DIESEL EQUIPMENT


PRINCIPLE

This system is also called FLAMESTART.

The purpose of this system is to heat the inlet air by igniting diesel in the inlet manifold. To do this,a solenoid valve directs diesel on to an incandes-cent filament (igniter) at a pressure of 0.2 bar.

If a fault is detected, the preheating unit causesthe warning light to flash on the instrument panelfor a minimum of 5 seconds.

DESCRIPTION

The device consists of:- an igniter supplied with + 12 volts via track 8

of the preheating unit,- a solenoid valve supplied with + 12 volts via

track 8 of the preheating unit,- a postheating computer.

OPERATION

This system is used to heat inlet air during coldstarting. It operates if the coolant temperature isless than 5°C and if the battery voltage is more

than 9 volts

If these conditions are not present, the preheatingwarning light illuminates for 2 seconds and thenextinguishes.

Preheating phase

When the ignition is switched on, the igniter andthe solenoid valve are supplied with power for aperiod ranging from 15 to 56 seconds, dependingon battery voltage.

The warning light remains permanently illumina-ted.

After this timed period, the warning light will ex-tinguish and the driver has 20 seconds to start theengine.

The igniter and the solenoid valve are suppliedwith power for this 20 second period.

When 20 seconds have elapsed, the warning lightremains extinguished and the FLAMSTART hea-ting system is inhibited. The driver can still startthe engine but without the assistance of the inletair heating system.

S9W engine

13-13



DIESEL EQUIPMENT


Starting phase

The igniter and the solenoid valve are suppliedwith power during this phase, except if the hea-

ting system is in an inhibited mode (as describedabove).

The warning light is extinguished.

Postheating phase

The igniter and the solenoid valve are suppliedwith power during this phase. The warning light isextinguished.

The postheating operates for a period of up to140 ± 15 seconds at the end of the preheatingphase if the ambient temperature is - 30°C and fora period of 25 seconds if the ambient tempera-ture is = 0°C. (There is no postheating for tempe-rature of > 5°C.)

NOTE: If the coolant temperature sensor isdefective:- the warning light will illuminate steadily

when the ignition is switched on and thenflash during the preheating phase;

- postheating is set at 170 seconds; the warninglight remains extinguished during this phase.

S9W engine

KEY TO THE WIRING DIAGRAM

104 Ignition switch244 Coolant temperature sensor

247 Instrument panel warning light257 Preheating unit260 Fuse box404 Advance solenoid valve597 Engine fuse box892 Solenoid valve893 IgniterAVC Before ignitionAPC After ignition

ALLOCATION TO COMPUTER TRACKS

1 Coolant temperature sensor information2 + 12 volts + before ignition3 Control for preheating warning light4 + 12 volts after ignition5 Not used6 Earth7 Starter information8 Igniter and solenoid valve control9 Advance solenoid valve control

13-14



DIESEL EQUIPMENT

Heating the inlet air 13S9W engine

PRF13400

OPERATIONAL WIRING DIAGRAM

13-15



DIESEL EQUIPMENT

Heating the inlet air / Fault finding 13S9W engine

CHECKING OPERATION

Note :Before commencing the check : If the preheating warning light flashes after a few seconds of steady

illumination to indicate the preheating phase, look for a fault in the engine coolant temperature sensorcircuit (white connector).

Function / componentto check

Actions / Testconditions

Customer complaint / checking values

Remedy

1Operation of

preheating warninglight.

Switch on ignition.Steady illumination of the warning light for aminimum of 2 seconds.

Check the control unitsupport to ensure thattrack 6 is earthed and

+after ignition issupplied to track 4

(20 A fuse for"stopping engine" in

fuse/relay box).

Ensure that there iscontinuity betweentrack 3 of the unitsupport and the

warning light. Checkcondition of bulb.

2

Circuit for solenoidvalve and diesel igniter

-Detection of

temperature sensorfault.

Switch off ignition.-

Disconnect coolanttemperature sensor(white connector).

-Switch on ignition.

(The voltage on thesolenoid valve and thediesel igniter should be

checked within 40seconds of the ignition

being switched on.)

Steady illumination of the warning light for aminimum of 2 secondsand then flashing forapprox. 25 seconds.

Check for the presenceof +Bat on the

solenoid valve and thediesel igniter and that

there is no voltagesupplied to the coldstart device (KSB)


solenoid valve and thediesel igniter.

Ensure that +beforeignition is present at

track 2 of the unit

support (70 A fuse inengine interconnectionunit).

3"Starting engine

information" circuit.

Switch off the ignition.-

Switch on the ignition.-

Wait for at least5 seconds after thestart of the flashing

phase.-

Attempt to startengine

The flashing shouldstop as soon as thestarter is activated.


"starting" position onthe ignition switch.

13-16



DIESEL EQUIPMENT

Heating the inlet air / Fault finding 13S9W engine

Supplementary checks

- Resistance of diesel igniter filament : R = approx. 0.2 ohms.

- Resistance of diesel solenoid valve : R = 8 ± 1 ohms.

