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TECHNICAL NOTE 3364A
C066 - C06C
Special featuresof the sequential gearbox
JH1/D7F and JH1/D4F
For parts not dealt with in this Technical Note,
refer to Repair Manual 305 and to Technical Note 2682.
77 11 294 022
"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which hisvehicles are constructed."
DECEMBER 2000
All copyrights reserved by Renault.
EDITION ANGLAISE
Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority of Renault.
© RENAULT 2000
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Contents
Page
07
12
13
16
17
VALUES AND SETTINGS
Tyres and wheels 07-1
Brakes 07-2
FUEL MIXTURE
Technical specifications 12-1
Inlet manifold 12-5
Motorised throttle body 12-7
FUEL SUPPLY
Special features 13-1Injector rail/injectors 13-2
STARTING - CHARGING
Alternator 16-1
Starter 16-2
INJECTION
Special features 17-1
Location of components 17-2
Accelerator pedal potentiometer 17-3
Immobiliser function 17-4
Injection programming/air conditioning 17-5Motorised throttle body 17-7
Idle speed correction 17-8
Richness regulation 17-9
Adaptive richness correction 17-11
Centralised coolant temperaturemanagement (GCTE) 17-12
Antipollution 17-13
Computer 17-14
Page
20
21
37
CLUTCH
Identification 20-1
MANUAL GEARBOX
Gears 21-1
Capacity - lubricant 21-1
Consumables 21-2
Parts to be systematically replaced 21-2
Hydraulic unit oil 21-2
Layouts 21-3Description 21-4
Diagram 21-5
Operation 21-6
Hydraulic unit 21-7 Accumulator 21-11
Pump unit 21-12
Pump 21-13Tank 21-15
Clutch module 21-16
Actuator module 21-19
Solenoid valves 21-23
Engagement position sensor 21-25
Selected position sensor 21-26
Clutch position sensor 21-27
Pressure sensor 21-28Computer 21-29
Relays 21-31
Fuses 21-32
Wiring harness 21-33
Gear lever 21-34
Programming 21-36
MECHANICAL ELEMENTS CONTROL
Master cylinder 37-1Brake servo 37-3
Air filter - Brake servo non-return valve 37-5
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VALUES AND SETTINGS
Tyres and wheels 07107VALUES AND SETTINGS
Tyres and wheels
(1) With full load and on motorways.
Tightening torque of the wheel nuts: 10.5 daNm
Rim run-out: 1.2 mm
Type Rim Tyres
Tyre pressure when
cold (in bar) (1)
Front Rear
C06 6
C06 C5.5 J 14 155/65 R14 T 2.2 2.0
07-1
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VALUES AND SETTINGS
Brakes 07
07-2
Brakes
(1) Drum: maximum wear diameter
Type
Disc thickness (in mm)
Drum diameter or
Disc thickness
(in mm)
Max. disc
run-out (in mm)Front Rear
Normal Min. Normal Max. (1)
C06 6
C06 C20.6 17.7 203 204.45 0.07
Type
Lining thicknesses (in mm) (including backing)
Brake fluidFront Rear
New Min. New Min.
C06 6C06 C 18 6.5 6.5 4.5 SAE J1703DOT 4
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FUEL MIXTURE
Specifications 12D7F ENGINE
112FUEL MIXTURE
Specifications
(1) at 2 500 rpm, the CO content should be 0. maximum.
Vehicles Gearbox
Engine
Depollution
standardType Index
Bore
(mm)
Stroke
(mm)
Capacity
(cm3 )
Compression
ratio
Catalytic
converter
C06 6 JH1 D7F 703 69 76.8 1149 9./1◊ C82
◊ C239
EU 00
(Euro 2000)
Tests at idle speed*
Fuel***
(minimum octane rating)Engine speed(rpm)
Pollutant emission **
CO (%) (1) CO2 (%) HC (ppm) Lambda (λ)
750 ± 50 0.5 max 14.5 min 100 max 0.97<λ<1.03 Super unleaded (95 RON)
*
*****
For a coolant temperature greater than 80 ˚C and after the speed has stabilised at 2 500 rpm for
approximately 30 seconds.
For legal values refer to your country specification.91 RON unleaded compatible.
Temperature in ˚C - 10 25 50 80 110
Air sensor
NTC type
Resistance in ohms
10 450 to 8 525 2 120 to 1 880 860 to 760 - -
Coolant sensor
NTC typeResistance in ohms
- 2 360 to 2 140 770 to 850 275 to 290 112 to 117
12-1
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FUEL MIXTURE
Specifications 12
12-2
D4F ENGINE
Vehicle Gearbox
Engine
Depollution
standardType Index
Bore
(mm)
Stroke
(mm)
Capacity
(cm3 )
Compression
ratio
Catalytic
converter
C06C JH1 D4F 702 69 76.8 1149 9.8/1 C127 EU 00
Engine
Tests at idle speed*
Fuel***
(minimum octane
rating)
Engine
speed(rpm)
Pollutant emission **
Type Suffix CO (%) (1) CO2 (%) HC (ppm) Lambda (λ)
D4F 702 750 ± 50 0.5 max 14.5 min 100 max 0.97<λ<1.03Unleaded
(95 RON)
(1)*
**
***
at 2 500 rpm the CO content should be 0.3 maximum.For a coolant temperature greater than 80 ˚C and after the speed has stabilised at 2 500 rpm for
approximately 30 seconds.For legal values refer to your country specification.
