N.T.

3303A
XB0J - XC0J

Special features of the F8Q 632

engine fitted with the Lucas Epic
injection pump

The cleanliness rules must be observed for all

operations on this vehicle.

For information not contained in this Technical Note, refer to MR 325 and 337.

77 11 206 456 SEPTEMBER 1999 Edition Anglaise

"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories
from which his vehicles are constructed."
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
Renault.

C RENAULT 1999
 Contents

Page Page

11 TOP AND FRONT OF ENGINE 14 ANTIPOLLUTION

Timing belt 11-1 Oil vapour rebreathing 14-1
Exhaust gas recirculation(EGR) 14-2

12 FUEL MIXTURE
Inlet/exhaust manifolds 12-1

13 DIESEL EQUIPMENT
Specifications 13-1
Special features 13-3
Cleanliness 13-5
Location of components 13-7
Operation 13-9
Injection warning light 13-10
Immobiliser function 13-11
Injection/air conditioning
programming 13-12
Idle speed correction 13-14
Pre-postheating control 13-15
Injectors 13-17
Negative flow solenoid valve and
electrical solenoid 13-18
Positive flow solenoid valve and
advance solenoid valve 13-20
Pump connector 13-22
Injection pump 13-24
Pump - Timing 13-27
Accelerator potentiometer 13-29
Centralised coolant temperature
management 13-30
Computer 13-31
Wiring diagram 13-32
Key 13-34
TOP AND FRONT OF ENGINE
Timing belt 11
The method for removing - refitting the timing
belt remains unchanged (refer to NT 2701A fea-
tures for HTD2 belts) except for the procedure for
timing the injection pump, for which the method
described in section 13 "Pump-Timing" MUST be
followed.

In contrast to existing pumps, the LUCAS EPIC

pump requires a complete timing operation, after
setting the tension of the new timing belt.

11-1
 FUEL MIXTURE
Inlet/exhaust manifolds 12
TIGHTENING TORQUES (in daN.m)

Manifold mounting nut 2.7

REMOVING THE INLET AND EXHAUST MANIFOLDS

Put the vehicle on a two post lift and disconnect the battery.

Remove the cover from the air filter unit (1).

From below, remove the mounting bolts (2) for the air filter unit.

15826R1

12-1
 FUEL MIXTURE
Inlet/exhaust manifolds 12
Remove the clip mounting the exhaust gas recir-
culation pipe.

Remove the diesel fuel supply pipe mounting on

the timing cover.

Remove the nuts mounting the inlet manifold :

- from above for nuts (A),
- from below for nuts (B).

Release the exhaust downpipe and attach it to the

engine sub-frame.

From above, remove the nuts (C) mounting the ex-

haust manifold.

PRO12.3

REFITTING

Observe the correct tightening torques for the

nuts.

NOTE : the nuts (B) may be refitted with their was-

hers before the exhaust manifold is refitted.

Remember to replace and correctly position the

seals (3) and (4) (see previous page).

12-2
 DIESEL EQUIPMENT
Specifications 13
Engine
Depollution
Vehicles Gearbox
Bore Stroke Capacity Catalytic standard
Type Suffix Ratio
(mm) (mm) (cm 3) converter

◊ C55
XB0J
JB1 F8Q 632 80 93 1870 21.5/1 or EURO 96
XC0J
◊ C101

ENGINE SPEED (rpm) SMOKE OPACITY

Idle speed Max. no load Max. with load Homologation value Legal maximum

825 ± 50 5175 ± 50 4600 ± 100 1.0 m-1 (33 %) 2.5 m-1 (64 %)

DESCRIPTION MAKE/TYPE SPECIAL NOTES

Electronic rotary pump with:

- a positive flow solenoid valve,
LUCAS DIESEL - a negative flow solenoid valve,
Injection pump E.P.I.C. - an advance solenoid valve,
R8640 A111A - an electrical solenoid,
H111.027 - a flow valve position sensor (cannot be removed),
- an advance valve position sensor (cannot be remo-
ved).

Pump timing - Timing using pin Mot. 1520 on the pump.

Positive flow solenoid valve - Resistance : 31 ± 2 Ω

Negative flow solenoid valve - Resistance : 31 ± 2 Ω

Advance solenoid valve - Resistance : 31 ± 2 Ω

Electrical solenoid - Resistance : 1.39 ± 0.1 Ω

Advance cam position sensor - Resistance : 52 ± 4 Ω

Flow valve position sensor - Resistance : 41 ± 4 Ω

Integral in pump
Pump temperature thermistor -
Resistance : 2716 ± 60 Ω at 20°C

Injection computer - D.C.U. Diesel Control Unit - 90 track

LUCAS
Injectors Rating: 125 to 140 bars
RDNOSDC 6751H

LUCAS Injector holder tightening: 7 daN.m

Injector holders
LCR 67354 Injector holder tightening on cylinder head: 7 daN.m

13-1
 DIESEL EQUIPMENT
Specifications 13
DESCRIPTION MAKE/TYPE SPECIAL NOTES

External diameter : 6 mm
Return pipes
- Internal diameter : 2.5 mm
Length: 300 mm

NAGARES With pre-postheating function (operation controlled

Pre-postheating unit
BRE/6-12 by computer)

