Renault master repair manual

Engine and peripherals ENGINE AND PERIPHERALS TOP AND FRONT OF ENGINE TURBOCHARGING DIESEL EQUIPMENT STARTING - CHARGING COOLING - EXHAUST SYSTEM FUEL TANK - ENGINE MOUNTING

FD0A - FD0C - UD0A - UD0C

77 11 195 441

AUGUST

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

1997

Edition Anglaise

All copyrights reserved by Renault.

The methods may be modified as a r esult of changes by the manufacturer in the production of the various component units and accessories from which his vehicles are constructed".

C

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

Renault 1997

EXPLODED VIEW

PRF1006

EXPLODED VIEW

PRF1006

Engine and peripherals Contents

Pages ENSEMBLE AND MOTEUR PERIPHERALS ET BAS 10 ENGINE

Oil pressure Engine - Gearbox

Pages

16 STARTING - CHARGING 10-1 10-2

11 TOP AND FRONT OF ENGINE

Alternator Starter motor

16-1 16-3

SYSTEM ENSEMBLE- EXHAUST MOTEUR ET BAS - FUEL 19 COOLING TANK - ENGINE MOUNTING

Accessories belt Timing belt Cylinder head gasket

11-1 11-2 11-5

12 TURBOCHARGING Turbocharger Wastegate Air-air exchanger Exhaust manifold Inlet manifold

12-1 12-3 12-5 12-6 12-8

13 DIESEL EQUIPMENT Fuel cut-out on impact Specifications Bosch coded solenoid valve Cold start device (KSB) Inlet air heater Inlet air heater/ Fault finding Pre-postheating unit Pre-postheating unit / Fault finding Idle speed correction Microswitch Fuel filter Pump Pump timing Adjustments

13-1 13-2 13-4 13-7 13-12 13-16 13-18 13-22 13-24 13-25 13-26 13-28 13-29 13-32

Cooling Specifications Filling - bleeding Checking Diagram Radiator temperature switch Radiator Engine cooling fan Cooling system Metal coolant pipe Water pump

19-1 19-2 19-3 19-4 19-6 19-7 19-7 19-8 19-9 19-11

Exhaust system General Exhaust assembly

19-13 19-14

Fuel tank General Fuel tank Filler neck Gauge and sender unit

19-16 19-17 19-20 19-21

Engine mounting Suspended engine mounting

19-24

ENGINE AND PERIPHERALS Oil pressure

ESSENTIAL SPECIAL TOOLING

Mot. 836 -05

Kit for measuring oil pressure

CHECKING

MEASUREMENT USING MOT. 836-05

The oil pressure should be checked when the engine is warm (approx. 80°C).

Remove the oil pressure sensor behind the alternator and fit Mot. 836-05.

Contents of kit Mot. 836-05.

13456R 87363R

USE S engines: C + F .

Oil pressure

Engine speed in rpm

Pressure in bar

Idling

0.8

4100

3.5

10-1

10

ENGINE AND PERIPHERALS Engine - Gearbox

10

ESSENTIAL EQUIPMENT

Suspension spring compressor Load positioner

Disconnect: - the wiring harness for the engine interconnection 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.

TIGHTENING TORQUES (in daN.m)

Wheel nuts

15.5

Lower calliper guide bolts

3

Upper calliper guide bolts

8

Drive shaft bellows screws

2.5

Steering ball joint nut

8

Upper ball joint nut

9

Lower ball joint stud

8

Bolt for suspended engine mounting right-hand side

4.5

Nut for suspended gearbox mounting Torque reaction arm stud

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

8 10.5

REMOVING

Place the vehicle on four axle stands (see section on "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.

12734S

NOTE: Before decompressing the spring, mark its

position using an indelible marker on the tool.

10-2

ENGINE AND PERIPHERALS Engine - Gearbox 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 brake calliper (secure it to the body), the drive shaft bellows screws and then separate the upper and lower arms to release the half axle, - the right-hand half axle (same operation as for the left-hand half axle), except for the drive shaft; the retaining flange for the intermediate bearing antifriction bearing must be taken out.

10

REFITTING

Position the engine - gearbox assembly in the body. Fitting the suspended engine mounting

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

NOTE: Use cloths to protect the drive shafts.

Take the lower radiator mountings off the body. Disconnect the power steering pipes from the pump. 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.

13447S1

Fit the load positioner. Remove the right-hand suspended engine mounting (rubber pad plus cover). Undo the nut for the rubber pad on the left-hand suspended mounting (but do not remove it). Use a bronze drift to tap the stud for the rubber pin so as to separate it from the rubber pad. NOTE: There is a risk that the engine will tilt when

the stud and rubber pad are separated. Remove the engine - gearbox assembly via the front.

10-3

ENGINE AND PERIPHERALS Engine - Gearbox

10

13450S

Start by positioning the right-hand suspended engine mounting by tilting the engine towards the rear of the vehicle (if necessary) and then tighten the mounting bolts for the rubber pad to a torque of 4.5 daN.m. Insert the left-hand suspended engine mounting stud into the rubber pad and then tighten 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 fitting and torque tighten them. Press the brake pedal several times to bring the pistons into contact with the brake pads. Fill and bleed the engine cooling circuit (see section 19 on filling and bleeding the system ). Top up the gearbox (see the general instructions in section 21 ).

10-4

TOP AND FRONT OF ENGINE Accessories belt


Mot. 1273

Tool for checking belt tension

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

Remove the underbody engine guard. Undo bolt (1) and slacken off the two bolts (2).

13458R

Remove the accessories belt. REFITTING

Refit in reverse order to removal. Refer to section 07 on the "Accessories belt"for information on accessories belt tensioning procedure.

11-1

11

TOP AND FRONT OF ENGINE Timing belt

11


Mot. 910

Pin for setting injection pump timing gear

Mot. 1054

TDC pin

Mot. 1273


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


Crankshaft pulley bolt Timing gear tensioner nut

20 4.5

Turn the engine to the timing adjustment position. Compress the tensioner roller spring and place an M14 nut, cut to form a U-shape, at the back of the push rod.


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.

85384-1S

PRF1100

11-2

TOP AND FRONT OF ENGINE Timing belt Align the mark on the camshaft with the mark on the cylinder head, and align the mark on the crankshaft pulley in relation to the mark on the crankcase.

11

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

85397R1

13459R

13460R

13533R

Remove the crankshaft accessories pulley.

11-3

TOP AND FRONT OF ENGINE Timing belt

11

Undo the tensioner nut to release the timing belt.

Checking the timing gear setting

REFITTING

Turn the crankshaft one more time in the normal direction of rotation and check the four timing points, using setting rods Mot. 910 and Mot. 1054.

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

Refit in reverse order to removal. Align the mark on the camshaft sprocket with the mark on the cylinder head cover.

Tighten the bolt on the crankshaft pulley to a torque of 20 daN.m.

Check that there is no play or stiffness in either the tensioner rollers or the tensioner when they are turned by hand. If any stiffness or play can be detected, 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 releasing and retightening the tensioner.

13460R1

11-4

TOP AND FRONT OF ENGINE Cylinder head gasket

11


Emb. 880

Pin extractor

Mot. 910

Rod for setting injection pump timing gear

Mot. 921

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

Mot. 1054

TDC rod

Mot. 1273


Mot. 1383

17 mm pipe wrench to remove high pressure pipes

Remove: - the retaining flange for the metal coolant pipes,


Bolt for crankshaft pulley Nut for timing tensioner

20 4.5

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

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.