- Cold start solenoid valve resistance : R = 6 ± 1 ohms.

Function /componentto check

Actions / testconditions

Customer complaint/ checking values

Remedy

4

Return to normaloperation of



Reconnect coolanttemperature sensor.


Steady illumination of warning light for a

minimum of 2 seconds.See point no. 1.

5Cold start device circuit

(KSB)

Engine started up.-

Wait, if necessary, forthe coolant

temperature to riseabove 6°C.

Check that +Bat ispresent at the solenoid

valve (cold start

function cancelled).

Ensure that there iscontinuity betweentrack 9 of the unit

support and thesolenoid valve.

13-17



DIESEL EQUIPMENT

Pre-postheating unit 13

13483R

13485R

S8U engine

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

Air temperature sensorCTN typeResistance in ohms

7470to

11970

3060to

4045

1315to

1600

300to

370

210to

270


Pre-postheating unit (1)

Postheating microswitch (2)

98162-1R

The postheating microswitch (2) is mounted onthe pump.

Coolant temperature sensor (3)

SPECIFICATIONS

13-18



DIESEL EQUIPMENT

Pre-postheating unit 13

PRINCIPLE OF OPERATION FOR PRE-POST

HEATING

1. "Preheating" when the ignition is turned on

a) Variable preheating

The time period during which the warninglight is illuminated and the heater plugsare fed is dependent on the coolanttemperature.

3. "Postheating" while the engine is running

Postheating has two phases:

a) Fixed postheating

After the engine has been started, theplugs are fed for 10 seconds.

b) Variable postheating

Variable postheating begins when fixedpostheating has ended.

During this phase the plugs are fedaccording to coolant temperature.

If the coolant temperature sensor is faulty,the heater plugs are fed systematically for12 seconds.

b) Fixed preheating

After the preheating warning light hasextinguished (variable preheating) theplugs remain fed for up to 8 seconds.

2. Starting

The plugs remain fed while the starter isactivated.

If the coolant temperature sensor is faulty,the heater plugs are always fed for 170seconds.

Variable postheating may be interrupted- completely when the coolant

temperature is > 40°C,- momentarily when the unit receives

full load information (postheatingmicroswitch opens) for more than3 seconds; postheating begins againwhen the engine returns to idle speedor low load (microswitch closes).

S8U engine

13489S

13490S

13-19





DIESEL EQUIPMENT

Pre-postheating unit 13S8U engine

PRF13401

WIRING DIAGRAM

13-21



DIESEL EQUIPMENT

Pre-postheating unit / Diagnostic 13S8U engine

CHECKING OPERATION

Function / component

to check

Actions / test

conditions

Customer complaint /

checking valuesRemedy

1Operation of

preheating warning

light.

Switch on ignition.Steady illumination of

warning light for a

minimum of 2 seconds.

Check 9-trackconnector of pre-post-heating unit to ensuretrack C2 is earthed and+after ignition is pre-sent at track B1 (20 A

engine fuse infuse/relay box). Checkthat +before ignition

is present at unit powerterminal (70 A fuse inengine interconnection

unit). Ensure there iscontinuity betweentrack B3 of 9-track

connector and warninglight. Check condition

of bulb.

2

Heater plugs circuit.-

Cold start device circuit(KSB)

-Detection of

temperature sensorfault

Switch off ignition.

-Disconnect coolanttemperature sensor(white connector).


(The voltage at theplugs must be checked

within 20 seconds of the ignition being

switched on.)

Steady illumination of warning light for

12 seconds.

Check presenceof +Bat at heater

plugs and at cold startdevice (KSB).

Ensure there iscontinuity between

tracks 1 and 2 of 2-track connectorsupplying heater plugs

and plugs (track 1:cylinders 2 and 4; track

2: cylinders 1 and 3).

Ensure there iscontinuity between

track C1 and cold startdevice. If necessary,

check coolant

temperature sensorcircuit.

3

"Engine startinginformation" circuit.

-Postheating

microswitch circuit(continuity).


Switch on the ignition.-

Wait for at least20 seconds

(preheating).-

Attempt to startengine.

Check presence of +Bat at heater plugs

(3 minutespostheating).

If there is nopostheating, checkcontinuity betweentrack B2 of 9-track

connector and"starter" position of

ignition switch.

If +Bat is only present

for 10 seconds, checkcontinuity of preheating

microswitch circuit.

13-22



DIESEL EQUIPMENT

Pre-postheating unit / Diagnostic 13S8U engine

Supplementary checks

- Cold start device resistance : R = 6 ± 1 ohms.

- Operation of postheatingmicroswitch : Make sure that the contact opens at approximately half throttle on

the fuel pump lead lever.

Function / componentto check

Actions / testconditions

Customer complaint/ checking values

Remedy

4

Circuit for postheatingmicroswitch (earth

insulation).-

Registration of "pumplever position"

information.


Switch on the ignition.

Wait for end of preheating

(20 seconds).-

Attempt to startengine.

-Disconnect postheating

microswitch.

Check that +Bat ispresent at heater plugs before disconnection

and then that novoltage is present3 seconds afterdisconnection.