Resistance : 0.6 Ω
Heater plugs BERU
Tightness: 2 daN.m

Accelerator potentiometer CTS Dual track potentiometer

Engine speed sensor MGI Resistance ≈ 760 Ω at 20°C

Absolute pressure sensor - Integral in computer

Electrical valve with integral flap and position sensor

EGR valve PIERBURG Valve resistance: 8 ± 0.5 Ω at 20 °C
Sensor resistance: 4 KΩ at 20 °C

Fault finding - Fault finding tool

Temperature in °C (± 1°) - 10 25 50 80

Air temperature sensor

10 454 to 8 623 2 175 to 1 928 857 to 763 325 to 292
(Resistance in Ohms)

Coolant temperature sensor

13 588 to 11 332 2 364 to 2 140 850 to 773 290 to 275
(Resistance in Ohms)

13-2
 DIESEL EQUIPMENT
Special features 13
The E.P.I.C. pump (Electronically Programmed Injection Control) is a completely electronic distributor type in-
jection pump. The following are located on the pump
- An advance solenoid valve (A).
- A positive flow solenoid valve (B).
- A negative flow solenoid valve (C).
- An electrical solenoid (D).
- A flow valve position sensor (cannot be removed) (E).
- An advance valve position sensor (cannot be removed) (F).
- A diesel fuel temperature sensor (cannot be removed, located in the pump body).

The positive flow solenoid valve and the advance solenoid valve cannot be separated. They are located on the
upper part of the pump.
The negative flow solenoid valve and the electrical solenoid cannot be separated. They are located on the lo-
wer section of the pump.

The two sensors for the position of the advance valve and the flow valve cannot be separated as it is vital that
their positions are memorised in the computer and in the injection pump. This operation can only be carried
out on an injection test bench.

The EPIC pump is associated with an injection computer known as the DCU (Diesel Control Unit). This controls
calculation of the advance and the flow, then depending on the result of these calculations, controls the sole-
noid valves. It also controls the EGR.

Before and during each operation on the EPIC system, the cleanliness rules must be observed.

15821R

13-3
 DIESEL EQUIPMENT
Special features 13
CHECKING AFTER REPAIR

After each operation, start the engine and run it at idle speed to check there are no leaks of diesel fuel.

IMPORTANT :

The engine should not be operated with diesel fuel containing more than 10 % diester (modified vegetable
oils).

After switching off the ignition, it may take 1 or 2 seconds for the engine to stop.

When repairing or removing the injection pump, the fuel supply unions, return unions and high pressure
outlets must be fitted with new plugs of a suitable size to prevent the introduction of impurities.

13-4
 DIESEL EQUIPMENT
Cleanliness 13
CLEANLINESS RULES WHICH MUST BE OBSERVED FOR OPERATIONS ON THE EPIC SYSTEM

Risks of contamination

The EPIC system is very sensitive to contamination. The risks involved in the introduction of contamination
are:
- damage to or destruction of the EPIC system,
- seizure or leakage of a component.
All after sales operations must be carried out under good conditions of cleanliness. Carrying out an operation
under good conditions of cleanliness means that no impurity (particle of several microns in size) has penetra-
ted the system during its removal or has penetrated the circuits via the fuel unions.

The cleanliness rules must be applied from the filter to the high pressure circuit components.

WHAT CAUSES CONTAMINATION?

The following cause contamination:

- metal or plastic swarf,
- paint,
- fibres from:
• card,
• brushes,
• paper,
• clothing,
• cloths.
- foreign bodies such as hairs,
- the ambient air,
- etc...

IMPORTANT: Do not clean the engine using a high pressure cleaner as there is a risk of damaging the connec-
tions. In addition, damp could stagnate in the connector, causing problems with the electrical connection.

RULES TO BE OBSERVED BEFORE ANY OPERATION ON THE INJECTION SYSTEM

• Ensure that plugs are available for the unions to be opened (the Parts Department sells a bag of plugs).
The plugs may only be used once. After use they must be discarded (once used, the plugs are dirtied.
Cleaning is not sufficient to allow them to be re-used.)
Plugs which are not used must also be discarded.

• Ensure that plastic bags are available which can be hermetically re-sealed several times, for storing the
parts which have been removed. There is less risk of parts becoming contaminated if they are stored in this
manner. The bags may only be used once, and must be discarded after use.

• Ensure that lint-free wipes are available (the wipes have a SODICAM part number). It is prohibited to use
cloths or conventional paper for cleaning. These materials leave lint which could contaminate the system’s
fuel circuit. Each wipe may only be used once.

13-5
 DIESEL EQUIPMENT
Cleanliness 13
RULES TO BE OBSERVED BEFORE ANY OPERATION ON THE INJECTION SYSTEM

• For each operation use new thinners (used thinners contains impurities). Pour it into an impurity-free
container.

• For each operation use a clean brush which is in good condition (the brush must not lose hairs).

• Use the brush and the thinners to clean the parts to be removed, the tools to be used and the part of the
workbench to be used.

• Blow compressed air over the parts to be cleaned (tools, workbench and the parts, unions and injection
system area).

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

• When using protective gloves, cover leather gloves with latex ones.

RULES TO BE OBSERVED DURING THE OPERATION

• As soon as the circuit is opened, plug the openings to prevent contamination entering. The plugs to be
used are available from the Parts Department. They must never be re-used.

• Hermetically seal the plastic bag, even if it is to be opened again shortly afterwards. The ambient air carries
contamination.

• All components of the injection system must be plugged and stored in an hermetically sealed plastic bag
once removed.