13448S

-

Disconnect the various sensors and the flamestart.

-

Disconnect the diesel pipes which are attached on the inlet manifold. Remove the oil vapour rebreathing reservoir.

11-5

the lifting bracket (flywheel side), the high pressure injection pipes, using Mot. 1383, the injector return pipe,

TOP AND FRONT OF ENGINE Cylinder head gasket -

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

-

11

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

84914R

Release the dipstick guide. Remove: - the stay between the turbocharger and the cylinder block,

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 manifold or the turbocharger. Remove: - cylinder head cover, - cylinder head bolts, - cylinder head.

13446S

84592S

11-6

TOP AND FRONT OF ENGINE Cylinder head gasket NOTE : Two studs are used to centre the cylinder

11

Checking the gasket face

head on the cylinder block (A). Do not pivot the cylinder head: lift it up to release it. (No risk of liners becoming detached as they are force-fitted.)

83179S

First remove the pre-combustion chambers. Then use a straight edge and a set of shims to check for gasket face bow. Maximum bow Maximum regrinding

: :

0.05 0.4

mm mm

CLEANING

After the cylinder head has been ground, the valves must be recessed according to the amount ground from the cylinder head.

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

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

Use Décapjoint to dissolve any parts of the gasket remaining on the metal.

Check the cylinder head for cracks.

85077R

Fit a new cylinder head gasket and refit the cylinder head.

Apply the product on the area to be cleaned; wait approximately 10 minutes then remove using a wooden spatula.

Tighten the cylinder head bolts (see section 07).

Gloves should be worn during this operation.

Refit in reverse order to removal.

Do not allow this agent to drip on to the paintwork.

See section 11 for information on refitting the timing gear.

Remember that this operation should be carried out with extreme care to avoid the risk of foreign bodies being introduced into the oilways bringing oil under pressure to the camshaft.

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

11-7

S9W engine

TURBOCHARGING Turbocharger

12


Mot. 1383

Pipe wrench for high pressure diesel pipes


Turbocharger nuts on exhaust manifold

2.5

Nuts, turbine outlet elbow

2.5

Oil inlet pipe

1.2

Screws for oil return pipe

1.2

Bracket mounting bolt for wastegate 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). 13446-1R

Disconnect the battery. -

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

the four nuts securing the turbocharger to the manifold.

Remove the turbocharger, taking it out underneath the vehicle.

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),

12-1

TURBOCHARGING Turbocharger

12

REFITTING - Special points

IMPORTANT :

Proceed in reverse order to removal. When refitting the turbocharger, ensure that the self-locking nuts securing the turbocharger on the exhaust manifold and the nuts for the turbine outlet el bow are replaced with new nuts.

Before starting the engine, ensure the connector for the solenoid valve on the diesel injection pump is still disconnected. Activate the starter motor until the oil pressure warning light extinguishes. (Keep operating it for several seconds.)

Special precautions

•

Before refitting, make sure that the lubrication is correct for the turbocharger bearings. To do this, first disconnect the diesel pump coded solenoid valve (to stop the engine starting up) and then operate the starter.

Reconnect the diesel pump solenoid valve. Wait for the warning light to extinguish and start the engine. Run the engine at idling speed and check that there are no leaks at the connections for oil and water.

Plenty of oil should be supplied by the oil supply pipe. (Place a container underneath to catch the oil.) If this is not the case, change the lubrication pipe. •

Ensure that no foreign bodies enter the tur bine or compressor during the refitting operation.

•

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 be removed, flushed with a cleaning agent and then left to drain properly.

•

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

12-2

S9W engine

TURBOCHARGING Wastegate

12


Mot. 1014

Kit for checking and adjusting turbo pressure

Mot. 1079-02

Dial gauge

Mot. 1311-01

Pressure gauge and connectors for 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

The pressure applied to the wastegate is varied using pressure gauge Mot. 1014. Calibration pressure values Pressures (mbar)

Rod movement (mm)

1100 ± 33

1

1220 ± 66

4

12-3

S9W engine

TURBOCHARGING Wastegate

12

Fitting on the vehicle

REMOVING

When checking the calibration pressure it may be necessary to adjust the wastegate rod length (A) (if it is not within tolerance).

Remove: - the pneumatic pipe (1) on the wastegate, - the circlip (2) on the wastegate; release the rod on the wastegate arm, - the two mounting screws for the wastegate assembly with its bracket (3).

This adjustment is made with the turbocharger in place.

Take out the wastegate.

13446R

13446R1

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

REFITTING

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

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

Next undo the lock nut and then slacken off or tighten the threaded end.

NOTE: Apply LOCTITE FRENBLOC to the wastegate

bracket mounting screws before refitting. Tightening torque: 1.5 daN.m.

Work half a turn at a time. (Tighten to increase calibration pressure. ) NOTE : The operation to replace the threaded

end on the regulator arm (A) will be easier if tool Mot. 1014 is used and if the pressure applied is increased.

12-4

S9W engine

TURBOCHARGING Air - air exchanger

12

REMOVING

Disconnect the battery. Remove: - the direction indicators, - the radiator grille, - the air filter unit, - the two air hoses on the air-air exchanger, - the bumpers, - the upper cross member, - the four mounting screws (1) for the air-air exchanger (2).

13495R

Take out the air-air exchanger. REFITTING

Refit the assembly in reverse order to removal.

12-5

S9W engine

TURBOCHARGING Exhaust manifold

12


Mot. 1383

Pipe wrench for high pressure diesel pipes


Mounting nuts for exhaust manifold

2.5

Union for oil delivery pipe

1.2

Mounting studs

1

The turbocharger and the inlet manifold do not have to be taken out to remove the exhaust manifold. REMOVING

Drive the vehicle on to a lift (minimum of 5 tonnes ) or so that it is over a pit (on axle stands). 13446-1R1

Disconnect the battery. 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 stay holding the turbocharger (2), - the heat shield on the manifold (3), - the exhaust manifold mounting bolts and take out the manifold from underneath the vehicle (exhaust manifold/turbocharger assembly not separated).

13451R

REFITTING

Refit in reverse order to removal. COMMENT: When refitting, always replace all

seals and gaskets for the manifold and for the tur bocharger oil return pipe with new ones.

12-6

S8U engine

TURBOCHARGING Exhaust manifold REFITTING


Exhaust manifold mounting nuts

12


2.5

Mounting studs

NOTE: When refitting, always replace all seals and

1

gaskets on the exhaust manifold with new ones.

REMOVING

Drive the vehicle on to a lift (minimum 5 tonnes) or so that it is over a pit (on axle stands). Disconnect the battery. Working from underneath the vehicle remove: - the guard under the engine, - the exhaust down pipe. Working from above the engine, remove: - the air filter assembly with trunking, - the heat shield on the manifold (3).

PRF1200

Remove the exhaust manifold mounting bolts (1) and take out the manifold from underneath the vehicle.

12-7

S9W engine

TURBOCHARGING Inlet manifold REFITTING


Inlet manifold mounting nuts

Refit in reverse order to removal. (Always replace seals and gaskets (2) on the inlet manifold with new ones.)