Ensure insulation toearth of connection between track B of

microswitch connectorand track A2 of 9-track

unit connector.

5

Return to normaloperation of



Reconnect coolanttemperature sensor

and microswitch.-

Switch on ignition.

Steady illumination of warning light for a

minimum of 2 seconds.

See point no. 1.

13-23





DIESEL EQUIPMENT

Microswitch 13S8U engine

98162-1R1


REMOVING

Undo the two mounting screws to remove theswitch.

The microswitch (1) cannot be adjusted.

13-25



DIESEL EQUIPMENT

Fuel filter 13


1 Fuel filter2 Electric heater (resistance 1.2 Ω)3 Hand priming unit

The electric diesel fuel heater and the thermostatare integral in the head of the filter.

Operating temperature

The heater operates if the diesel temperature isless than 2°C. The feed is cut if the temperature isgreater than 20°C.

13484R1

13-26



DIESEL EQUIPMENT

Fuel filter 13

REMOVAL - REFITTING (Special notes)

To remove the filter assembly use toolMot. 1311-06 for the quick release unions.

When refitting, refit the quick release unions byhand and ensure they click back together correctly(two O-rings ensure sealing).

99461R

13-27



DIESEL EQUIPMENT

Pump 13

REMOVING


Disconnect the battery

Remove:- the guard under the engine,- the air filter,- the sound-deadening material in the engine

compartment,- the high-pressure pipes (use tool Mot. 1383).

Disconnect the electrical connections to the ad-vance solenoid valve.

Disconnect the diesel pump solenoid valve or thecoded solenoid valve.

Remove:- the oil decanter,- the stud securing the wiring harness (moun-

ted on the engine behind the pump).

Disconnect:- the diesel delivery and return pipes,- the accelerator cable,- the diesel return pipe leading from the injec-

tors.

• On the S9W engine, disconnect:- the pipe on the pump leading to the tur-

bocharger compensator,- the diesel pipe leading to the

FLAMESTART solenoid valve.

• On the S8U engine:- Disconnect the postheating microswitch

connector.- Take off the vacuum pump.

• On all types of engine, remove:- the three nuts securing the pump (use tool

Mot. 909-02 to unscrew the lower nut)and then pull it out,

- the hub with the help of an extractor(tightening torque 5 daN.m). Keep the key

to use again. (There are two types of hub -a short hub and a long hub.)


Mot. 909-02 12-sided wrench for removinginjection pump mounting

Mot. 1383 Spanner for removing high-pressure pipe

MS801359S1

Pump mounting nut 2.5

TIGHTENING TORQUES (en daN.m)

REFITTING

Fit the pump in place.

Set the pump timing (see section 13 "Pumptiming").


13-28



DIESEL EQUIPMENT

Pump timing 13

ATTENTION: When carrying out checking ortiming adjustment, the engine should only beturned in the direction of rotation. (If you turn theengine in the opposite direction during thisoperation, repeat the procedure right from thestart.)

OPERATION TO CARRY OUT BEFORE PERFORMING

CHECKING OR TIMING OPERATIONS


Remove:- the air filter,- the sound-deadening mat in the engine

compartment,- the high-pressure pipes,- the guard under the engine,- the oil decanter.

Disconnect the KSB/advance lever connection.(Undo bolt (1).)


Mot. 856 Dial gauge holder

Mot. 909-02 12-sided wrench for removing injectionpump mounting

Mot. 997 Socket for removing injection holder

Mot. 1054 TDC pin

Mot. 1383 Wrench for removing high pressure tube

13478R1

Pump mounting nut 2.5


13-29



DIESEL EQUIPMENT

Pump timing 13

13481R

CHECKING TIMING

Screw in dial gauge holder Mot. 856 in place of plug (2).

Secure the gauge on the gauge holder.

13480R

Turn the engine twice in the direction of rotation.

Zero the gauge to BDC on the injection pump pis-ton.

Set the engine with tool Mot. 1054. To do this:- Turn the engine in the direction of rotation

(clockwise on timing gear side).- Watch until the mark on the camshaft pulley

appears.- Stop turning the engine until it is half a notch

before the two marks align.

MS801354R

Fit pin Mot. 1054.

13482R

13-30



DIESEL EQUIPMENT

Pump timing 13

Apply pressure to pin Mot. 1054.

Turn the engine slowly until the pin engages inthe notch on the flywheel.

Read the pump piston lift as registered on thegauge.

The value should be:- 1.1 ± 0.02 mm for engine S9W 702,- 0.97 ± 0.02 mm for engine S8U 770.

If the value is not correct, adjust the timing (see below).

ADJUSTING INJECTION PUMP TIMING

Slacken off the three bolts securing the pump.

Fit the dial gauge if this has not already beendone.

Turn the engine twice in the direction of rotation.

Zero the dial gauge to BDC on the injection pumppiston.

Turn the pump towards the engine so that theoblong holes make contact with the screws. This isto allow the entire setting range to be used.