• After opening the circuit, it is prohibited to use a brush, thinners, blower, scraper, or conventional cloth.
These may cause contamination to enter the system.

• If a component is being renewed, only take the new component out of its packaging when its is ready to
be fitted on to the vehicle.

13-6
 DIESEL EQUIPMENT
Location of components 13

Photo 16 623

1 Air filter
2 Inlet air temperature sensor
3 EGR valve
4 Accelerator pedal position potentiometer
5 D.C.U. computer
6 Feed relay
7 Preheating unit
8 Fuel filter
9 Engine speed sensor and coolant temperature sensor
10 Negative flow solenoid valve and electrical solenoid
11 Positive flow and advance solenoid valves
12 EPIC injection pump

13-7
 DIESEL EQUIPMENT
Location of components 13

15821R1

2 Positive flow and advance solenoid valves 10 TDC sensor

4 Inlet air temperature sensor 11 Coolant temperature sensor
5 EGR valve 12 Negative flow solenoid valve and electrical
6 Pre-postheating unit solenoid
7 Accelerator pedal position potentiometer 14 Injection pump pin opening

15759R 15763R2

13-8
 DIESEL EQUIPMENT
Operation 13
The DCU computer permanently monitors the parameters from the system sensors. Depending on this infor-
mation and the mapping values memorised, it generates the control signals for the various solenoid valves.
The results obtained are continuously monitored, allowing corrective action to be taken.

The EPIC injection pump is a rotary distributor type pump based on the DPC injection pump principle. The die-
sel fuel is taken up by the supply pump and regulated in the pump body to a pressure called the transfer pres-
sure.

The pressure generation principle, which is identical to that for the DPC injection pump, uses piston plungers
driven by rollers in contact with a cam ring.

The precisely machined cam ring determines the start and duration of the injection phase. Using the advance
solenoid valve, the injection computer determines the position of this cam ring while modifying the start of
movement of the piston plungers.
The position sensor for this cam ring permanently informs the computer of the position of the start of injec-
tion.

The stroke of the piston plungers determines the amount of diesel injected to each cylinder. Two solenoid
valves called the positive flow and negative flow solenoid valves allow this stroke to be modified and there-
fore the flow of diesel injected to be modified.
The rotor position sensor (or flow valve) permanently informs the computer of the amount of diesel injected.

The diesel fuel is then sent to the distribution section of the pump which determines the cylinder to be sup-
plied. This function, which is identical to the DPC pump, is carried out by a piston which has a circular move-
ment.

The engine operates in the various states below:

Pre-starting

When the ignition is turned on until the engine starts, the system carries out a series of checks:
- rotor maximum stop position,
- advance piston minimum stop position,
- positive and negative flow solenoid valves operation,
- advance solenoid valve operation.

Starting

While the engine is starting, the rotor moves to the position indicated and the electrical solenoid is control-
led.

Normal operation

The flow is modified by the computer using the positive and negative flow solenoid valves. For major accele-
rations and decelerations, the flow is adjusted or cut depending on the mapping.

Stopping the engine

When the driver switches off the ignition, the computer controls the closure of the electrical solenoid then
checks the change in engine speed. If the engine speed does not drop, the computer operates the negative
flow solenoid valve.

13-9
 DIESEL EQUIPMENT
Injection warning light 13
PRINCIPLE OF ILLUMINATION OF THE INJECTION WARNING LIGHT

A single warning light on the instrument panel is used for the two operations below:
- when the ignition is switched on, the injection warning light illuminates during the preheating phase then
extinguishes,
- if there is a fault in the injection system, the warning light illuminates.

If a fault is present from when the ignition is switched on, the warning light illuminates for a few seconds du-
ring the preheating phase then extinguishes for a short moment before illuminating again to indicate the
fault.

Components which may illuminate the injection warning light if they are faulty:
- feed to the computer or the injection pump,
- engine speed sensor,
- pump internal memory,
- accelerator pedal position potentiometer,
- positive flow solenoid valve,
- negative flow solenoid valve,
- electrical solenoid,
- cam position sensor,
- computer.

13-10
 DIESEL EQUIPMENT
Immobiliser function 13
This vehicle is fitted with a 2nd generation immobiliser. The injection computer MUST have been program-
med with the immobiliser code to operate.

REPLACING AN INJECTION COMPUTER

Injection computers are supplied uncoded.

If an injection computer is to be replaced, the code for the vehicle must be programmed in, then a check
made to ensure that the immobiliser is operating correctly.

To do this, switch on the ignition for a few seconds then switch it off again.

CHECKING OPERATION OF THE IMMOBILISER

Remove the ignition key, after 10 seconds the red immobiliser warning light should flash (to check that it is
impossible to start the engine, refer to section 82 of M.R. 325 and 337.

TESTING AN UNCODED INJECTION COMPUTER FROM STORES

(this operation is NOT recommended)

IMPORTANT: before testing an injection computer, it must have been programmed with the immobiliser
code for the vehicle, so that it will operate. After the test, the computer MUST be decoded before being re-
turned to stores. If this is not done, the computer will not be able to be used again. This operation must be
carried out by personnel who have received adequate training. To decode the computer, refer to section 82
of M.R. 325 or 337.

IT IS IMPOSSIBLE TO BORROW A CODED COMPUTER FROM ANOTHER VEHICLE TO CARRY OUT A TEST.

13-11
 DIESEL EQUIPMENT
Injection/air conditioning programming 13
INJECTION COMPUTER/AC COMPUTER CONNECTION

The compressor is of the variable capacity type.