2.5

Mounting studs

1

Fuel supply pipe for fuel on Flamestart solenoid valve

1

Flamstart on inlet manifold

12

NOTE: When refitting, make sure that all the

connections are correctly aligned and check the condition of the copper seals.

3.5

REMOVING

Disconnect the battery. 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 connection, - the air inlet tube on the turbocharger, - the mounting nuts for the inlet manifold. Remove the inlet manifold (1) from underneath the vehicle.

PRF1201

12-8

S8U engine

TURBOCHARGING Inlet manifold

12


Inlet manifold mounting nuts

2.5

Mounting studs

1

REMOVING

Disconnect the battery. Working from above the vehicle, remove - the air filter unit assembly with trunking, - the mounting nuts for the inlet manifold. Remove the inlet manifold (1) from underneath the vehicle.

13493R

REFITTING

Refit in reverse order to removal. NOTE: When refitting, always replace all seals and

gaskets on the inlet manifold with new ones.

12-9

DIESEL EQUIPMENT Fuel cut-off on impact

13

AIM

The aim of this function is to avoid a fire after an accident due to a fuel leak. To accomplish this, all components which pump fuel from the fuel tank may only be started again by a reset procedure performed by the driver or repair mechanic. DESCRIPTION

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

13484R

It is fitted between the + feed and the fuel shut off 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 its seat and breaks the electrical current at the + feed to the fuel shut off or the coded solenoid valve . The pump can no longer draw fuel. Any risk of fire from the high pressure diesel spray over the engine is removed. RESETTING THE SWITCH AND SWITCH OPERATION

To reset the inertia switch, press the top to reposition the ball in its seat.

13-1

DIESEL EQUIPMENT Specifications

13

Engine Vehicles

Gearbox

XD0C

PF1

Type Suffix

Bore (mm)

Stroke (mm)

Capacity (cc)

Compression ratio

Catalytic converter

S9W

94.4

100

2799

19/1

C83

702

ENGINE SPEED (rpm)

Idling speed

EU95

SMOKE DENSITY

Max. - no load

Max. - with load

Homologation value

Legal maximum

4000 ± 100

3600 ± 100

1.52 m -1 (46 %)

3 m -1 (71 %)

800 ± 25

DE SIGNAT ION

Injection pump

Pump timing obtained by 8 mm diameter TDC pin (Mot. 1054) Injector holders

Injectors

MAKE /T YPE

SPECIAL NOTES

BOSCH VE 4/12 F1800 R721 VE 4/12 F1800 R713-1

Rotary pump with cold start solenoid incorporating thermo switch (KSB). Pump piston lift: 1.1 ± 0.02 mm.

Tightening torque of injector nut to injector holder : 4.5 daN.m. Tightening torque of injector holder to cylinder head: 4 daN.m.

KBEL 110 P 140

BOSCH

Checking: 240 +8 - 5 bars Max.variation in pressure: 8 bars

DSLA 134 P604

Fuel filter

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

Fuel pipes

-

Internal diameter: 1.85 mm Length: 470 mm

Cold start solenoid (KSB)

-

Resistance: 5 Ω Waxstat format

-

Igniter coil resistance: 0.2 Ω Solenoid valve resistance: 8 Ω

FLAMESTART cold start system (with solenoid valve control) Turbocharger

Depollution standard

Calibration: 1100 ± 33 mbar for a rod travel of 1 ± 0.02 mm 1220 ± 66 mbar for a rod travel of 4 ± 0.02 mm

"GARETT" GT 17

13-2

DIESEL EQUIPMENT Specifications

13

Engine Vehicles

Gearbox Type Suffix

XD0A

PF1

S8U

770

Bore (mm)

Stroke (mm)

Capacity (cc)

Compression ratio

Catalytic converter

93

92

2499

22/1

217 (1)

Depollution standard

EU95

(1) Non-impregnated catalytic converter

ENGINE SPEED (rpm)

Idling speed

SMOKE DENSITY

Max. - no load

Max. - with load

Homologation value

Legal maximum

4600 ± 100

4200 ± 100

1.60 m -1 (48 %)

2.5 m -1 (64 %)

800 ± 25

DESCRIPTION

Injection pump

Pump timing obtained by 8 mm diameter TDC pin (Mot. 1054) Injector holders

Injectors

MAKE/ T YPE

SPECIAL NOTES

BOSCH VE 4/10 F2100 R717-1 VE 4/10 F2100 R725-1

Tightening torque for injector nut to holder: 8 daN.m. Tightening torque for injector to cylinder head: 4 daN.m.

KBE 5858

BOSCH

Checking : 120 +8 - 5 bars Max. variation in pressure : 8 bars

Fuel filter -

Separate priming pump. The filter is equipped with an electrical fuel heater.

-

Internal diameter: 2 mm Length: 520 mm cylinders 1 and 4 460 mm cylinders 2 and 3

-

With pre-postheating function and advance solenoid valve control.

Fuel pipes

Plugs Cold start solenoid (KSB)

- a cold start solenoid with thermo switch (KSB), - a postheating cut-off microswitch. Pump piston lift: 0.97 ± 0.02 mm.

DNOSD 301

Preheating unit

Rotary pump with:

BERU

Resistance: 0.2 Ω Tightening torque: 2.5 daN.m Resistance: 5 Ω Waxstat format

-

13-3

DIESEL EQUIPMENT BOSCH coded solenoid valve The operation to remove the screening which gives access to the coded solenoid valve and the fuel shut off device must be performed with the pump in situ on the engine ESSENTIAL SPECIAL TOOLING

Mot. 1372

Kit for removing self-shearing bolts on 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

13

DIESEL EQUIPMENT BOSCH coded solenoid valve

13

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).

99780G3

13-5

DIESEL EQUIPMENT BOSCH coded solenoid valve

13

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 program

the 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 approximately 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. Enter command G04* with the ignition still switched off. (The passive protection mode bar graph will illuminate.)

-

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

13-6

DIESEL EQUIPMENT Cold start device (KSB) DESCRIPTION

OPERATION OF S8U ENGINE

When cold, the system increases the injection advance point.

Ignition off

13

The electrically heated Waxstat is not energised and therefore retracts the advance lever into its cold advance position.

The system consists of an electrically heated Waxstat (1) (R ≈ 5 Ω). It is mounted on the pump. It is linked to the cold start lever.

When the ignition is switched on, and with the engine running

With the engine cold and the coolant temperature below 10°C, the Waxstat is not energised and the cold start is at maximum. When the engine reaches a temperature of 10°C, the Waxstatis energised, it heats the wax and progressively reduces the advance over several minutes by releasing the advance lever. (The heat from the engine adds to the process). When the ignition is switched off

The Waxstat is not electrically energised. It is still released (advance lever in its hot position). It returns to its initial position as a function of the decrease in engine temperature. 13479R

NOTE: The KSB device is permanently energised if

The KSB device is supplied via: - the pre-postheating computer on the S8U engine (track C1), - the computer for intake air preheating on the S9W engine (track 9).

the coolant temperature sensor is defective.

The KSB Waxstat retracts the cold advance lever when it is not supplied with a + feed and.