Immobilise the engine using tool Mot. 1054 (me-thod described in the section on "Checking pumptiming").

Turn the pump so that the timing value can beread off the dial gauge:- 1.1 ± 0.02 mm for the S9W 702 engine,- 0.97 ± 0.02 mm for the S8U 770 engine.

ATTENTION: If you exceed the timing value as youturn the pump, readjust so that the oblong holesmake contact with the screws and then repeat thetiming operation from the beginning.

Tighten the pump mounting bolts.

Remove the timing pin Mot. 1054.

Check the timing.

Carry out the other refitting operations in reverseorder to removal.

Do not forget to reactivate the cold start deviceKSB (see the section on the"Cold starting de-vice").

13-31



DIESEL EQUIPMENT

Adjustments 13

COLD START DEVICE (KSB) ADJUSTMENT

Cold engine

Check dimension (X).

Fit a shim (Z) between the idling screw (B) and theload lever (E).

Undo ball joint (R) and move the ball joint so thatit makes contact with the load lever (E). Then tigh-ten the ball joint.

Warm engine

Check:- that lever (C) makes contact with stop (G),- that there is clearance (Y) of between 1 and 3

mm between lever (C) and cable grip (2).

S8U engine

13488R

Dimensions (X) and (Z) depend on the temperature of the cold start device (KSB).

Cold start device (KSB)temperature

(in °C)

Dimension (X)(in mm)

Dimension (Z)(in mm)

18

2225303540

6.5

5.95.54.75

43.25

5.5

4.53.72.51.20

13-32



DIESEL EQUIPMENT

Adjustments 13

CHECKING IDLING SPEEDS (version with AC)

First adjust the cold starting device (KSB).

With the engine warm:

A Checking idling speed

Check if the engine speed is 800 ± 25 rpm.

COMMENT: If the speed is not correct,complete adjustment will be necessary (see E).

B Checking the residual flow

Check the residual flow if the idling speed is800 ± 25 rpm. To do this, place a 2 mm shim between the stop screw (2) and the load lever(accelerator) (6). The speed should increase by70 ± 30 rpm.

If the increase in speed is greater than 100rpm, the complete adjustment procedure is re-quired (see method "E").

If the increase in speed is less than 40 rpm, on-ly the short adjustment procedure is required

(see method described in point "d" of "E").

C Checking fast idling speed

Position lever (4) so that it makes contact withstop (5).

Check that the fast idling speed is 875 ± 25rpm. If it is not, perform the adjustment pro-cedure described in method "F".

D Checking the position of the fast idling cablegrip

Check that the cable and the cable grip are inthe correct position.

Hold the cable taut; lever (4) is in rest position(at idling).

Check that cable grip (1) is distance X > 1 mmfrom lever (4) (lever (4) in contact with screw(3)). If this is not the case, carry out the

adjustment procedure described in method"G".

S8U engine

ADJUSTING IDLING SPEED (version without AC)

First adjust the cold start device (KSB).

Warm up the engine.

Check the idling speed: 800 ± 25 rpm.

If adjustment is required, slacken off the lock nut,adjust the engine idling speed by moving screw(B) and tighten the lock nut again. Lever (E)should make contact with screw (B).

98347R2

13-33



DIESEL EQUIPMENT

Adjustments 13

F Adjusting fast idling

Position lever (4) so that it makes contact withthe stop screw (5).

Slacken off the lock nut on screw (5) thenmove screw (5) to obtain a speed of 875 ±

25 rpm.

Release lever (4).

Tighten the lock nut on screw (5).

Check the fast idling speed .

If the fast idling speed is outside tolerance, re-peat the operation.

G Adjusting the position of the fast idling cablegrip

This adjustment must be carried out under thesame conditions as adjustment operations onthe engine (engine warm).

Hold the cable so that it is taut.

Undo the cable grip (1). Check that the lever(4) is making contact with screw (3) (vehicle atidling speed).

Position the cable grip so that it is between 1and 3 mm from the lever (4).

Retighten the cable grip.

NOTE: Adjust the accelerator damper and thencheck the adjustment of the cold starting device(KSB) again.

S8U engine

ADJUSTING IDLING SPEEDS (version with AC)


With the engine warm.

E Adjust the idling speed and the residual flow

a Slacken off the lock nut on screw (2) andturn the screw (2) enough to until theidling speed stops falling. Then slacken off the screw by two additional turns. (Checkthat the cable grip does not prevent thelever from moving (4).)

b Adjust the idling speed to 800 rpm,slacken off the lock nut for screw (3) andturn screw (3) to obtain an idling speed of 800 rpm.

c Fit a 2 mm shim between the stop screw(2) and the load lever (accelerator) (6) (di-mension Y).

COMMENT: The idling speed should notincrease once the shim has been fitted. If this is not the case, repeat the procedure

(methods "a" and "b"), slackening off thescrew (2) slightly more.

d Tighten screw (2) until an increase in theidling speed of 70 ± 30 rpm is obtained.Tighten the lock nut on screw (2). Removethe 2 mm shim and check if the idlingspeed is as it was originally.