91 RON unleaded compatible.
Temperature in ˚C - 10 25 50 80 110
Air temperature sensor
NTC typeResistance in ohms 10 450 to 8 625 2 065 to 2 040 815 to 805 - -
Coolant temperature sensor
NTC type
Resistance in ohms
- 2 360 to 2 140 850 to 770 290 to 275 117 to 112
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FUEL MIXTURE
Specifications 12
12-3
D7F ENGINE
DESCRIPTION MARQUE/TYPE SPECIAL NOTES
Injection and ignition computer SAGEM S 2000112 tracksSequential multipoint injection
Static ignition
Motorised throttle body Ø 40 mm
(double track integrated
potentiometer)
MGI/VDOEngine resistance = 1.6 ± 0.3 Ω
Potentiometer resistance = 1 200 ± 240 Ω
Accelerator pedal sensor (mounted
on the sub-frame)CTS
Double track potentiometer
Track resistance = 1 700 ± 15 Ω
Ignition coils SAGEM
Two coils with two grouped outputs
Primary resistance ≈ 0.5 Ω
Secondary resistance: 11 ± 1 kΩ
Manifold pressure sensor DELCO Resistance ≈ 50 kΩ
Pinking sensor SAGEM Piezoelectric type
Magnetic sensor
(TDC and engine speed)ELECTRIFIL/SIEMENS
Variable reluctance type
Resistance = 200 to 270 Ω
Oxygen sensors (upstream and
downstream)NTK
Heater resistance = 6 ± 1 Ω at 23 ˚CInternal resistance = 5 kΩ maximum
Rich mixture > 750 mV ± 70
Lean mixture < 150 mV ± 50
Injector SIEMENS Resistance: 14.5 ± 0.7 Ω at 20 ˚C
Canister solenoid valve SAGEMIntegrated into the canister
Resistance: 26 ± 4 Ω at 23 ˚C
Coolant pressure sensor. TEXAS INSTRUMENTSFor the use of air conditioning without a cold
loop (omission of air conditioning computer)
Booster pump -Pressure: 3.5 bar ± 0.06 Minimum flow: 80 at 100 l/h
Spark plugs NGK BKR 5 EK
Idle speed manifold pressure - 340 ± 40 mbar
Exhaust counter-pressure -
Upstream of the pre-catalytic converter
1 500 rpm
3 000 rpm
4 500 rpm
5 500 rpm
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FUEL MIXTURE
Specifications 12
12-4
D4F ENGINE
DESCRIPTION MARQUE/TYPE SPECIAL NOTES
Injection and ignition computer MAGNETI MARELLI 96 tracksSequential multipoint injection
Static ignition
Motorised throttle body (double
track integrated potentiometer)
MAGNETI MARELLI Ø 42 mm
Engine resistance: 2 ± 0,3 Ω
Potentiometer resistance: 2 500 ± 500 Ω
Accelerator sensor
(mounted on sub-frame)
CTS Double track potentiometer
Track 1 resistance = 1 700 ± 900 Ω
Track 2 resistance = 3000 ± 2200 Ω
Ignition coils ELECTRICFIL Two coils with two grouped outputs
Primary resistance = 0.4 ± 0.02 Ω
Secondary resistance = 11 ± 1 kΩ
Manifold pressure sensor DELCO
Pinking sensor SAGEM
Magnetic sensor
(TDC and engine speed)
SIEMENS Resistance = 200 to 270 Ω
Oxygen sensor (upstream and
downstream)
NTK Heater resistance = 3.3 ± 0.5 Ω at 23 ˚C
Internal resistance = 5 kΩ maximum
Rich mixture > 850 mvolts
Lean mixture < 100 mvolts
Injectors MAGNETI MARELLI"PICO"
Resistance: 14.5 ± 0.7 Ω at 20˚C
Canister solenoid valve SAGEM Integrated into the canister
Resistance: 26 ± 3 Ω at 23˚C
Coolant pressure sensor.TEXAS
INSTRUMENTS
Booster pump Pressure: 3.5 bar ± 0.06
Minimum flow: 80 to 100 l/h
Spark plugs CHAMPIONREA 8 MCL Gap: 0.9 mm
Idle speed manifold pressure 350 ± 50 mbars
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FUEL MIXTURE
Inlet manifold 12
12-5
D4F ENGINE Inlet manifold
REMOVAL
Disconnect the battery.
Remove:
– the air filter unit, – the engine cover.
Disconnect:
– the injection computer connectors,
– interconnection (A) on the engine wiring harness, – the manifold pressure sensor (1).
Remove the anti-interference condenser located
behind the engine (arrow B).
Disconnect:
– the ignition coil connector and remove the anti-
interference condenser,
– the high voltage spark plug leads by pulling themthrough the extension cable,
– the pinking sensor and release the inlet manifold
wiring,
– the coolant temperature sensor (2).
Disconnect
– the brake servo vacuum pipe (manifold side),
– the fuel vapour rebreathing pipe,
– the fuel supply pipe,
– the starter cables.
Remove:
– the inlet manifold bolts,
– the inlet manifold by shifting it to the right while
disconnecting the motorised throttle body connector,
the air temperature sensor and the injectors.