13-7

DIESEL EQUIPMENT Cold start device (KSB) OPERATION OF S9W ENGINE

Ignition off

The Waxstat is not energised and therefore not released. The cold advance is active. When the ignition is switched on

If the coolant temperature is greater than 6°C, the Waxstat is energised. If the temperature is below 6°C, the Waxstat is not energised from the time the ignition is switched on to the end of the starting phase (disappearance of starter information). Once the starting phase is complete, the Waxstat is not energised for a maximum of 10 minutes; after this time it is energised. If the coolant temperature exceeds 6°C before 10 minutes have elapsed, the Waxstat is supplied with power directly. When the Waxstat is energised, it heats the wax and progressively reduces the advance over several minutes. (The heat from the engine adds to the process). When the ignition is switched off

The Waxstat is not electrically energised. It is still released advance lever in hot position). It returns to its initial position as a function of the decrease in engine temperature. NOTE :

-

-

If the coolant temperature information is incorrect, the Waxstat is energised 10 minutes after completion of the starting phase. If the starter information is incorrect, the Waxstat is energised 1 hour after + after ignition appears.

13-8

13

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 been performed on the pump , check that the lever (1) rests on the plastic ring (2).

13478R

13-9


13

If you have slackened off the tube holder bolt (3) to reset the cold start device, push lever (1) and the tube holder until they make contact with the plastic ring (2). Tighten the bolt (3). If work has been performed on the pump

Engine cold. Check dimension (X). (You can check this dimension with a drill bit.)

13477R

Dimension (X) depends on the temperature of the cold start device.

KSB WaxstatTemperature (in °C)

Dimension (X) (in mm)

18 22 25 30 35 40

6.5 5.9 5.5 4.75 4 3.25

13-10


13

Warm up the engine or provide a 1+12V feed to the Waxstat for 10 minutes . Check: - that lever (1) makes contact with stop (4), - that clearance (Y) between tube holder (5) and lever (1) is between 1 and 3 mm.

13478-1R

13-11

DIESEL EQUIPMENT Heating the inlet air

S9W engine

13

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

13487R

13486R

Igniter coil resistance : 0.2 Solenoid valve resistance : 8

Ω Ω

13483R

Temperature in °C (± 1 °) Air temperature sensor CTN type Resistance en ohms

0

20

40

80

90

7470 to 11970

3060 to 4045

1315 to 1600

300 to 370

210 to 270

13-12

S9W engine

DIESEL EQUIPMENT Heating the inlet air 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 incandescent filament (igniter) at a pressure of 0.2 bar. If a fault is detected, the preheating unit causes the warning light to flash on the instrument panel for 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 cold starting. It operates if the coolant temperature is less than 5°C and if the battery voltage is more than 9 volts If these conditions are not present, the preheating warning light illuminates for 2 seconds and then extinguishes. Preheating phase

When the ignition is switched on, the igniter and the solenoid valve are supplied with power for a period ranging from 15 to 56 seconds , depending on battery voltage. The warning light remains permanently illuminated. After this timed period, the warning light will extinguish and the driver has 20 seconds to start the engine. The igniter and the solenoid valve are supplied with power for this 20 second period. When 20 seconds have elapsed, the warning light remains extinguished and the FLAMSTART heating system is inhibited. The driver can still start the engine but without the assistance of the inlet air heating system.

13-13

13

S9W engine


Starting phase

KEY TO THE WIRING DIAGRAM

The igniter and the solenoid valve are supplied with power during this phase, except if the heating system is in an inhibited mode (as described above).

104 244 247 257 260 404 597 892 893 AVC APC

The warning light is extinguished. Postheating phase

The igniter and the solenoid valve are supplied with power during this phase. The warning light is extinguished.

13

Ignition switch Coolant temperature sensor Instrument panel warning light Preheating unit Fuse box Advance solenoid valve Engine fuse box Solenoid valve Igniter Before ignition After ignition

ALLOCATION TO COMPUTER TRACKS

The postheating operates for a period of up to 140 ± 15 seconds at the end of the preheating phase if the ambient temperature is - 30°C and for a period of 25 seconds if the ambient temperature is = 0°C. (There is no postheating for temperature of > 5°C.)

1 2 3 4 5 6 7 8 9

NOTE: If the coolant temperature sensor is

defective: - the warning light will illuminate steadily when the ignition is switched on and then flash during the preheating phase; - postheating is set at 170 seconds ; the warning light remains extinguished during this phase.

13-14

Coolant temperature sensor information + 12 volts + before ignition Control for preheating warning light + 12 volts after ignition Not used Earth Starter information Igniter and solenoid valve control Advance solenoid valve control

S9W engine


13

OPERATIONAL WIRING DIAGRAM

PRF13400

13-15

DIESEL EQUIPMENT S9W engine

13

Heating the inlet air / Fault finding

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 sensor circuit (white connector). Function / component to check

1

Operation of preheating warning light.

Actions / Test conditions

Switch on ignition.

Customer complaint / checking values

Steady illumination of the warning light for a minimum of 2 seconds .

Remedy

Check the control unit support to ensure that track 6 is earthed and +after ignition is supplied to track 4 (20 A fuse for "stopping engine" in fuse/relay box). Ensure that there is continuity between track 3 of the unit support and the warning light. Check condition of bulb.

2

3

Circuit for solenoid valve and diesel igniter Detection of temperature sensor fault.

"Starting engine information" circuit.

Switch off ignition. Disconnect coolant temperature sensor (white connector). Switch on ignition. (The voltage on the solenoid valve and the diesel igniter should be checked within 40 seconds of the ignition being switched on.) Switch off the ignition. Switch on the ignition. Wait for at least 5 seconds after the start of the flashing phase. Attempt to start engine

13-16

Steady illumination of the warning light for a minimum of 2 seconds and then flashing for approx. 25 seconds . Check for the presence of +Bat on the solenoid valve and the diesel igniter and that there is no voltage supplied to the cold start device (KSB)

The flashing should stop as soon as the starter is activated.

Ensure that there is continuity between track 8 of the unit support and the solenoid valve and the diesel igniter. Ensure that +before ignition is present at track 2 of the unit support (70 A fuse in engine interconnection unit).

Ensure that there is continuity between track 7 of the unit support and the "starting" position on the ignition switch.

DIESEL EQUIPMENT S9W engine

4

5

Heating the inlet air / Fault finding

13

Function /component to check

Actions / test conditions

Customer complaint/ checking values

Remedy

Return to normal operation of preheating warning light.

Switch off ignition. Reconnect coolant temperature sensor. Switch on ignition.

Steady illumination of warning light for a minimum of 2 seconds .

See point no. 1.

Cold start device circuit (KSB)

Engine started up. Wait, if necessary, for the coolant temperature to rise above 6°C.

Check that +Bat is present at the solenoid valve (cold start function cancelled).

Ensure that there is continuity between track 9 of the unit support and the solenoid valve.

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.

13-17

S8U engine

DIESEL EQUIPMENT Pre-postheating unit

13

Postheating microswitch (2)

LOCATION OF COMPONENTS

Pre-postheating unit (1)

98162-1R

The postheating microswitch (2) is mounted on the pump.

13485R

Coolant temperature sensor (3)

13483R

SPECIFICATIONS

Temperature in °C (± 1 °) Air temperature sensor CTN type Resistance in ohms

0

20

40

80

90

7470 to 11970

3060 to 4045

1315 to 1600

300 to 370

210 to 270

13-18

S8U engine

DIESEL EQUIPMENT Pre-postheating unit 3.