Accelerate sharply 3 or 4 times and allowthe engine to return to idle.

Check the idle speed is consistent anddoes not vary between accelerations.Check the idling speed again + 70 rpmusing a 2 mm shim. If these two opera-tions are not satisfactory, repeat the adjustment (method "c").

13-34



DIESEL EQUIPMENT

Adjustments 13

1 Cable grip

98154R1

S8U engine

13-35





DIESEL EQUIPMENT

Adjustments 13S9W engine

With the engine warm

Check:- that lever (C) is in contact with stop (G),- that there is clearance (Y) of between 1 and 3 mm between lever (C)

and cable grip (2).

13478-1R1

13-37



DIESEL EQUIPMENT

Adjustments 13

ADJUSTING IDLING SPEED (version with AC)

First adjust the cold start device (KSB).


A Checking idling speed

Check if the engine speed is 800 ± 25 rpm.

COMMENT: If the speed is not correct, thecomplete adjustment procedure must be car-ried out (see "E").

B Checking residual flow

If idling speed is 800 ± 25 rpm, check the resi-dual flow. To do this, place a 2 mm shim bet-ween the stop screw (2) and the load lever (ac-celerator) (6). The speed should increase by330 ± 30 rpm.

If the increase in speed is greater than 360rpm, the complete adjustment procedure is re-quired (see method "E").

If the increase in speed is less than 300 rpm,

only the short adjustment procedure is requi-red (see method described in point "d" of "E").

C Checking fast idling speed

Position lever (4) so that it makes contact withstop (5).

Check that the fast idling speed is 875 ± 25rpm. If it is not, perform the adjustment pro-cedure described in method "F".

D Checking the position of the fast idling cablegrip

Check that the cable and the cable grip are inthe correct position.

Hold the cable taut; lever (4) is in rest position(on idling).

Check cable grip (1) is distance X > 1 mm

from lever (4) (lever (4) in contact with screw(3)). If this is not the case, carry out theadjustment procedure described in method"G".

S9W engine

ADJUSTING IDLING SPEED (version without AC)

With the engine warm

Check that lever (E) makes contact with stop (B).After slackening off the lock nut, turn screw (B)until a speed of 800 ± 25 rpm is obtained.

98345R

13-38



DIESEL EQUIPMENT

Adjustments 13

F Adjusting fast idling

Position lever (4) so that it makes contact withthe stop screw (5).

Slacken off the lock nut on screw (5) then turnscrew (5) to obtain a speed of 875 ± 25 rpm.

Release lever (4).

Tighten the lock nut on screw (5).

Check the fast idling speed .

If the fast idling speed is outside tolerance, re-peat the operation.

G Adjusting the position of the fast idling cablegrip

This adjustment must be carried out under thesame conditions as adjustment operations onthe engine (engine warm).

Hold the cable so that it is taut.

Undo the cable grip (1). Check that the lever

(4) is making contact with screw (3) (vehicle atidling speed).

Position the cable grip so that it is between 1and 3 mm from the lever (4).

Retighten the cable grip.

NOTE: Adjust the accelerator damper and thencheck the adjustment of the cold starting device(KSB) again.

S9W engine

ADJUSTING IDLING SPEEDS (version with AC)



E Adjust the idling speed and the residual flow

a Slacken off the lock nut on screw (2) andturn the screw (2) enough to stop theidling speed falling. Then slacken off thescrew by two additional turns. (Check thatthe cable grip does not prevent the leverfrom moving (4).)

b Adjust the idling speed to 800 rpm,slacken off the lock nut for screw (3) andturn screw (3) to obtain an idling speed of 800 rpm.

c Fit a 2 mm shim between the stop screw(2) and the load lever (accelerator) (6) (di-mension Y).

COMMENT: The idling speed should notincrease once the shim has been fitted. If this is not the case, repeat the procedure

(methods "a" and "b"), slackening off thescrew (2) slightly more.

d Tighten screw (2) until an increase in theidling speed of 330 ± 30 rpm is obtained.Tighten the lock nut on screw (2). Removethe 2 mm shim and check if the idlingspeed is as it was originally.

Accelerate sharply 3 or 4 times and allowthe engine to return to idle.

Check the idle speed is consistent anddoes not vary between accelerations.Check the idling speed again + 330 rpmusing a 2 mm shim. If these two opera-tions are not satisfactory, repeat the adjustment (method "c").

13-39



DIESEL EQUIPMENT

Adjustments 13

1 Cable grip

98154R1

S9W engine

13-40



DIESEL EQUIPMENT

Adjustments 13

99914R1

ADJUSTING THE ACCELERATOR DAMPER BALL

JOINT LINK

When the above adjustments have been made,

the length of the accelerator damper must be adjusted.

With engine warm

Position the paint mark as shown below.

If adjustment is required, move the upper ball joint (A).

X = 2 mm.

13-41



STARTING - CHARGING

Alternator 16

CHECKING

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

OPERATION - FAULT FINDING

These vehicles are fitted with alternators with in-ternal ventilation, an integral regulator and awarning light on the instrument panel which ope-rates as follows:- when the ignition is turned on, the warning

light illuminates,- when the engine starts, the warning light ex-

tinguishes,- if the warning light illuminates again when

the engine is running, there is a "charging"fault.