The injection computer and the AC computer are connected by two wires:

- Power absorbed information (track 47). This informs the injection computer of the power absorbed by the
compressor. It is possible to display the power absorbed using the fault finding tool. With the AC opera-
ting, the value should be between 250 and 5000 Watts.

- The connection from the injection computer to the air conditioning computer (track 55). This wire trans-
mits information on the authorisation or prevention of compressor operation.

When the AC function is selected, the idle speed is modified to a maximum of 875 rpm, when the power ab-
sorbed by the compressor is 500 Watts.

IMPORTANT: the power absorbed is never 0, regardless of the status of the compressor, operating or not. The
minimum value read is approximately 250 Watts.

13-12
 DIESEL EQUIPMENT
Injection/air conditioning programming 13
COMPRESSOR OPERATION PROGRAMMING

In certain phases of operation, the injection computer prevents the operation of the compressor.

Engine starting phase

Compressor operation is prevented after the engine has been started for 5 seconds.

Return of performance

If there is a major change in the position of the accelerator pedal (difference in potentiometer information
greater than 32 %) and if the engine speed is less than 2000 rpm, compressor operation is prevented for a few
seconds.

Return of power when the vehicle moves

If the potentiometer position is less than 30 % and if the engine speed is less than 1000 rpm, compressor ope-
ration is cut. It is started again after a few seconds if conditions allow.

Anti-stalling protection

If the no load position is not recognised and if the engine speed is less than 500 rpm, compressor operation is
cut. It is started again after 4 seconds if the engine speed increases.

Thermal protection programming

Compressor operation is prevented if the coolant temperature is greater than 105 °C.

Protective programming at maximum engine speed

Compressor operation is prevented if the engine speed is greater than 4700 rpm.

13-13
 DIESEL EQUIPMENT
Idle speed correction 13
IDLE SPEED CORRECTION DEPENDING ON COOLANT TEMPERATURE

The idle speed is increased and may reach 900 rpm for a coolant temperature of - 23 °C.

IDLE SPEED CORRECTION DEPENDING ON HEATED WINDSCREEN INFORMATION

If the heated windscreen is selected at the instrument panel, the computer receives + 12 Volts information
on track 18.

The idle speed is increased to 1000 rpm.

CORRECTION DEPENDING ON ELECTRICAL BALANCE

This correction aims to compensate for the drop in voltage due to the operation of consumers when the bat-
tery charge is low. To do this, the idle speed is increased, allowing the alternator to rotate more, and conse-
quently increasing the battery voltage.

The lower the battery voltage, the greater the correction made. Correction of the speed is therefore variable.
It begins when the voltage drops below approximately 12 Volts. The idle speed may reach a maximum of 900
rpm.

IDLE SPEED CORRECTION IN THE EVENT OF A POTENTIOMETER FAULT

If one of the accelerator pedal potentiometer tracks is faulty, the idle speed is held at 1000 rpm.

If both of the accelerator pedal potentiometer tracks are faulty, the idle speed is held at 1300 rpm.

In both cases, pressing the brake pedal allows the idle speed to return to normal (information from the stop
switch).

If the information from the accelerator pedal position potentiometer is incoherent with the information
from the stop switch, the idle speed is set to 925 rpm.

IDLE SPEED CORRECTION DEPENDING ON GEAR SELECTION

The idle speed is modified according to the gear engaged in the gearbox :
- in 1st gear, the idle speed is set to 850 rpm,
- in 2nd gear, the idle speed is set to 875 rpm,
- for the other gears, the idle speed is set to 900 rpm.

13-14
 DIESEL EQUIPMENT
Pre-postheating control 13
The pre-postheating function is controlled by the preheating unit.

PRINCIPLE OF PRE-POSTHEATING OPERATION 2) Starting

1) Ignition - Preheating The plugs are fed while the starter motor is
operating.
a) Variable preheating

The time that the warning light is illumi-
nated and the heater plugs are fed de-
pends on the coolant temperature and
the atmospheric pressure.
3) Engine running - Postheating
In this phase the plugs are fed continuously
depending on the coolant temperature and
the position of the flow valve.

time (s)

For a given idle speed with no

action at the accelerator pedal

180

15876-1S - 20 0 20 40 60

In all cases the injection warning light will Coolant

not be illuminated for longer than 15 se- temperature °C
conds.

b) Fixed preheating

After the warning light has extinguished,

the plugs remain fed for a fixed period of
15 seconds.

13-15
 DIESEL EQUIPMENT
Pre-postheating control 13
If the coolant temperature sensor is faulty, the
plugs are fed for a a period calculated depen-
ding on the air temperature.

15762S

In all cases the plugs may not be fed for longer

than 180 seconds.

13-16
 DIESEL EQUIPMENT
Injectors 13
TIGHTENING TORQUES (in daN.m) REFITTING

Injector holder on cylinder head 7 Replace the flame arresting washer and the seals
under the injectors.
High pressure pipe nuts 2.5
Fit:
- the injectors,
REMOVING THE INJECTORS - the pipes.

Hand tighten the two nuts for each pipe.

THE CLEANLINESS RULES MUST BE STRICTLY
OBSERVED Tighten :
- the injectors to the correct torque,
- the pipes to the correct torque.
Disconnect the battery.
Run the engine at idle speed to check there are no
Remove: leaks.
- the high pressure pipes,
- the injectors.