PRINCIPLE OF OPERATION FOR PRE-POST HEATING

13

"Postheating" while the engine is running

Postheating has two phases: 1.

"Preheating" when the ignition is turned on a) Fixed postheating a) Variable preheating

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

The time period during which the warning light is illuminated and the heater plugs are fed is dependent on the coolant temperature.

b) Variable postheating

Variable postheating begins when fixed postheating has ended. During this phase the plugs are fed according to coolant temperature.

13489S

If the coolant temperature sensor is faulty, the heater plugs are fed systematically for 12 seconds . b) Fixed preheating 13490S

After the preheating warning light has extinguished (variable preheating) the plugs remain fed for up to 8 seconds . 2.

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

Starting

Variable postheating may be interrupted - completely when the coolant temperature is > 40°C, - momentarily when the unit receives full load information (postheating microswitch opens) for more than 3 seconds ; postheating begins again when the engine returns to idle speed or low load (microswitch closes).

The plugs remain fed while the starter is activated.

13-19

S8U engine

DIESEL EQUIPMENT Pre-postheating unit Connector (A)

KEY TO WIRING DIAGRAM

62 104 244 247 257 260 404 597 632 633

13

+ Bat

Postheating microswitch Ignition switch Coolant temperature sensor Instrument panel Preheater unit Fuse box Cold start device Engine fuse box Heater plugs 1 and 3 Heater plugs 2 and 4

+ before ignition feed

Connector (B) 1 2

Feed to heater plugs 1 and 3 Feed to heater plugs 2 and 4

Connector (C) A1 / S2

Load dependence solenoid control (ALFB)

IDENTIFICATION OF CONNECTORS

92206-2R

13-20

A2 / PC

Load lever microswitch information

A3 / CTN

CTN type sensor coolant temperature information

B1/+APC

+ after ignition feed

B2 / DEM

Starter information

B3 / Tem

Preheating warning light control (via earth)

C1 / S1

Not used

C2 / -Bat

Earth

C3 / Clim

Fast idle solenoid valve control

S8U engine

DIESEL EQUIPMENT Pre-postheating unit

13

WIRING DIAGRAM

PRF13401

13-21

S8U engine

DIESEL EQUIPMENT Pre-postheating unit / Diagnostic

13

CHECKING OPERATION

Function / component to check

1

2

3

Operation of preheating warning light.

Heater plugs circuit. Cold start device circuit (KSB) Detection of temperature sensor fault

"Engine starting information" circuit. Postheating microswitch circuit (continuity).


Switch on ignition.

Switch off ignition. Disconnect coolant temperature sensor (white connector). Switch on ignition. (The voltage at the plugs must be checked within 20 seconds of the ignition being switched on.)

Switch off the ignition. Switch on the ignition. Wait for at least 20 seconds (preheating). Attempt to start engine.

13-22

Customer complaint / checking values

Remedy


Check 9-track connector of pre-postheating unit to ensure track C2 is earthed and +after ignition is present at track B1 (20 A engine fuse in fuse/relay box). Check that +before ignition is present at unit power terminal (70 A fuse in engine interconnection unit). Ensure there is continuity between track B3 of 9-track connector and warning light. Check condition of bulb.

Steady illumination of warning light for 12 seconds . Check presence of +Bat at heater plugs and at cold start device (KSB).

Check presence of +Bat at heater plugs (3 minutes postheating).

Ensure there is continuity between tracks 1 and 2 of 2track connector supplying heater plugs and plugs (track 1: cylinders 2 and 4; track 2: cylinders 1 and 3). Ensure there is continuity between track C1 and cold start device. If necessary, check coolant temperature sensor circuit. If there is no postheating, check continuity between track B2 of 9-track connector and "starter" position of ignition switch. If +Bat is only present for 10 seconds, check continuity of preheating microswitch circuit.

S8U engine

DIESEL EQUIPMENT Pre-postheating unit / Diagnostic

Function / component to check


Customer complaint/ checking values

13 Remedy

Switch off the ignition. Switch on the ignition.

4

5

Circuit for postheating microswitch (earth insulation). Registration of "pump lever position" information.

Return to normal operation of preheating warning light.

Wait for end of preheating ( 20 seconds ). Attempt to start engine. Disconnect postheating microswitch. Switch off ignition. Reconnect coolant temperature sensor and microswitch. Switch on ignition.

Check that +Bat is present at heater plugs before disconnection and then that no voltage is present 3 seconds after disconnection.

Ensure insulation to earth of connection between track B of microswitch connector and track A2 of 9-track unit connector.


See point no. 1.

Supplementary checks

-

Cold start device resistance

-

Operation of postheating microswitch

: R = 6 ± 1 ohms.

: Make sure that the contact opens at approximately half throttle on the fuel pump lead lever.

13-23

DIESEL EQUIPMENT Correcting the idling speed CORRECTING IDLING SPEED TO ALLOW FOR THE USE OF THE HEATED WINDSCREEN OR THE AIR CONDITIONING

If the heated windscreen is switched on or if the clutch on the air conditioning compressor is engaged, the fast idling speed vacuum capsule is then activated. The idling speed is increased to 875 rpm.

13-24

13

S8U engine

DIESEL EQUIPMENT Microswitch

13


98162-1R1

REMOVING

Undo the two mounting screws to remove the switch. The microswitch (1) cannot be adjusted.

13-25

DIESEL EQUIPMENT Fuel filter

13


13484R1

1 2 3

Fuel filter Electric heater (resistance 1.2 Ω) Hand priming unit

The electric diesel fuel heater and the thermostat are integral in the head of the filter. Operating temperature

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

13-26

DIESEL EQUIPMENT Fuel filter REMOVAL - REFITTING (Special notes)

To remove the filter assembly use tool Mot. 1311-06 for the quick release unions. When refitting, refit the quick release unions by hand and ensure they click back together correctly (two O-rings ensure sealing).

99461R

13-27

13

DIESEL EQUIPMENT Pump

13


Mot. 909909-02 02

1212-sid sided wren rench fo for rem remo ovin ving injection pump mounting

Mot. 1383

Spanner for removing highpressure pipe

•

TIGHTENING TORQUES (en daN.m)

Pump mounting nut

2.5

REMOVING

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

On all all typ types es of engi engine ne,, remo remove ve:: - the the thre threee nuts nuts secu securi ring ng the the pump pump (us (usee too tooll Mot. 909-02 to unscrew the lower nut) and then pull it out, - the the hub hub with with the the hel help p of of an an ext extra ract ctor or (tightening torque 5 daN.m). Keep the key to use again. (There are two types of hub a short hub and a long hub.)

Disconnect the battery Remove: - the the guar guard d unde underr the eng engine, ine, - the air filter, - the the sou sound nd-d -dead eaden enin ing g mat mater eria iall in in the the engi engine ne compartment, - the the hig highh-pr pres essu sure re pipe pipess (us (usee too tooll Mot. 1383). Disconnect the electrical connections to the advance solenoid valve. Disconnect the diesel pump solenoid valve or the coded solenoid valve. Remove: - the oil decanter, - the the stu stud d secu securi ring ng the the wiri wiring ng harn harnes esss (mo (moun un-ted on the engine behind the pump).