LOOKING FOR FAULTS

The warning light does not illuminate when theignition is turned on.

Check:- the electrical connections are correct,- the bulb is not blown (to do this, earth the cir-

cuit; the bulb should illuminate).

The warning light illuminates when the engine isrunning

There is a charging fault which could be due to:- the alternator drive belt being broken or the

charging cable being cut,- internal damage to the alternator (rotor, sta-

tor, diodes or brushes),- regulator fault,- excess voltage.

The customer complains of a charging fault and

the warning light operates correctly.

If the voltage is less than 13.5 V, check the alterna-tor. The fault could be caused by:- a destroyed diode,- a cut phase,- track contamination or wear.

Engine rpm 75 amps 100 amps

1500 22 26

2000 46 57

4000 68 94

CHECKING THE VOLTAGE

Connect a voltmeter across the battery terminalsand read the battery voltage.

Start the engine and increase the engine speeduntil the voltmeter needle stabilises at the regula-ted voltage.

This voltage should be between 13.5 V and 14.8 V.

Connect as many consumers as possible. The regu-lated voltage should remain between 13.5 V and14.8 V.

IMPORTANT: If arc welding is carried out on thevehicle, the battery and the alternator must bedisconnected.

16-1



STARTING - CHARGING

Alternator 16

REMOVING



Remove the guard under the engine.

Disconnect the alternator.

Undo bolt (1).

Slacken off both bolts (2).


Mot. 1273 Tool for testing belt tension

13458R

Take off the accessories belt.

Remove the upper and lower studs securing thealternator and then release the alternator by mo-ving it towards the rear of the vehicle.

REFITTING


To tension the accessories belt, see section 07 on"Tensioning the accessories belt".

16-2



STARTING - CHARGING

Starter motor 16

REMOVING



Remove :- the air filter unit and the air filter intake duct,- the heat shield for the starter motor, if one is

fitted.

13454S

Disconnect the starter motor.

Remove the three mounting bolts for the startermotor.

REFITTING


Engine Starter motor

S8U - S9WMITSUBISHI

M002T87671

16-3



COOLING

Specifications 19

COOLANT CAPACITY AND TYPE

Engine Volume (in litres) Grade Special notes

S8U 7

S9W 7

GLACEOL RX Type D

Use coolant only

Protection down to - 20°C ± 2°Cfor hot, temperate and coldcountries.Protection down in - 37°C ± 2°Cfor extremely cold countries.

19-1



COOLING

Filling - bleeding 19

There is no water control valve.

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

FILLING

The following bleed screw must be opened onthe S9W engine :

On the upper radiator hose.

Both engines :Fill the circuit at the expansion bottle opening.

Close the bleed screw as soon as the fluid runs outin a continuous jet.

Start the engine (2500 rpm).

Adjust the level by overflow for approximately4 minutes.

Close the expansion bottle.

BLEEDING

Let the engine run for 20 minutes at 2500 rpm,until the engine cooling fan operates (time requi-red for automatic degassing).

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

NEVER OPEN THE BLEED SCREW WHEN THE

ENGINE IS RUNNING.

TIGHTEN THE EXPANSION BOTTLE CAP WHEN THE

ENGINE IS WARM.

19-2



COOLING

Checking

2 - Checking rating of expansion bottle cap

If fluid passes through the expansion bottle capvalve, the cap must be replaced.

Adapt pump M.S. 554-07 to fit tool M.S. 554-06

and fit this to the valve to be checked.

Increase the pressure which should stabilise at thecalibration value for the cap valve, with a test to-lerance of ± 0.1 bar.

Valve rating value:

19

1 - Checking cooling circuit sealing

Replace the expansion bottle cap with tool M.S.

554-01.

Connect tool M.S. 554-07 to this.

Let the engine warm up then turn the ignition off.

Pressurise the cooling circuit using the pumpmechanism to a value of 0.1 bar less than theexpansion cap rating.

Stop pumping at 0,1 bar let than the rating valueof the expansion bottle cap.

The pressure should not drop. If it does, look forthe leak.

Slowly unscrew the union of tool M.S. 554-07 todecompress the cooling circuit, then remove toolM.S. 554-01 and refit the expansion bottle capfitted with a new seal.


M. S . 554-01 Adaptor for M.S. 554-05

M. S. 554-06 Adaptor for M.S. 554-05

M. S. 554-07 Kit for checking cooling circuit

sealing

97871R

Engine Valve colour Rating (in bar)

S9W - S8U Brown 1.2

19-3



COOLING

Diagram 19

1 Engine2 Radiator3 Expansion bottle with permanent degassing4 Heater matrix

Water pump

Thermostat

Temperature switch

13528R

S8U engine

19-4



COOLING

Diagram 19

1 Engine2 Radiator3 Expansion bottle with permanent degassing4 Heater matrix

Water pump

Thermostat

Bleed valve

Temperature switch

13527R

S9W engine

19-5



COOLING

Radiator temperature switch 19

REMOVING


Remove:- the air filter unit,- the trunking to the air filter unit,- the radiator temperature switch using a 29

mm pipe spanner.