TIGHTENING TORQUES (in daNm)
Inlet manifold/cylinder head (bolts 4 and 5) 0.6
then all the bolts 1
Inlet manifold/cylinder head cover 1
18445R
18444S
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FUEL MIXTURE
Inlet manifold 12
12-6
D4F ENGINE
REFITTING
Replace the inlet manifold gasket, the cylinder head
cover/inlet manifold gasket and the oil vapour
rebreather pipe gasket.
Refit:
– the inlet manifold, reconnecting the injectors, the air
temperature sensor and the motorised throttle body,
– the eight bolts on the inlet manifold using Loctite
FRENETANCH and pre-tighten to 0.6 daNm on bolts(4) and (5).
Loosen bolts (4) and (5).
Tighten bolts (1) to (8) definitively, applying a torque of
1 daNm.
Refit and tighten the four upper mounting bolts on the
manifold in a cross-wise pattern to a torque of
1 daNm.
Continue the refitting procedure in the reverse order to
removal.
WARNING: the mounting bolts for the inlet
manifold on the cylinder head project into the
cylinder head. It is vital that you fit them usingLoctite FRENETANCH.
18444R1
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FUEL MIXTURE
Motorised throttle body 12
12-7
D7F ENGINE Motorised throttle body
IMPORTANT:
Never:
– change the position of the stop screw (A),
– remove the support clip from the axis (B),
– remove the motor bolts from the motorised
throttle body (C).
Motorised throttle body connector:
1 Earth
2 Track 1 potentiometer signal
3 Motor supply
4 Motor earth
5 5 V supply
6 Track 2 potentiometer signal
REMOVAL
Removing the motorised throttle body does not pose
any special problems.
17790R
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FUEL MIXTURE
Motorised throttle body 12
12-9
D4F ENGINE
ALLOCATION OF CONNECTOR TRACKS
MOTORIZED THROTTLE BODY CONNECTOR
18440S
TRACK Description1
2
3
4
5
6
Earth
Track 1 potentiometer signal
Motor supply
Motor earth
5 volt supply
Track 2 potentiometer signal
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FUEL SUPPLY
Special notes 13113FUEL SUPPLY
Special notes
The petrol fuel supply system for the engine is a no-return circuit.
The petrol fuel pressure no longer varies depending on the engine load.
The circuit comprises:
– a rail (1) without a union to return piping and without a supply pressure regulator,
– a single pipe (2) coming from the tank, – a pump/feed gauge assembly (3) fitted with a pressure regulator (4) (located in the tank),
– a fuel filter (5) located under the car,
– a tank for reabsorbing fuel vapour (6).
OPERATING DIAGRAM OF THE PETROL CIRCUIT
15777R
13-1
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FUEL SUPPLY
Injector rail/injectors 13
13-2
D7F ENGINE Injector rail/injectors
Removing the rail does not pose any special problems and can be done
without removing the inlet manifold.
REMOVAL
Remove:
– the wiring harness clips,
– the wiring harness,
– the injector mounting clips,
– the injectors.
Take note of the injection clips position on the injectors.
17791R
REFITTING
Replace the injector O-rings.
Listen for the click that indicates the fuel supply union is correctly fastened.
For the other operations, refitting is the reverse of removal.
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STARTING - CHARGING
Starter 16116STARTING - CHARGING
Starter
REMOVAL
– Put the car on a two-post lift and disconnect the
battery.
– Remove the cooling fan,
– disconnect the starter electrical connections.
Remove the two starter mounting bolts.
REFITTING
Refitting is the reverse of removal.
10076R
16-1
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INJECTION
Special features 17D7F ENGINE
117INJECTION
Special features
SPECIAL FEATURES OF THE SEQUENTIAL MULTIPOINT INJECTION
q A SAGEM "S 2000" 112 track computer controls the injection and ignition.
q Multipoint injection operating in sequential mode without a camshaft position sensor . This means that phasing is
controlled by software using the TDC sensor.
q Integrated OBD "On Board Diagnostic" indicator light on control panel (linked to an EOBD "European On Board
Diagnostic" system).
q Injection warning light on instrument panel.
q Motorised throttle body regulates airflow and idle speed.
q Use of two oxygen sensors (upstream and downstream of the catalytic converter).
q Injection computer controls the fan assemblies and the coolant temperature warning lights on the instrument panel.
q Idling speed correction depending on:
– battery voltage,
– air conditioning.
q Idle speeds:
– nominal idle speed
– idle speed with automatic transmission operation
752 rpm
848 rpm
q Maximum engine speeds: – when the coolant temperature is lower than 40˚ C
– for a temperature of > - 40 ˚ C in 1st and 2nd gear (depending on SRBCI) – for a temperature of > - 40 ˚ C in 3rd, 4th and 5th gear
– when reversing
6 100 rpm
6 100 rpm6 100 rpm
6 100 rpm
17-1
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INJECTION
Special features 17
17-2
D4F ENGINE
SPECIAL FEATURES OF THE SEQUENTIAL MULTIPOINT INJECTION
q A MAGNETI MARELLI "5NR" 96 track computer controls the injection and ignition.
q Multipoint injection operating in sequential mode without a camshaft position sensor . This means that phasing is
controlled by software using the TDC sensor.
q Injection warning light on the instrument panel. Special injection warning light (OBD "On Board Diagnostic"
warning light) integrated as part of the EOBD "European On Board Diagnostic" system.