The supply opening and the injector head must

be plugged.

Take care to prevent diesel spraying on electrical

equipment which could cause an operating fault.

DI1323

13-17
 DIESEL EQUIPMENT
Negative flow solenoid valve and electrical solenoid 13
TIGHTENING TORQUES It is vital to note the position of these wires in the
connector.
Solenoid valve mounting bolt 6± 0.6 Nm
Slacken the four bolts holding the solenoid valve
High pressure pipe nut 2.5 ± 0.2 daN.m
unit and the solenoid valve mounting, beginning
with the outer bolts. ENSURE CLEANLINESS IS
MAINTAINED.
REMOVAL OF THE NEGATIVE FLOW SOLENOID
VALVE AND THE ELECTRICAL SOLENOID Remove the solenoid valve unit and the plastic
mounting ( IMPORTANT: the electrical solenoid
The solenoid valves on the lower part of the EPIC core is not attached to the solenoid valve, it is also
injection pump cannot be replaced separately. fitted behind a spring).
They are:
- the negative flow solenoid valve, Remove the three seals.
- the electrical solenoid.
Wipe the solenoid valve sealing faces with lint-
free wipes. Do not clean the sealing faces on the
THE CLEANLINESS RULES MUST BE STRICTLY pump or on the solenoid valves with detergents.
OBSERVED Do not use a blower.

Disconnect:
- the battery,
- the electrical connector for the pump.

Remove the bolts mounting the electrical

connector to the connector mounting.

In the connector, remove the wires for the

negative flow solenoid valve and the electrical
solenoid (red/white and blue/white) (see section
13 "Pump connector").

15824S

15822S

13-18
 DIESEL EQUIPMENT
Negative flow solenoid valve and electrical solenoid 13
REFITTING

Renew the old seals.

Fit the new seals on the pump body. Do not fit

them on the solenoid valves. To hold them in
position, dampen them with a little diesel fuel.

Position the solenoid valves and the mounting

opposite their position, holding them in place by
hand (do not let the seals, the core or the spring
fall from the electrical solenoid).

Simultaneously screw in but do not tighten the

two inner mounting bolts, in order to bring the
solenoid valves up against the pump body.

Hand tighten the two other mounting bolts for

the solenoid valves.

Torque tighten the four bolts.

Take care when refitting not to damage the

terminals and the connector (first fit the terminals
into the clip holder in order to ensure they are
correctly clipped in, then refit the remainder of
the connector) (see section 13 "Pump connector").

Refitting is then the reverse of removal.

Run the engine at idle speed to check there are no

leaks.

NOTE : the core of the electrical solenoid is

matched to the body. If it is replaced, take care to
order a part with identical markings/references.

13-19
 DIESEL EQUIPMENT
Positive flow solenoid valve and advance solenoid valve 13

15823S

TIGHTENING TORQUES (in Nm) Disconnect:

- the battery,
Solenoid valve mounting bolt 6± 0.6 - the electrical connector for the pump.

Remove the bolts mounting the electrical

REMOVAL OF THE POSITIVE FLOW SOLENOID
VALVE AND THE ADVANCE SOLENOID VALVE
The solenoid valves on the upper part of the EPIC
injection pump cannot be replaced separately.
They are:
- the positive flow solenoid valve,
- the advance solenoid valve.
connector to the connector mounting.
In the connector, remove the four terminals for
the two solenoid valves (see section 13 "Pump
connector"). Note their position in the connector.
Slacken the four bolts holding the solenoid valve
unit beginning with the outer bolts. ENSURE
CLEANLINESS IS MAINTAINED.

Remove the solenoid valve unit and remove the

THE CLEANLINESS RULES MUST BE STRICTLY four seals.
OBSERVED

13-20
 DIESEL EQUIPMENT
Positive flow solenoid valve and advance solenoid valve 13
Wipe the solenoid valve sealing faces with lint-
free wipes. Do not clean the sealing faces on the
pump or on the solenoid valves with detergents.
Do not use a blower.

REFITTING

Renew all the old seals.

Fit the new seals on the pump body. Do not fit

them on the solenoid valves.

Position the solenoid valve unit and tighten the

inner bolts, then the outer ones.

Hand tighten the four mounting bolts for the

solenoid valves then torque tighten them.

Take care when refitting not to damage the

terminals and the connector (first fit the terminals
into the clip holder in order to ensure they are
correctly clipped in, then refit the remainder of
the connector) (see section 13 "Pump connector").

Refitting is then the reverse of removal.

Run the engine at idle speed to check there are no

leaks.

13-21
 DIESEL EQUIPMENT
Pump connector 13
SPECIAL TOOLING REQUIRED

Elé. 1044 -01 Tool for removing the connector

clips

REMOVAL OF THE INJECTION PUMP CONNECTOR

THE CLEANLINESS RULES MUST BE STRICTLY REFITTING

OBSERVED
Push on the wire to be clipped in.

To remove the connector, remove the following Gently pull it to lock the tabs.
components in order:
- the black connector holder (A), Refit:
- the comb(B), - the clip holder (D),
- the white wiring retaining clip (C), - the white wiring retaining clip (C),
- the clip holder (D), - the comb (B).
- the terminals (E) unlocking the tabs using tool
Elé. 1044-01 and simultaneously pulling on the Reposition the assembly in the black connector
wire to be removed. holder (A).