REFITTING

Refitting is in reverse order to removal.

19-6



Engine cooling fan

COOLING

Radiator 19


REMOVING

Remove:- the air filter unit,- the intake trunking for the air filter unit,- the direction indicators,- the radiator grille,

13532S

12835S

- the bumper,- the shock absorbers,- the front cross member,- the upper radiator cross member,

- the plastic deflectors on the radiator.

Disconnect the radiator temperature switch.

Remove the upper and lower radiator hoses.

Remove the radiator mounting bolts.

REFITTING


Fill and bleed the cooling circuit (see section on"Filling and bleeding").

13531S

The radiator has to be removed to take out the fan(s).

19-7



COOLING

Cooling system 19


REMOVING

Remove:- the air filter unit,- the intake trunking for the air filter unit,- the direction indicators,- the radiator grille,

13532S

12835S

- the bumper,- the shock absorbers,- the front cross member,- the upper radiator cross member,

- the plastic deflectors for the radiator.

Disconnect the radiator temperature switch.

Remove:- the turbocharger pipes (if fitted),

- the upper and lower radiator hoses.

Disconnect the wiring harness from the coolingsystem.

Remove the two lower radiator mountings.

REFITTING


Fill and bleed the cooling system (see section on

"Filling and bleeding").

13531S

19-8



COOLING

Metal coolant pipe 19REMOVING THE METAL COOLANT PIPE AT THE

BACK OF THE ENGINE


REMOVING

Remove:- the air filter unit,- the intake trunking for the air filter unit- the air filter to turbocharger pipe.

Disconnect the hose from the pipe (between thepipe and the thermostat bracket).

Remove:

- the expansion bottle,- the hose (which connects at (1) on the pipe),

13451-1R

- the three pipe mounting bolts,- the pipe.

- the starter motor heat shield (if one is fitted),

13454S

Clean the gasket contact surface on the waterpump.

REFITTING


Fill up and bleed the cooling circuit (see section on"filling and bleeding").

13451-1R1

19-9



COOLING

Metal coolant pipe 19

REMOVING THE METAL COOLANT PIPE AT THE

FRONT OF THE ENGINE

Drive the vehicle on to a lift (minimum of 5

tonnes) or so that it is over a pit (on axle stands).


REMOVING

Remove:- the guard under the engine,- the air filter unit,- the intake trunking on the air filter unit,- the oil decanter,

13449S

- the lifting bracket (2).

Separate the two hoses (3) from the pipes.

Remove:- wiring harness bracket (4),- metal pipe retaining flange (5),- the oil filter,- the retaining clamps for the metal pipes on

the heat exchanger side,- the metal coolant pipes

REFITTING


Fill and bleed the cooling system (see section on"Refilling and bleeding").

13448R

- the two bolts (1) on the metal pipe retainer,

19-10



COOLING

Water pump 19



ESSENTIAL EQUIPMENT

Engine support

Bolts for sound-deadening tie rod 4.5

Bolts for suspended engine mounting

cover 4.5

Bolts for rubber pad on body 4.5

Bolts for water pump pulley 2




Remove :- the guard under the engine,- the accessories belt (see section 11 on

"Accessories belt"),- the bonnet air duct.

Affix straps to mount the engine support.

13297S

Remove:- the accoustic damper (tie rod) on the engine

support,- the suspended engine mounting (cover equip-

ped with rubber pad),

- the water pump pulley.

Compress the tensioner roller spring and fit a M14nut, cut to form a U-shape, at the back of the pis-ton.

85384-1S

19-11



COOLING

Water pump 19

Remove:- the upper mounting stud for the alternator,

then tilt the alternator towards the rear of thevehicle,

- the two nuts for securing the metal coolanttube (water pump side),

- the water pump mounting bolts.

13453S

REFITTING

Replace the water pump O-ring.

Apply one or two drops of Loctite FRENTANCH tothe water pump mounting bolts.


Refit the suspended engine mounting by tighte-ning the bolts for the rubber pad, the bolts for thecover and the bolts for the accoustic damper (tierod) to a torque of 4.5 daN.m.

Fill and bleed the coolant system (see section on"Filling and bleeding").

19-12





EXHAUST

Exhaust assembly 19

1 Catalytic converter2 Silencer and expansion chamber

S9W 702 engine

13340R

19-14



EXHAUST

Exhaust assembly 19

S8U 770 engine

1 Non-impregnated oxidising catalytic conver-ter

2 Expansion chamber3 Silencer

13341R

19-15



FUEL TANK

General 19

There are two types of fuel tanks for this vehicle: one with capacity of 70 litres (15.4 gallons) and anotherwith capacity of 100 litres (22 gallons).

The methods for removal and refitting are similar.

The tank is vented via a valve (1) mounted on the tank.

Another function of the valve is to prevent fuel spillage if the vehicle overturns.