q Use of two oxygen sensors (upstream and downstream of the catalytic converter).
q Motorised throttle body to regulate the airflow and the idle speed.
q Fuel circuit without return to the tank (the pressure regulator is located on the pump/sender unit).
q Idling speed correction depending on:
– battery voltage,
– air conditioning.
q Canister drain solenoid valve controlled by Opening Cyclic Ratio (RCO).
q Injection computer controls the fan assemblies and the coolant temperature warning light on the instrument panel
(GCTE function).
q Injection computer controls the air conditioning (the air conditioning computer is no longer fitted).
q
Idle speeds: – nominal idle speed – idle speed with automatic transmission operation
750 rpm
750 rpm
q Maximum engine speeds:
– when the coolant temperature is lower than 40˚ C
– in 1st gear (depending on SRBCI) – in 2nd, 3rd, 4 th and 5th gears
– when reversing
6 300 rpm
6 100 rpm
6 300 rpm
6 300 rpm
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INJECTION
Location of components 17
17-4
D4F ENGINE
PHOTO 19681
1
2
3
4
5
6
7
8
9
10
1112
13
Inertia switch
Monobloc coil with double output
Manifold pressure sensor Injection computer
Motorised throttle body with integrated temperature sensor
Accelerator pedal potentiometer
Supply relay
Fuel vapour tank (canister) with integrated solenoid valve
TDC sensor
Coolant temperature sensor
Pinking sensor Injector railSequential gearbox computer
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INJECTION
Accelerator pedal potentiometer 17
17-5
ENGINES
D4F - D7F Accelerator pedal potentiometer
The accelerator pedal position potentiometer is
located on the front sub-frame.
To remove, place the car on a two-post lift. There are
no special instructions for removal.
Potentiometer connector:
1 Track 2 potentiometer signal
2 Track 1 potentiometer signal
3 Track 2 supply
4 Track 1 supply5 Track 2 earth6 Track 1 feed
17974-1S
15760S
15759R1
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INJECTION
Immobiliser function 17
17-6
D7F ENGINE Immobiliser function
This vehicle is fitted with an engine immobiliser controlled by a random rolling code key recognition system.
REPLACING AN INJECTION COMPUTER
The injection computers are supplied without a code but they must all be programmed with one.
When the computer is replaced, the vehicle code must be programmed in and then a check must be made to ensure
that the immobiliser system is operational.
To do this, simply switch on the ignition for a few seconds without starting the engine, then switch it off. When theignition is off, the engine immobiliser function will be activated after approximately 10 seconds (red engine
immobiliser warning light flashes).
IMPORTANT:
With this engine immobiliser, the computer keeps its immobiliser code for life.
In addition, this system does not have a security code.
Consequently, it is forbidden to perform tests with computers borrowed from the stores or from another
vehicle which must then be returned.
It will no longer be possible to decode them.
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INJECTION
Injection/air conditioning management 17
17-7
D7F ENGINE Injection/air conditioning management
THE COMPRESSOR IS OF VARIABLE DISPLACEMENT TYPE
INJECTION COMPUTER / AIR CONDITIONING COMPUTER CONNECTION
The injection computer is linked to the air conditioning computer by two wires and to the coolant pressure sensor
by three wires:
– one injection computer wire leads to the air conditioning computer track C-F3. The instruction to authorise or
prohibit compressor operation is conveyed along this wire.
– one air conditioning computer wire leads to the injection computer track C-A1. This consists of the absorbed
power information signal.
– three injection computer wires lead to the coolant pressure sensor. Track B-J3 for Freon pressure information.
When the air conditioning is switched on, the air conditioning computer authorises compressor operation.
The injection computer either authorises or blocks engagement of the compressor clutch, orders modified idle speed
and controls the fan unit. In this case, the engine speed can reach 880 rpm depending on how much power is
absorbed by the compressor.
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the injection computer stops the compressor from functioning.
Engine start programming
The compressor is prevented from operating for 12 seconds after the engine has started.
Heat protection
The compressor is not engaged in cases where the coolant temperature is greater than 115 °C .
Overspeed protection programming
The compressor is prevented from operating if the engine speed is greater than 6 200 rpm.
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INJECTION
Injection/air conditioning management 17
17-8
D7F ENGINE
Recovery of performance
The compressor is disengaged for 8 seconds when the following conditions are combined:
Entry conditions
– throttle position potentiometer at full load
– and engine speed less than 3 000 rpm.
– and vehicle speed less than 55 mph (85 km/h).
Exit conditions
– Full load not recognised
– or delay of 8 seconds expired
– or engine speed greater than or equal to 3 500 rpm
– or vehicle speed greater than 55 mph (87 km/h).
Recovery of power at full load
When at full load the air conditioning compressor is disengaged for 15 seconds when the power absorbed by the air
conditioning compressor is significant:
Entry conditions
– engine speed less than 3 000 rpm.
– and vehicle speed less than 2.5 mph (4 km/h).
– and 1st or 2nd gear is engaged
– and the throttle section greater than 0 mm2
Exit conditions
– delay of 15 seconds expired
– or engine speed greater than or equal to 3 500 rpm
– or vehicle speed greater than 9 mph (15 km/h).
Recovery of power at full load when the vehicle starts moving
The air conditioning compressor is disengaged if the following conditions are met to help initial movement of the
vehicle:
Entry conditions
– engine speed greater than 2 208 rpm
– and vehicle speed less than 2.5 mph (4 km/h).