MS801359S1

Disconnect: - the the die diese sell d del eliv iver ery y and and retu return rn pipe pipes, s, - the acce ccelerat rator cab cable, - the the die diese sell ret return urn pipe pipe leadi leading ng from from the the inje injecctors. •

•

REFITTING

Fit the pump in place. Set the pump timing (see section 13 "Pump timing ").

On the the S9W S9W engi engine ne,, d dis isco conn nnec ect: t: - the the pip pipee on on the the pump pump lead leadin ing g to to the the turtur bocharger compensator, - the the die diese sell pip pipee lea leadi din ng to to the the FLAMESTART solenoid valve.


On the S8U engine: - Disc Discon onne nect ct the the post posthe heat atin ing g micro microsw swit itch ch connector. - Take of off th the va vacuum pump ump.

13-28

DIESEL EQUIPMENT Pump timing

13


Mot. 856

Dial gauge holder

Mot. Mot. 909909-02 02

12-s 12-sid ided ed wren wrench ch for for rem removin oving g inj injec ecti tion on pump mounting

Mot. 997

Socket for removing injection holder

Mot. 1054

TDC pin

Mot. 1383

Wrench fo for re removing hi high pr pressure tu tube

OPERATION TO CARRY OUT BEFORE PERFORMING CHECKING OR TIMING OPERATIONS


Pump mounting nut

2.5

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

ATTENTION: When carrying out checking or

Remove: - the air filter, - the the sou sound nd-d -dea eade deni ning ng ma matt in in the the eng engin inee compartment, - the the high igh-pre -presssure sure pipe pipess, - the the guard uard unde underr the the engi engin ne, - the oil decanter.

timing adjustment, the engine should only be turned in the direction of rotation. (If you turn the engine in the opposite direction during this operation, repeat the procedure right from the start.)

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

13478R1

13-29


13

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.

CHECKING TIMING

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

13481R

Secure the gauge on the gauge holder.

MS801354R

Fit pin Mot. 1054.

13480R

Turn the engine twice in the direction of rotation. Zero the gauge to BDC on the injection pump piston.

13482R

13-30


13

Apply pressure to pin Mot. 1054.

ATTENTION: If you exceed the timing value as you

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

turn the pump, readjust so that the oblong holes make contact with the screws and then repeat the timing operation from the beginning.

Read the pump piston lift as registered on the gauge.

Tighten the pump mounting bolts. Remove the timing pin Mot. 1054.

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

Check the timing. Carry out the other refitting operations in reverse order to removal.

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

Do not forget to reactivate the cold start device KSB (see the section on the"Cold starting device").

ADJUSTING INJECTION PUMP TIMING

Slacken off the three bolts securing the pump. Fit the dial gauge if this has not already been done. Turn the engine twice in the direction of rotation. Zero the dial gauge to BDC on the injection pump piston. Turn the pump towards the engine so that the oblong holes make contact with the screws. This is to allow the entire setting range to be used. Immobilise the engine using tool Mot. 1054 (method described in the section on "Checking pump timing "). Turn the pump so that the timing value can be read off the dial gauge: - 1.1 ± 0.02 mm for the S9W 702 engine, - 0.97 ± 0.02 mm for the S8U 770 engine.

13-31

DIESEL EQUIPMENT Adjustments

S8U engine

13

COLD START DEVICE (KSB) ADJUSTMENT

Cold engine

Check dimension (X). Fit a shim (Z) between the idling screw (B) and the load lever (E). Undo ball joint (R) and move the ball joint so that it makes contact with the load lever (E). Then tighten the ball joint. Warm engine

Check: - that that lever lever (C) ma make kess con conta tact ct with with sto stop p (G) (G),, - that that ther theree is clea cleara ranc ncee (Y) (Y) of of betw betwee een n 1 and 3 mm between lever (C) and cable grip (2).

13488R

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


18 22 25 30 35 40

6.5 5.9 5.5 4.75 4 3.25

13-32

Dimension (Z) (in mm)

5.5 4.5 3.7 2.5 1.2 0

S8U engine


13

ADJUSTING IDLING SPEED (version without AC)

CHECKING IDLING SPEEDS (version with AC)

First adjust the cold start device (KSB).

First adjust the cold starting device (KSB).

Warm up the engine.

With the engine warm:

Check the idling speed: 800 ± 25 rpm.

A

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).

Chec Checki king ng idli idling ng spee speed d

Check if the engine speed is 800 ± 25 rpm. COMMENT: If the speed is not correct,

complete adjustment will be necessary (see E). B

Chec Checki king ng the the resi residu dual al flow flow

Check the residual flow if the idling speed is 800 ± 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 by 70 ± 30 rpm. If the increase in speed is greater than 100 rpm, the complete adjustment procedure is required (see method "E"). If the increase in speed is less than 40 rpm, only the short adjustment procedure is required (see method described in point " d" of "E"). C

Chec Checki king ng fast fast idli idling ng spee speed d

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

98347R2

Check that the fast idling speed is 875 ± 25 rpm. If it is not, perform the adjustment procedure described in method "F ". D Checking Checking the position position of the the fast fast idling idling cable cable grip

Check that the cable and the cable grip are in the correct position. Hold the cable taut; lever (4) is in rest position (at idling). Check that 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 the adjustment procedure described in method " G".

13-33

S8U engine

DIESEL EQUIPMENT Adjustments F

ADJUSTING IDLING SPEEDS (version with AC)

First adjust the cold starting device ( KSB).

13

Adjusting fast idling

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

With the engine warm. E

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

Adjust the idling speed and the residual flow a

b

c

Slacken off the lock nut on screw (2) and turn the screw (2) enough to until the idling speed stops falling. Then slacken off the screw by two additional turns. (Check that the cable grip does not prevent the lever from moving (4).)

Release lever (4). Tighten the lock nut on screw (5). Check the fast idling speed .

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

If the fast idling speed is outside tolerance, repeat the operation. G Adjusting the position of the fast idling cable grip

Fit a 2 mm shim between the stop screw (2) and the load lever (accelerator) (6) (dimension Y).

This adjustment must be carried out under the same conditions as adjustment operations on the engine (engine warm).

COMMENT: The idling speed should not

increase once the shim has been fitted. If this is not the case, repeat the procedure (methods "a" and "b"), slackening off the screw (2) slightly more. d

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 at idling speed).

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

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

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

NOTE: Adjust the accelerator damper and then

check the adjustment of the cold starting device (KSB) again.

Check the idle speed is consistent and does not vary between accelerations. Check the idling speed again + 70 rpm using a 2 mm shim. If these two operations are not satisfactory, repeat the ad justment (method "c").

13-34

S8U engine


13

98154R1

1

Cable grip

13-35


S9W engine

13

ADJUSTING THE COLD STARTING DEVICE (KSB)

With the engine cold

Check dimension (X). (You can check this dimension with a drill bit.)

13488R1

Dimension (X) depends on the temperature of the cold start device (KSB).

Cold start device (KSB) temperature (in °C)

18 22 25 30 35 40


6.5 5.9 5.5 4.75 4 3.25

13-36

S9W engine


13

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

S9W engine


13

ADJUSTING IDLING SPEED (version without AC)

ADJUSTING IDLING SPEED (version with AC)

With the engine warm

First adjust the cold start device (KSB).

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.