15825R

13-22
 DIESEL EQUIPMENT
Pump connector 13
TERMINAL IDENTIFICATION

15820R

Marking Marking
Computer
on pump wiring Allocation Colour
marking
side side

1 - - - -

2 - - - -

3 13 13 Advance valve position sensor signal Green

4 Flow valve position sensor trigger Red

4 + AVC
5 Advance valve position sensor trigger Red

6 11 30 Electrical solenoid control White-Red

7 10 14 Flow valve position sensor signal Yellow

8 9 12 Flow valve position sensor compensation White

9 8 51 Pump memory connection Orange

10 7 67 Pump memory and diesel temperature common wire Blue

11 6 36 Diesel temperature in the pump Brown

12 5 60 Positive flow solenoid valve control White-Black

13 Positive flow solenoid valve feed White-Black

14 Electrical solenoid feed White-Red

4 + AVC
15 Advance solenoid valve feed White-Green

16 Negative flow solenoid valve feed White-Blue

17 3 89 Advance solenoid valve control White-Green

18 2 90 Negative flow solenoid valve control White-Blue

- 1 9 Screening -

13-23
 DIESEL EQUIPMENT
Injection pump 13
TIGHTENING TORQUES (in daN.m) REPLACEMENT OF THE REAR FITTING

Closure plate 0.55 ± 0.05

Rear fitting 2.2 ± 0.3 IMPORTANT: if this method is not observed, there
is a major risk of stressing the hydraulic head.

REPLACEMENT OF THE CLOSURE PLATE SEAL

NOTE: when replacing a cylinder head, observe
the methods for removing/refitting the fitting
described above.
THE CLEANLINESS RULES MUST BE STRICTLY
OBSERVED.

Disconnect the battery.

Remove the closure plate mounting bolts (P).

Replace the seal.

Wipe off the diesel residue using lint-free wipes.

Reposition the closure plate and torque tighten

the bolts.

12569S

REMOVAL

Remove the rear fitting before slackening the

mounting bolts for the pump, located behind the
drive pulley.

REFITTING

Fit the pump mounting bolts.

Position the rear fitting and hand tighten the

bolts.
15822R

Torque tighten :
- the pump bolts,
- the rear fitting bolts.

13-24
 DIESEL EQUIPMENT
Injection pump 13
SPECIAL TOOLING REQUIRED

Mot. 1200-01 Pulley retaining tool

Mot. 1054 TDC pin
Mot. 1520 Injection pump setting pin
Mot. 1522 Pump setting wheel
Mot. 1525 Pulley extractor

TIGHTENING TORQUES (in daN.m) Remove:

- the pump pulley housing,
Injector pipe nut 2.5 ± 0.6 - the high pressure pipes,
- the pump rear fitting,
Rear fitting bolt 2.2 ± 0.3
- the diesel supply and return pipes.
Pump mounting bolt 2.5 ± 0.3
Pulley nut 5.5 ± 0.5 Fit plugs to all the pipes and outlets which have
been disconnected.

Disconnect the pump electrical connector.

REMOVAL OF THE INJECTION PUMP
Fit tool Mot. 1200-01 to retain the pump pulley.

THE CLEANLINESS RULES MUST BE STRICTLY Slacken the pulley mounting nut.
OBSERVED.

Disconnect the battery.

Pin the engine at TDC using tool Mot. 1054.

15872R

12419R

13-25
 DIESEL EQUIPMENT
Injection pump
Fit tool Mot. 1525 for extracting the pulley then
release the pulley from the pump shaft.
Slacken the three pump mounting bolts (fit the
tool between the pulley spokes).
NOTE : there is a flat to prevent tool Mot. 1525
from turning.
Remove the injection pump by slackening the
mounting bolts.
Place the pump in a sealed bag if it is to remain
removed.
13-26
13
REFITTING
Renew the O ring on the pump drive shaft.
IMPORTANT : it is vital to keep tool Mot. 1520
clean and in good condition.
Position the pump setting pin by turning the shaft
using the wheel Mot. 1522 (see section 13 "Pump
timing").
Refit the injection pump.
Fit then hand tighten the three pump mounting
bolts on the accessories mounting.
Position then hand tighten the rear fitting bolts.
Torque tighten the pump mounting bolts then
those of the rear fitting.
IMPORTANT: the tightening of the pump support
is important. Hand tighten all the bolts then
torque tighten them.
Fit the high pressure diesel pipes. Hand tighten
the two nuts then torque tighten them.
Follow the procedure for setting the EPIC pump
(see section 13 "Pump timing").
IMPORTANT: remember the TDC pin and the
pump setting tool.
Run the engine at idle speed to check there are no
leaks.
 DIESEL EQUIPMENT
Pump - Timing 13
SPECIAL TOOLING REQUIRED

Mot. 1200-01 Pulley retaining tool

Mot. 1054 TDC pin
Mot. 1520 Injection pump setting pin
Mot. 1522 Pump setting wheel
Mot. 1525 Pulley extractor

TIGHTENING TORQUES Slacken the pump drive shaft nut.

Pump nut 5.5 ± 0.5 daN.m Release the pump from the pulley using the pulley
extractor tool Mot. 1525.
Plug for pump pin 5 Nm

PROCEDURE FOR SETTING THE INJECTION PUMP

Checking the timing requires a complete timing

operation.

IMPORTANT: never turn the engine in the oppo-

site direction to normal operation.

Move the diesel filter to one side and remove the

injection pump pulley housing.

Bring the engine to the timing mark using the pin

Mot. 1054.