– and throttle section greater than 0 mm2
– and 1st or 2nd gear is engaged
Exit conditions
– vehicle speed greater than 15 mph (25 km/h).
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INJECTION
Motorised throttle body 17
17-9
ENGINES
D4F - D7F Motorised throttle body
MOTORISED THROTTLE BODY
The motorised throttle body carries out idle speed regulation and engine air intake modulation functions. It consists
of an electric motor and a throttle position potentiometer.
When the engine is idling, the throttle position is adjusted according to the idle speed setting. This setting takes into
account the major power consumers (air conditioning), operating conditions (air temperature and coolant
temperature) and acceleration request.
When the driver presses the accelerator pedal, his request is translated as the angle of the throttle opening.
However, to improve driving pleasure, the throttle opening is not directly proportional to the driver's request.
To eliminate misfires, facilitate gear changes and safety functions, the throttle body modulates the engine torque.
MOTORISED THROTTLE BODY DEFECT MODES
The motorised throttle body has three types of defect mode.
q Reduced Performance Mode: this mode covers electrical faults for which there is a viable backup solution for theinjection system (loss of one of the two tracks on the pedal or the throttle body).
This mode results in reduced acceleration and limits the maximum opening of the throttle.
q Driver Override Mode: this mode is also called Electrical Limp Home. This mode is applied when the accelerator
pedal signal disappears completely, but the injection computer still controls the intake of air to the engine (automatic
throttle control is still operational).
In this mode, the injection computer imposes a set engine speed for each gear ratio and imposes the idle speedwhen the brake pedal is pressed.
q Mechanical Limp Home Mode: this mode covers breakdowns which result in loss of the automatic throttle control(the throttle can no longer be controlled).
In this case the throttle is in the mechanical rest position and the injection computer limits the engine speed by
cutting off the injection.
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INJECTION
Idle speed adjustment 17
17-10
D7F ENGINE Idle speed adjustment
ELECTRICAL CORRECTION AS A FUNCTION OF BATTERY VOLTAGE AND ELECTRIC POWER BALANCE
The lower the battery voltage, the greater the correction. Correction of the engine speed is therefore variable. It
begins when the voltage drops to below 12.7 Volts. The idling speed may reach 128 rpm maximum.
IDLING SPEED CORRECTION DEPENDING ON AIR CONDITIONING STATUS
If air conditioning is selected on the instrument panel, the idling speed is set to 880 rpm.
ADAPTIVE IDLE SPEED ADJUSTMENT
This adjustment only takes effect if the coolant temperature is above 70 ˚C, 30 seconds after the engine is started
and during the idle speed regulation phase.
VALUES OF THE IDLING OPENING CYCLIC RATIO AND ITS ADAPTIVE CORRECTION
Each time the ignition is switched off, the computer programs the minimum and maximum motorised throttle body
stops.
IMPORTANT: after erasing the computer memory, it is essential to start the engine then stop it to allow themotorised throttle body to be reset. Start it again and let it run at idle speed so that the adaptive correction can take
place.
PARAMETERS D7F 703 Engine
Nominal idle speed X = 752 rpm
Idling opening cyclic ratio 0 % ≤ # 12 ≤ 10 %
Adaptive idling opening cyclic ratio Stop:
minimum: - 3.9 %
maximum: 6.25 %
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INJECTION
Mixture control 17
17-11
D7F ENGINE Mixture control
An engine using the SAGEM S 2000 computer is equipped with two oxygen sensors, called the upstream sensor
and the downstream sensor.
HEATING THE SENSORS
Heating the oxygen sensors is controlled by the computer:
– if the inlet manifold pressure is below a threshold which varies according to the engine speed,
– if the speed is below 150 mph (255 km/h),
– after the engine has been running for a certain length of time, programmed according to the top dead centre
(outside no load position) and the coolant temperature for the downstream sensor.
Heating the oxygen sensors stops:
– if vehicle speed is greater than 150 mph (255 km/h), (example),
– with the throttle potentiometer in the full load position.
UPSTREAM SENSOR VOLTAGE
The value read on the diagnostic equipment (except XR25) under the upstream sensor voltage parameter
represents the voltage supplied to the computer by the oxygen sensor located upstream of the catalytic converter. It
is expressed in millivolts.
The voltage should fluctuate between two values during richness regulation:
– 20 mV ± 50 for a lean mixture,
– 840 mV ± 70 for a rich mixture.
The smaller the difference between the minimum and maximum values, the poorer the signal from the sensor (the
difference is usually at least 500 mV).
NOTE: if the difference is small, check the sensor heater.
DOWNSTREAM SENSOR VOLTAGE
The value read on the diagnostic equipment (except XR25) under the downstream sensor voltage parameter
represents the voltage supplied to the computer by the oxygen sensor located downstream of the catalytic
converter. It is expressed in millivolts.
The function of this sensor is to locate faults on the catalytic converter and to perform a second more precise check
on the richness (slow regulation loop). This function does not operate at idle speed and only starts operating after
the engine has been running for a while.
When the engine is operating in a closed loop, at stabilised speed, the voltage should vary within the range600 mV ± 100.
When the engine is decelerating, the voltage should be less than 200 mV.
The voltage read on the diagnostic tools at idling speed should be ignored.