With the engine warm. A

Checking idling speed

Check if the engine speed is 800 ± 25 rpm. COMMENT: If the speed is not correct, the

complete adjustment procedure must be carried out (see "E"). B

Checking residual flow

If idling speed is 800 ± 25 rpm, check the residual flow. To do this, place a 2 mm shim between the stop screw (2) and the load lever (accelerator) (6). The speed should increase by 330 ± 30 rpm. If the increase in speed is greater than 360 rpm, the complete adjustment procedure is required (see method "E"). If the increase in speed is less than 300 rpm, only the short adjustment procedure is required (see method described in point "d" of " E").

98345R

C

Checking fast idling speed

Position lever (4) so that it makes contact with stop (5). Check that the fast idling speed is 875 ± 25 rpm. If it is not, perform the adjustment procedure described in method "F ". D Checking the position of the fast idling cable grip

Check that the cable and the cable grip are in the 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 the adjustment procedure described in method " G".

13-38

S9W engine

DIESEL EQUIPMENT Adjustments F

ADJUSTING IDLING SPEEDS (version with AC)

First adjust the cold starting device ( KSB).

13

Adjusting fast idling

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

With the engine warm. E

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

Adjust the idling speed and the residual flow a

b

c

d

Slacken off the lock nut on screw (2) and turn the screw (2) enough to stop the idling speed falling. Then slacken off the screw by two additional turns. (Check that the cable grip does not prevent the lever from moving (4).)

Release lever (4). Tighten the lock nut on screw (5). Check the fast idling speed . If the fast idling speed is outside tolerance, repeat the operation.

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

G Adjusting the position of the fast idling cable grip

Fit a 2 mm shim between the stop screw (2) and the load lever (accelerator) (6) (dimension Y).

This adjustment must be carried out under the same conditions as adjustment operations on the engine (engine warm).

COMMENT: The idling speed should not

Hold the cable so that it is taut.

increase once the shim has been fitted. If this is not the case, repeat the procedure (methods "a" and "b"), slackening off the screw (2) slightly more.

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

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

Position the cable grip so that it is between 1 and 3 mm from the lever (4). Retighten the cable grip. NOTE: Adjust the accelerator damper and then

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

check the adjustment of the cold starting device (KSB) again.

Check the idle speed is consistent and does not vary between accelerations. Check the idling speed again + 330 rpm using a 2 mm shim. If these two operations are not satisfactory, repeat the ad justment (method "c").

13-39

S9W engine


13

98154R1

1

Cable grip

13-40


13

ADJUSTING THE ACCELERATOR DAMPER BALL JOINT LINK

When the above adjustments have been made, the length of the accelerator damper must be ad justed. With engine warm

Position the paint mark as shown below. If adjustment is required, move the upper ball joint (A).

99914R1

X = 2 mm.

13-41

STARTING - CHARGING Alternator

16

CHECKING

CHECKING THE VOLTAGE

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

Connect a voltmeter across the battery terminals and read the battery voltage.

Engine rpm

75 amps

100 amps

1500

22

26

2000

46

57

4000

68

94

Start the engine and increase the engine speed until the voltmeter needle stabilises at the regulated voltage. This voltage should be between 13.5 V and 14.8 V. Connect as many consumers as possible. The regulated voltage should remain between 13.5 V and 14.8 V.

OPERATION - FAULT FINDING IMPORTANT: If arc welding is carried out on the

These vehicles are fitted with alternators with internal ventilation, an integral regulator and a warning light on the instrument panel which operates as follows: - when the ignition is turned on, the warning light illuminates, - when the engine starts, the warning light extinguishes, - if the warning light illuminates again when the engine is running, there is a " charging " fault.

vehicle, the battery and the alternator must be disconnected.

LOOKING FOR FAULTS

The warning light does not illuminate when the ignition is turned on.

Check: - the electrical connections are correct, - the bulb is not blown (to do this, earth the circuit; the bulb should illuminate). The warning light illuminates when the engine is running

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, stator, 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 alternator. The fault could be caused by: - a destroyed diode, - a cut phase, - track contamination or wear.

16-1

STARTING - CHARGING Alternator

16


Mot. 1273

Tool for testing belt tension

REMOVING

Drive the vehicle on to a lift (minimum of 5 tonnes ) or so that it is over a pit (on axle stands). Disconnect the battery. Remove the guard under the engine. Disconnect the alternator. Undo bolt (1). Slacken off both bolts (2).

13458R

Take off the accessories belt. Remove the upper and lower studs securing the alternator and then release the alternator by moving it towards the rear of the vehicle. REFITTING

Refit in reverse order to removal. To tension the accessories belt, see section 07 on "Tensioning the accessories belt ".

16-2

STARTING - CHARGING Starter motor

Engine

16

Starter motor MITSUBISHI

S8U - S9W

M002T87671

REMOVING

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


16-3

COOLING Specifications

19

COOLANT CAPACITY AND TYPE

Engine

Volume (in litres)

S8U

7

Grade

GLACEOL RX Type D

Use coolant only S9W

7

19-1

Special notes

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

COOLING Filling - bleeding There is no water control valve. Coolant circulates continuously in the heater matrix, assisting with engine cooling. FILLING

The following bleed screw must be opened on the 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 out in a continuous jet. Start the engine (2500 rpm). Adjust the level by overflow for approximately 4 minutes . Close the expansion bottle. BLEEDING

Let the engine run for 20 minutes at 2500 rpm, until the engine cooling fan operates (time required for automatic degassing). Check the fluid level is close to the "maximum " mark. NEVER OPEN THE BLEED SCREW WHEN THE ENGINE IS RUNNING. TIGHTEN THE EXPANSION BOTTLE CAP WHEN THE ENGINE IS WARM.

19-2

19

COOLING Checking

19

ESSENTIAL SPECIAL TOOLING M . S . 554-01 M . S . 554-06

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

M . S . 554-07

Kit for checking cooling circuit sealing

1 - Checking cooling circuit sealing

2 - Checking rating of expansion bottle cap

Replace the expansion bottle cap with tool M.S. 554-01.

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

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

Adapt pump M.S. 554-07 to fit tool M.S. 554-06 and fit this to the valve to be checked.

Let the engine warm up then turn the ignition off. Increase the pressure which should stabilise at the calibration value for the cap valve, with a test tolerance of ± 0.1 bar .

Pressurise the cooling circuit using the pump mechanism to a value of 0.1 bar less than the expansion cap rating.

Valve rating value :

Stop pumping at 0,1 bar let than the rating value of the expansion bottle cap. The pressure should not drop. If it does, look for the leak. Slowly unscrew the union of tool M.S. 554-07 to decompress the cooling circuit, then remove tool M.S. 554-01 and refit the expansion bottle cap fitted with a new seal.

Engine

Valve colour

Rating (in bar)

S9W - S8U

Brown

1.2

97871R

19-3

S8U engine

COOLING Diagram

19

13528R

1 2 3 4

Engine Radiator Expansion bottle with permanent degassing Heater matrix

Water pump Thermostat Temperature switch

19-4

S9W engine

COOLING Diagram

19

13527R

1 2 3 4

Engine Radiator Expansion bottle with permanent degassing Heater matrix

Water pump Thermostat Bleed valve Temperature switch

19-5

COOLING Radiator temperature switch REMOVING

Disconnect the battery. 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

19

COOLING Radiator Disconnect the battery.