PRF1902

19-16



Mot. 1265-01 Pliers for removing quick re-

lease unions

FUEL TANK

Fuel tank 19

IMPORTANT: During the complete removal andrefitting operation, do not smoke and keep allheat sources away from the working area.

DRAINING THE FUEL TANK



As there is no electric fuel pump on diesel vehicles,a pump must be used to drain the fuel tank.

For example, use an INTAIRCO pneumatic pump

(see EQUIPMENT catalogue).

ESSENTIAL EQUIPMENT

INTAIRCO, pneumatic pump for draining the fuel

tank (see EQUIPMENT catalogue).


12649R

Connect the pipe (1) to the pneumatic pump.

Drain the fuel tank.

99641S

Disconnect (under the vehicle) the quick releaseunion (1) which supplies fuel (Mot. 1265-01). Thecolour of the union is green.

19-17



FUEL TANK

Fuel tank 19

REMOVING

Disconnect the pipe (6) connecting the filler neckto the tank.

12645R

Fit a hydraulic jack (8) or a jack under the fueltank, depending on what is available.

Disconnect:- the electrical connector for the gauge (2),

- the diesel supply and return pipes (3).

12649R1

12648R

12643R

Remove the four screws (4) securing the twostraps (7) holding the tank.

19-18



FUEL TANK

Fuel tank 19

Lower the fuel tank slightly and then disconnectthe pipe (5).

12644R

Remove the fuel tank.

REFITTING

Proceed in reverse order to removal.

Take care not to compress the pipes (risk of aleak).

Fit the quick release unions by hand and ensurethey click together correctly.

19-19



FUEL TANK

Filler neck 19

Disconnect the rubber pipe (6) from the tank (7).REMOVING



Drain the fuel tank (see section 19 on the "Fueltank)".

Tilt the part marked (1) of the plastic protector (2).

12640R

Remove screw (3) and then unclip the plastic pro-tector (2).Remove the four screws (4) securing the filler neck(5).

12641R

12645R1

Release clamp (8) then extract the pipe (6).

Release clamp (9) then disconnect the rubber pipe

(10) from the filler neck.

12642R

Remove the filler neck by lifting it upwards, out of the vehicle.

REFITTING

To refit, work in reverse order to removal.

19-20



Mot. 1264-01 Wrench for removing pump -

sender unit

Mot. 1265-01 Pliers for removing quick

release unions (diesel engine)

FUEL TANK

Pump and sender unit 19


IMPORTANT : During all operations on the fueltank or fuel supply circuit, it is vital to:- avoid smoking and keep all heat sources

away from the working area,- take precautions against fuel splashes due to

the residual pressure in the fuel pipes whenthey are removed.

REMOVING

The fuel tank must be removed to take out thepump and sender unit assembly (see section onthe "Fuel tank").

Disconnect the electrical connector (1),

Remove clips (2).

97163R5

Using pliers Mot. 1265-01 disconnect:- the fuel supply pipe (3) (marked by a green

quick release union),- the fuel return pipe (4) (marked by a red quick

release union and an arrow (B)).

96420R4

19-21



FUEL TANK

Pump and sender unit 19

First fit the seal on the fuel tank before refittingthe assembly.

Fit the pump and sender unit (F), making sure that

the sender unit is correctly aligned.

Fit the nut and tighten it to a torque of 5.5 daN.m.

Clip the fuel pipes back together (pliers Mot.1265-01 do not need to be used).

Refit the safety clips (2).

Reconnect the electrical connector.

Refit the fuel tank.

ALLOCATION OF CONNECTOR TRACKS

TRACK ALLOCATION

A1 Earth

A2 Low fuel warning light

B1 Gauge information to instrument panel

B2 Not used

C1 Not used

C2 Not used

Remove mounting nut (5) using tool Mot. 1264-01(release the nut, remove the tool then unscrewthe nut by hand and remove it).

Remove the pump and sender unit assembly.

99367R

NOTE: If several hours are likely to elapse bet-ween removing and refitting the sender unit as-sembly, refit the nut to the fuel tank to prevent itfrom distorting.

REFITTING

Change the seal (6) and check that it is in the cor-rect position.

13334R

19-22



FUEL TANK

Gauge 19

CHECKING THE GAUGE SENDER UNIT

Ensure that the resistance varies by moving thefloat.

Display

Value between terminals

A1 and B1 (in Ω)

70 litres 100 litres

4/4 < 20 20 ± 4

3/4 40 ± 6 40 ± 6

1/2 68 ± 10 68 ± 10

1/4 109 ± 15 109 ± 15

Minimum 235±

15 235±

15

Display

Height H (in mm)

70 litres 100 litres

4/4 121 28

3/4 179 103,5

1/2 206 192

1/4 244 235

Minimum 283 288

Measuring the height H

With the gauge sender unit removed, place it on a

flat surface.

H is the height measured between the float pinand the seal contact surface (upper part of thegauge, connection between the fuel tank and thegauge).

NOTE: These values are given for informationonly.

19-23



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Renault master repair manual

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