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INJECTION
Mixture control 17
17-12
D7F ENGINE
MIXTURE ADJUSTMENT
The value read on the diagnostic tools (except XR25) under the richness correction parameter represents the
average of the richness corrections applied by the computer depending on the richness of the fuel mixture asdetermined by the oxygen sensor located upstream of the catalytic converter.
The correction value has a mid-point of 128 and limits of 0 and 255:
– value less than 128: leaner mixture required,
– value greater than 128: richer mixture required.
ENTRY INTO RICHNESS REGULATION MODE
Loop phase
Entry into richness regulation takes place after a time of 28 seconds to 210 seconds from the time the engine isstarted, if the coolant temperature is greater than 22 ˚C.
Unlooping phase
In mixture regulation mode, the phases of operation during which the computer ignores the value of the voltage from
the sensor are:
– at full load,
– during heavy acceleration, – during deceleration with a no load signal,
– when the oxygen sensor is faulty.
DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT
If the voltage from the oxygen sensor is incorrect (varies only slightly or not at all) during richness regulation, the
computer will only enter defect mode (value = 128) if the fault has been present for a period of time (at least
10 minutes' delay). Only in that case will the fault will be stored.
If an oxygen sensor fault is present and detected and if the fault has already been stored, the system goes directly to
the open loop mode. In this case, the richness correction parameter = 128.
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INJECTION
Adaptive richness adjustment 17
17-13
D7F ENGINE Adaptive richness adjustment
PRINCIPLE
In looping phase, the richness regulation corrects the injection time to obtain fuel dosing as close as possible to a
richness of 1. The correction value is close to 128, with limits of 0 and 255.
Adaptive mixture adjustment makes it possible to of fset the injection mapping to reset the richness regulation to 128.
Adaptive adjustments take 128 as an average value after initialization (erasing the memory) and have the following
limit values:
ROAD TEST
Conditions:
– engine warm (coolant temperature above 75 ˚C),
– do not exceed an engine speed of 4 290 rpm
– disconnect the canister solenoid valve or block the inlet pipe on the engine.
Pressure zones which must be passed through during the test
Following this test the adjustments will be operational.
The test must then be continued by driving normally, in a varied manner for 3 to 6 miles (5 to 10 km).
After the test, record the values of the adaptive programs. Initially 128, they may have changed. If not, repeat thetest ensuring that the test conditions are observed.
INTERPRETATION OF VALUES OBTAINED FROM A ROAD TEST'
In the case of a lack of fuel, the richness regulation (in #35) increases to obtain a richness as close as possible to 1
and the adaptive richness correction increases until the richness correction again fluctuates at around 128.
In the event of an excessive amount of fuel, the logic is reversed: the richness regulation decreases and the
adaptive richness correction also decreases to realign the richness correction at around 128.
PARAMETERS D7F 703 Engine
Mixture adjustment 89 ≤ #35 ≤ 166
Operating adaptive richness 64 ≤ #30 ≤ 192
Idle adaptive richness 64 ≤ #31 ≤ 192
Zone no. 1
(mbars)
Zone no. 2
(mbars)
Zone no. 3
(mbars)
Zone no. 4
(mbars)
Zone no. 5
(mbars)
D7F 703 259 381 529 677 825 873
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INJECTION
Coolant temperature management (GCTE) 17
17-14
D7F ENGINECoolant temperature management (GCTE)
The fan unit is controlled by the injection computer.
ANTIPERCOLATION FUNCTION
The antipercolation system is controlled by the injection computer.
The coolant temperature signal used is the one from the injection system.
After the engine is switched off the system enters monitoring mode. If the coolant temperature exceeds the limit of
101 ˚C during the 35 seconds after the engine is switched off, the fan unit is controlled at slow speed.
If the coolant temperature falls below 95 ˚C, the fan unit relay is cut off (the fan unit cannot be controlled for more
than 3 minutes).
OPERATION OF THE FAN UNITS
– The fan unit is controlled at slow speed if the coolant temperature exceeds 98 ˚C and is switched off when thetemperature falls below 96 ˚C.
– The fan unit is controlled at high speed if the coolant temperature exceeds 103 ˚C and is switched off when the
temperature falls below 100 ˚C.
– The fan unit is controlled when the air conditioning function is selected on the instrument panel.
OPERATION OF THE TEMPERATURE LIGHT
The coolant temperature warning light comes on if the coolant temperature exceeds 118 ˚C and goes out when the
temperature falls below 115 ˚C.
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INJECTION
Antipollution 17
17-15
D7F ENGINE Antipollution
ANTIPOLLUTION
CANISTER PURGE CONDITIONS
The canister purge solenoid valve is controlled by RCO (Opening Cyclic Ratio) signals:
– when the coolant temperature is greater than 20˚ C,
– when the temperature is greater than 10˚ C,
– with the accelerator pedal position at no load,
– when the engine speed is greater than 1 470 rpm,
– when the manifold pressure is greater than 990 mbar ,
IMPORTANT:
The valve of the closed solenoid valve is never equal to 0. The minimum read value is approximately 1.20 %.