-

REMOVING

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

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

13531S

-

the plastic deflectors on the radiator.

Disconnect the radiator temperature switch. 13532S

Remove the upper and lower radiator hoses. Remove the radiator mounting bolts. REFITTING

Refitting is in reverse order to removal. Fill and bleed the cooling circuit (see section on "Filling and bleeding ").

12835S

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

19-7

COOLING Cooling system Disconnect the battery.

-

REMOVING

19

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

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

13531S

-

the plastic deflectors for the radiator.

Disconnect the radiator temperature switch. 13532S

Remove: - the turbocharger pipes (if fitted), - the upper and lower radiator hoses. Disconnect the wiring harness from the cooling system. Remove the two lower radiator mountings. REFITTING

Refitting is in reverse order to removal. Fill and bleed the cooling system (see section on "Filling and bleeding ").

12835S

19-8

COOLING Metal coolant pipe REMOVING THE METAL COOLANT PIPE AT THE BACK OF THE ENGINE

-

19

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

Disconnect the battery. 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 the pipe and the thermostat bracket). Remove: - the expansion bottle, - the hose (which connects at (1) on the pipe),

13454S

-

the three pipe mounting bolts, the pipe.

13451-1R

13451-1R1

Clean the gasket contact surface on the water pump. REFITTING

Refitting is in reverse order to removal. Fill up and bleed the cooling circuit (see section on "filling and bleeding ").

19-9

COOLING Metal coolant pipe -

REMOVING THE METAL COOLANT PIPE AT THE FRONT OF THE ENGINE

19

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


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

13448R

-

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

13449S

Refitting is in reverse order to removal. Fill and bleed the cooling system (see section on "Refilling and bleeding ").

19-10

COOLING Water pump

19


Mot. 1273


ESSENTIAL EQUIPMENT

Engine support

Remove: - the accoustic damper (tie rod) on the engine support, - the suspended engine mounting (cover equipped with rubber pad), - the water pump pulley.


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

Compress the tensioner roller spring and fit a M14 nut, cut to form a U-shape, at the back of the piston.

2

Drive the vehicle on to a lift (minimum of 5 tonnes ) or so that it is over a pit (on axle stands). Disconnect the battery. Remove : - the guard under the engine, - the accessories belt (see section 11 on " Accessories belt"), - the bonnet air duct.

85384-1S

Affix straps to mount the engine support.

13297S

19-11

COOLING Water pump

19

Remove: - the upper mounting stud for the alternator, then tilt the alternator towards the rear of the vehicle, - the two nuts for securing the metal coolant tube (water pump side), - the water pump mounting bolts.

13453S

REFITTING

Replace the water pump O-ring. Apply one or two drops of Loctite FRENTANCH to the water pump mounting bolts. Refit in reverse order to removal. Refit the suspended engine mounting by tightening the bolts for the rubber pad, the bolts for the cover and the bolts for the accoustic damper (tie rod) to a torque of 4.5 daN.m. Fill and bleed the coolant system (see section on "Filling and bleeding ").

19-12

EXHAUST General The catalytic converter reaches high temperatures during operation and consequently the vehicle should never be parked in an area where there is combustible material which could come into contact with the exhaust and pose a fire risk.

FITTING EXHAUST SYSTEM UNDER BODY

The exhaust system is hooked under the vehicle by means of silentbloc fittings (1). These can be released by hand by relieving the strain of the exhaust system.

Under certain conditions, this type of material could catch fire. IMPORTANT:

-

-

19

sealing between the exhaust manifold gasket face and the catalytic converter must be perfect, any seals removed MUST be renewed (especially at the catalytic converter flange), during removal and refitting the catalytic converter should not be subjected to repeated mechanical impacts as it may be damaged.

HEAT SHIELD IMPORTANT: After the rear section of the exhaust

12650R

(2) and the heat shields (3) have been removed and refitted, check that the heat shields are properly secured and cannot come into contact with the exhaust system.

12646R

19-13

EXHAUST Exhaust assembly

19

S9W 702 engine

13340R

1 2

Catalytic converter Silencer and expansion chamber

19-14

EXHAUST Exhaust assembly

19

S8U 770 engine

13341R

1 2 3

Non-impregnated oxidising catalytic converter Expansion chamber Silencer

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 another with 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

FUEL TANK Fuel tank

19


Mot. 1265-01

Pliers for removing quick release unions

ESSENTIAL EQUIPMENT

INTAIRCO, pneumatic pump for draining the fuel tank (see EQUIPMENT catalogue).

IMPORTANT: During the complete removal and refitting operation, do not smoke and keep all heat sources away from the working area. DRAINING THE FUEL TANK

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

12649R

Connect the pipe (1) to the pneumatic pump. Drain the fuel tank.

99641S

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

19-17

FUEL TANK Fuel tank

19

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

REMOVING

Disconnect the pipe (6) connecting the filler neck to the tank.

12643R 12645R

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

Disconnect: - the electrical connector for the gauge (2), - the diesel supply and return pipes (3).

12648R

12649R1

19-18

FUEL TANK Fuel tank

19

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

12644R

Remove the fuel tank. REFITTING

Proceed in reverse order to removal. Take care not to compress the pipes (risk of a leak). Fit the quick release unions by hand and ensure they click together correctly.

19-19

FUEL TANK Filler neck

19

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

REMOVING

Drive the vehicle on to a lift (minimum of 5 tonnes ) or so that it is over a pit (on axle stands). Disconnect the battery. Drain the fuel tank (see section 19 on the "Fuel tank )". Tilt the part marked (1) of the plastic protector (2).

12645R1

Release clamp (8) then extract the pipe (6). Release clamp (9) then disconnect the rubber pipe (10) from the filler neck.

12640R

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

12642R

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

To refit, work in reverse order to removal. 12641R

19-20

FUEL TANK Pump and sender unit

19


Mot. 1264-01

Wrench for removing pump sender unit

Mot. 1265-01

Pliers for removing quick release unions (diesel engine)

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)).

IMPORTANT : During all operations on the fuel tank 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 when they are removed. REMOVING

The fuel tank must be removed to take out the pump and sender unit assembly (see section on the "Fuel tank"). Disconnect the electrical connector (1), Remove clips (2).

96420R4

97163R5

19-21

FUEL TANK Pump and sender unit Remove mounting nut (5) using tool Mot. 1264-01 (release the nut, remove the tool then unscrew the nut by hand and remove it).

19

First fit the seal on the fuel tank before refitting the assembly. Fit the pump and sender unit (F), making sure that the sender unit is correctly aligned.

Remove the pump and sender unit assembly.

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 99367R

TRACK

ALLOCATION

NOTE: If several hours are likely to elapse bet-

ween removing and refitting the sender unit assembly, refit the nut to the fuel tank to prevent it from distorting. REFITTING

Change the seal (6) and check that it is in the correct position.

13334R

19-22

A1

Earth

A2

Low fuel warning light

B1

Gauge information to instrument panel

B2

Not used

C1

Not used

C2

Not used

FUEL TANK Gauge

19

CHECKING THE GAUGE SENDER UNIT

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

Ensure that the resistance varies by moving the float. Height H (in mm) Display 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 pin and the seal contact surface (upper part of the gauge, connection between the fuel tank and the gauge). NOTE: These values are given for information

only.

19-23

Renault master repair manual

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