Position the injection pump pulley retaining tool

Mot. 1200-01.

15872R

NOTE : a flat is provided to prevent tool Mot. 1525

from turning.

12419R

13-27
 DIESEL EQUIPMENT
Pump - Timing 13
Fit the adjusting wheel Mot. 1522 at the end of Gently tighten tool Mot. 1520 to find the point
the pump drive shaft. where the setting pin goes into the pump by the
greatest amount. In this position, the pin will
immobilise the pump.

In this position, tighten the drive shaft nut on the

pump to immobiliser the sprocket.

Remove the tool Mot. 1200-01.

Remove tool Mot. 1054 from the engine and tool

Mot. 1520 from the injection pump.

Refit the plugs for the timing opening.

Refit the sprocket housing and reposition the

diesel fuel filter.

IMPORTANT: remember to remove the TDC pin

and the injection pump setting pin.

Let the engine run at idle speed to check there are

15871R1 no leaks and that engine operation is correct.

IMPORTANT : it is vital to keep tool Mot. 1520

Position a container under the pump to collect the clean and in good condition.
diesel fuel. Remove the setting plug on the pump.

IMPORTANT: take care since there will be a large

amount of fuel in the unions and the injection
pump. Protect any sensitive parts.

Turn the pump in its direction of rotation using

the wheel to bring the pump to the setting point
(look into the timing opening for the position of
the groove).

IMPORTANT: do not alter the position of bolts

(A). If either of these bolts is slackened, the pump
must be returned to an injection test bench.

13-28
 DIESEL EQUIPMENT
Accelerator potentiometer 13
Track allocation: REMOVAL OF THE POTENTIOMETER
1 Signal from track 2
2 Signal from track 1 Remove the unit from under the master cylinder.
3 5 V feed for track 2
4 Earth for track 1 Unhook the accelerator cable from the unit. The
5 Earth for track 2 potentiometer is supplied by the Parts
6 5 V feed for track 1 Department with the unit.

REFITTING

Refitting is the reverse of removal.

The repair must be validated using the fault

finding tool.

15759R1

Track resistance : 1.7 ± 0.5 KΩ

15760S

NOTE : a fault in one of the two accelerator pedal

position potentiometer tracks will cause a
modification to the idle speed or engine
operation (see section 13 "Idle speed
correction").

13-29
 DIESEL EQUIPMENT
Centralised Coolant Temperature Management 13
Centralised Coolant Temperature Management (GCTE) OPERATION

Sensor 244 allows:

- indication of the coolant temperature on the
instrument panel,
- the injection computer to be informed of the
engine coolant temperature.

Depending on the coolant temperature, the

injection computer manages:
- the injection system,
- the E.G.R.
- the fan relays:
• the cooling fan is operated at slow speed if
the coolant temperature exceeds 99 °C and is
stopped when the temperature drops below
96 °C,
• the cooling fan is operated at high speed if
the coolant temperature exceeds 102 °C and
is stopped when the temperature drops
below 99 °C,
15763R1 • the fan assembly may be operated for the
AC.
244 Coolant temperature sensor (injection and
coolant temperature indication on For vehicles not fitted with AC, only the slow fan
instrument panel). speed is operational.
3 track sensor, 2 for coolant temperature
information and 1 for instrument panel
indication. COOLANT TEMPERATURE WARNING LIGHT

This system allows control of the engine cooling This warning light is controlled by the DCU
fan by the injection computer. It comprises a computer.
single coolant temperature sensor used for the
injection, the fan, the coolant temperature It is operated when the temperature exceeds
indication and the temperature warning light on 105 °C.
the instrument panel.