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INJECTION
Computer 17
17-16
D7F ENGINE Computer
INJECTION COMPUTER TRACK ASSIGNMENTS
CONNECTOR A
H2
H3
H4
G2
G4
F2
F3
F4
E4
B2
B3
B4
←
---
------
---
---
←
---
←
→
→
→←
LOAD POTENTIOMETER SIGNAL (TRACK 1)
LOAD POTENTIOMETER EARTH (TRACK 1)
POWER EARTHLOAD POTENTIOMETER SUPPLY (TRACK 1)
POWER EARTH
LOAD POTENTIOMETER SUPPLY (TRACK 2)
LOAD POTENTIOMETER SIGNAL (TRACK 2)
LOAD POTENTIOMETER EARTH (TRACK 2)
BRAKE SIGNAL
COOLANT TEMPERATURE WARNING LIGHT CONTROL
ON BOARD DIAGNOSTIC WARNING LIGHT CONTROL
FAULT FINDING
CONNECTOR B
M2
M3M4
L2L3
L4K3
K4J3
H2
H3
H4
G2
G3
G4
F2
F3
F4
E2
E3
E4
D2
D3
D4
C2
C3
B2
A2
A4
→
→ →
→ →
→
→←
→←
←
---
←
---
---
←
---
←
←
---
←
---
←
←
←
→
---
←
---
←
---
INJECTOR 4 CONTROL
(-) MOTORISED THROTTLE CONTROL(+) MOTORISED THROTTLE CONTROL
INJECTOR 3 CONTROLINJECTOR 2 CONTROL
INJECTOR 1 CONTROLMULTIPLEXING (ENGINE/GEARBOX)
MULTIPLEXING (ENGINE/GEARBOX)REFRIGERANT PRESSURE SENSOR SIGNAL
REFRIGERANT SENSOR AND MANIFOLD PRESSURESENSORS SUPPLY
MANIFOLD PRESSURE SENSOR SIGNAL
REFRIGERANT SENSOR AND MANIFOLD PRESSURE
SENSOR SUPPLY
MOTORISED THROTTLE BODY POTENTIOMETER FEED
MOTORISED THROTTLE BODY POTENTIOMETER
SIGNAL (TRACK 1)
MOTORISED THROTTLE BODY POTENTIOMETER
EARTH (TRACK 1)
COOLANT TEMPERATURE SIGNAL
ENGINE SPEED SENSOR SIGNAL
COOLANT TEMPERATURE SENSOR EARTH
AIR TEMPERATURE SIGNAL
AIR TEMPERATURE SENSOR EARTH
ENGINE SPEED SENSOR SIGNAL
IMMOBILISER
MOTORISED THROTTLE POTENTIOMETER SIGNAL
(TRACK 2)
ACTUATOR CONTROL RELAY
PINKING SENSOR SCREENING
VEHICLE SPEED INFORMATION
PINKING SENSOR EARTH
PINKING SENSOR SIGNAL
+ AFTER IGNITION
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INJECTION
Computer 17
17-17
D7F ENGINE
INJECTION COMPUTER TRACK ASSIGNMENTS (CONT)
CONNECTOR C
A2
A1
B3B2
B1
C2
C1
D1
E1
F3
F2
F1
G3
G2
G1
H3
H2
H1
←
←
→ ---
←
→
---
→
→
→
→
→
→
---
→
→
→
---
DOWNSTREAM OXYGEN SENSOR SIGNAL
AIR CONDITIONING INFORMATION
ENGINE SPEED INFORMATIONDOWNSTREAM OXYGEN SENSOR SIGNAL EARTH
UPSTREAM OXYGEN SENSOR SIGNAL
INJECTION FAULT WARNING LIGHT CONTROL
DOWNSTREAM OXYGEN SENSOR SIGNAL EARTH
PUMP/COIL CONTROL RELAY
CANISTER BLEED SOLENOID VALVE
AIR CONDITIONING COMPRESSOR CLUTCH RELAY
HIGH SPEED FAN UNIT CONTROL RELAY
LOW SPEED FAN UNIT CONTROL RELAY
UPSTREAM OXYGEN SENSOR HEATER CONTROL
+ AFTER RELAY FEED
UPSTREAM OXYGEN SENSOR HEATER CONTROL
IGNITION COIL CONTROL CYLINDERS 2 AND 3 (opposite
track H3)IGNITION COIL CONTROL CYLINDERS 1 AND 4 (opposite
track H3)
POWER EARTH
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INJECTION
Computer 17
17-18
D4F ENGINE
INJECTION COMPUTER TRACK ASSIGNMENTS
CONNECTOR A (BLACK)
A1A3
A4
B1
B3
B4
C1
C2
C3
C4
D2
D3D4
E1
E3E4
F1
F4
G1
H1
H2
H3
J1
J4
K1K2
K4
L3
L4
M1
M2
M3
L4
→ →
→
---
←
---
---
→
←
---
←
← →
---
→ →
---
←
→
←
←
---
←
---
← ---
---
---
---
→
→
→
---
INJECTION FAULT WARNING LIGHT CONTROLON BOARD DIAGNOSTIC WARNING LIGHT CONTROL
AIR CONDITIONING COMPRESSOR CONTROL
ACCELERATOR PEDAL POTENTIOMETER SUPPLY
(TRACK 1)
BRAKE SWITCH (CLOSURE)
ACCELERATOR PEDAL POTENTIOMETER SUPPLY
(TRACK 2)
REFRIGERANT PRESSURE SENSOR SUPPLY
HIGH SPEED FAN CONTROL
BRAKE SWITCH (OPENING)
ACCELERATOR PEDAL POTENTIOMETER SUPPLY
(TRACK 1)
AIR CONDITIONING CYCLE INFORMATION
IMMOBILISER SYSTEMLOW SPEED FAN CONTROL
DOWNSTREAM OXYGEN SENSOR EARTH