13-30
 DIESEL EQUIPMENT
Computer 13
ALLOCATION OF INJECTION COMPUTER TRACKS

3 - >< - FAULT FINDING LINE L

4 --<-- AIR TEMPERATURE SENSOR INPUT
8 --<-- LOAD POTENTIOMETER SENSOR INPUT (1)
9 ----- INJECTION PUMP SCREENING
11 --<-- ENGINE SPEED SENSOR SIGNAL (TRACK B)
12 --<-- ROTOR COMPENSATION INPUT (PUMP)
13 --<-- CAM POSITION SENSOR INPUT (PUMP)
14 --<-- ROTOR POSITION SENSOR INPUT (PUMP)
15 --<-- PUMP SENSOR INPUT
17 --<-- VEHICLE SPEED INPUT
18 --<-- HEATED WINDSCREEN INPUT
19 --<-- PLUG FAULT FINDING INPUT (2)
20 --<-- IMMOBILISER INPUT
22 - ->-- PAS ELECTRO-PUMP ASSEMBLY (if AC option)
23 -->-- FAST SPEED FAN RELAY CONTROL (if AC option)
24 -->-- PREHEATING WARNING LIGHT OUTPUT
26 -->-- ENGINE SPEED INFORMATION OUTPUT
30 -->-- ELECTRICAL SOLENOID OUTPUT
33 - >< - FAULT FINDING LINE K
34 --<-- COOLANT TEMPERATURE SENSOR INPUT
35 --<-- EGR VALVE FLAP POSITION INPUT
36 --<-- DIESEL TEMPERATURE SENSOR INPUT
37 --<-- LOAD POTENTIOMETER SENSOR INPUT (TRACK 2)
39 ----- EGR VALVE FLAP POSITION FEED
41 ----- LOAD POTENTIOMETER SENSOR FEED (TRACK 1)
42 ----- LOAD POTENTIOMETER SENSOR FEED (TRACK 2)
46 --<-- BRAKE SWITCH INPUT
47 --<-- AC INFORMATION (if AC option)
49 --<-- PLUG FAULT FINDING INPUT (1)
51 - >< - PUMP MEMORY INPUT/OUTPUT
52 -->-- PREHEATING RELAY CONTROL
53 -->-- SLOW SPEED FAN RELAY CONTROL
54 -->-- COOLANT TEMPERATURE WARNING LIGHT OUTPUT
55 -->-- AC PREVENTION OUTPUT (if AC option)
59 -->-- EGR SOLENOID VALVE OUTPUT
60 -->-- NEGATIVE FLOW SOLENOID VALVE CONTROL OUTPUT
61 ----- LOAD POTENTIOMETER SENSOR EARTH (TRACK 1)
62 ----- LOAD POTENTIOMETER SENSOR EARTH (TRACK 2]
63 ----- EGR VALVE FLAP POSITION EARTH
65 ----- AIR TEMPERATURE SENSOR EARTH
66 ----- COOLANT TEMPERATURE SENSOR EARTH
67 --<-- PUMP DIESEL TEMPERATURE SENSOR
74 ----- ENGINE SPEED SENSOR EARTH (TRACK A)
76 ----- + BEFORE IGNITION FEED
77 ----- + BEFORE IGNITION FEED
78 ----- EARTH
79 ----- EARTH
81 ----- + AFTER IGNITION FEED
82 ----- ACTUATOR RELAY CONTROL
84 -->-- FAULT WARNING LIGHT OUTPUT
85 -->-- FUEL CONSUMPTION OUTPUT
89 -->-- ADVANCE SOLENOID VALVE CONTROL OUTPUT
90 -->-- POSITIVE FLOW SOLENOID VALVE CONTROL OUTPUT

--<-- INPUT
-->-- OUTPUT

PRO15097

13-31
 DIESEL EQUIPMENT
Wiring diagram 13

16600G

13-32
 DIESEL EQUIPMENT
Wiring diagram 13

16600D

13-33
 DIESEL EQUIPMENT
Wiring diagram 13
KEY

104 Immobiliser
107 Battery
120 Injection computer (D.C.U.)
160 Stop switch
225 Diagnostic socket
234 Fan assembly relay
238 Injection locking relay
244 Coolant temperature sensor
247 Instrument panel
250 Vehicle speed sensor (passenger compartment)
257 Preheating unit
272 Injection air temperature sensor
273 Engine speed sensor
398 EGR valve
419 AC control unit
597 Engine fuse box
645 Passenger compartment connection ECU
680 to 682 Heater plugs
711 Diesel pump
777 Power feed fuse board
921 Accelerator potentiometer
927 Impact sensor (inertia sensor)

13-34
 ANTIPOLLUTION
Oil vapour rebreathing 14
PRESENTATION OF THE CIRCUIT

13042R

1 Engine
2 Oil decanter
3 Air filter unit
4 Inlet manifold

CHECKING

In order to guarantee the correct operation of the

antipollution system, the oil vapour rebreathing
circuit must be kept clean and in good condition.

14-1
 ANTIPOLLUTION
Exhaust gas recirculation (EGR) 14
PRESENTATION OF THE CIRCUIT

15881R

1 Engine
2 Injection computer
3 Inlet manifold
4 Exhaust manifold
5 EGR valve
6 Coolant temperature sensor

REMOVING THE VALVE

The EGR valve is press fitted in the inlet manifold.

To make it easier to replace, remove the manifolds.

AIM OF THE EGR SYSTEM

Exhaust gas recirculation is used to reduce the amount of nitrous oxides

(NOx) in exhaust gas.

The injection computer authorises the passage of the gas using an elec-
trical valve.

14-2
 ANTIPOLLUTION
Exhaust gas recirculation (EGR)
OPERATING PRINCIPLE
The valve is controlled by an RCO signal from the
injection computer. The RCO signal allows the
valve opening to be modified, consequently
changing the amount of exhaust gas diverted to
the exhaust manifold.
The computer permanently checks to determine
the position of the EGR valve flap.
14
The computer does not operate the EGR if there is
a fault in:
• the coolant temperature sensor,
• the air temperature sensor,
• the atmospheric pressure sensor,
• the vehicle speed information,
• one of the flow solenoid valves,
• the EGR valve.

OPERATING CONDITIONS

The following parameters determine the

operation of the EGR solenoid valve:
- air temperature,
- coolant temperature,
- atmospheric pressure,
- accelerator pedal position,
- engine speed,
- vehicle speed,
- battery voltage.

EGR operation is stopped if :

- the air temperature is less than 15 °C or greater
than 60 °C,
- the coolant temperature is less than 15 °C or
greater than 120 °C,
15761R
- the battery voltage is less than 10 Volts,
- atmospheric pressure is less than 890 mbars,
- mapping (load potentiometer/engine speed 1 Solenoid feed
pair) is greater than a certain threshold. 2 Sensor feed
4 Sensor earth
The EGR valve is fed for 30 seconds after the 5 Solenoid earth
engine is started if the preliminary conditions 6 Sensor output
allow.

The vehicle must then exceed 6 mph (10 km/h)

before the exhaust gas recirculation cycle at idle
speed can be implemented. The EGR valve is then
closed for 30 seconds whenever the engine
returns to idle speed.

14-3