COOLANT TEMPERATURE WARNING LIGHT CONTROLSPEED INFORMATION
ACCELERATOR PEDAL POTENTIOMETER SUPPLY(TRACK 2)
VEHICLE SPEED
FUEL PUMP CONTROL RELAY
ACCELERATOR PEDAL POTENTIOMETER SIGNAL 1
DOWNSTREAM OXYGEN SENSOR SIGNAL
MULTIPLEX CONNECTION (UCH)
REFRIGERANT PRESSURE SENSOR SIGNAL
MULTIPLEX CONNECTION (UCH)
ACCELERATOR PEDAL POTENTIOMETER SIGNAL 2REFRIGERANT PRESSURE SENSOR EARTH
DIAGNOSTIC (LINE K)
+ AFTER IGNITION
+ BEFORE IGNITION
DOWNSTREAM OXYGEN SENSOR HEATER CONTROL
ACTUATOR CONTROL RELAY
CANISTER BLEED CONTROL
+ AFTER IGNITION
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INJECTION
Computer 17
17-19
D4F ENGINE
INJECTION COMPUTER TRACK ASSIGNMENTS (CONT)
CONNECTOR B (BROWN)
A1A2
B2
C1
C2
C3
D1
D2
D3
D4
E3
E4
F1
F2F3
F4
G1
G3
J1
K1
K3
K4
L1
L2
L3
L4M1
M2
M3
M4
← ←
---
---
←
←
---
---
---
←
←
←
---
---←
←
---
←
→
→
→
→
→
---
---
---→
→
→
→
SPEED SENSORSPEED SENSOR
MANIFOLD PRESSURE SENSOR FEED
MOTORISED THROTTLE BODY POTENTIOMETERS
SUPPLY (5V)
PINKING SENSOR
PINKING SENSOR
UPSTREAM OXYGEN SENSOR EARTH
PINKING SENSOR SHIELDING
AIR TEMPERATURE SENSOR SUPPLY
AIR TEMPERATURE SENSOR SIGNAL
UPSTREAM OXYGEN SENSOR SIGNAL
AIR TEMPERATURE SENSOR SIGNAL
COOLANT TEMPERATURE SENSOR SUPPLY
MANIFOLD PRESSURE SENSOR EARTHMANIFOLD PRESSURE SENSOR SIGNAL
THROTTLE BODY POSITION POTENTIOMETER
SIGNAL 2THROTTLE BODY POSITION POTENTIOMETER EARTH
THROTTLE BODY POSITION POTENTIOMETERSIGNAL 1
INJECTOR 1 CONTROL
INJECTOR 2 CONTROL
INJECTOR 3 CONTROL
INJECTOR 4 CONTROL
MOTORISED THROTTLE BODY CONTROL
POWER EARTH
POWER EARTH
POWER EARTHMOTORISED THROTTLE BODY CONTROL
IGNITION COIL 2-3 CONTROL
IGNITION COIL 1 CONTROL
UPSTREAM OXYGEN SENSOR HEATER CONTROL
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CLUTCH
Identification 20120CLUTCH
Identification
VEHICLE
TYPE
GEARBOX
TYPE
ENGINE
MODELMECHANISM PLATE
C06 6
C06 C
JH1 003JH1 002
JH1 007
D7F
D4F
180 DST 3500
26 splines
E = 7.6 mmD = 181.5 mm
BL: Blue
W : WhiteB : Black
R : Red
20-1
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MANUAL GEARBOX
Ratios 21
21-1
121MANUAL GEARBOX
Ratios
Capacity - Lubricants
CAPACITY
JH1 5 speed gearbox: 3.40 l.
VISCOSITY GRADE
TRX 75W 80W
CHECKING THE LEVEL
Filling is by overflow
JH1
Index TypeDifferential
ratio
Speedometer
gear 1st 2nd 3rd 4th 5th Reverse
gear
002 C06 61556
2119
1137
2241
2837
3029
4131
1139
003 C06 615
58
21
19
11
37
22
41
28
37
30
29
39
32
11
39
007 C06 C1561
2119
1137
2241
2837
3435
3932
1139
92081R
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MANUAL GEARBOX
Consumables 21
21-2
Consumables
Parts which must always be replaced
Hydraulic unit oil
Check the oil level every time the car is serviced. For information on levels see the Tank section.
Oil specified:
ELF RENAULTMATIC D3 SYN (to be ordered from ELF) Standard DEXRON III.
Capacity in litres
DESCRIPTION COMPONENT CONCERNED
MOLYKOTE 33 Medium
Part No.: 77 01 028 179Control axis half-moons
Loctite FRENBLOC Brake caliper mounting bolt
Parts to be replaced when they have been removed:
– self-locking nuts,
– gaskets,
– rubber seals.
Hydraulic unit
Total volume 0.6
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MANUAL GEARBOX
Introduction 21
21-3
Introduction
A sequential gearbox is an automated manual gearbox. Clutch engaging and disengaging and gear changing are
computer controlled.
Thus the clutch pedal disappears, gear selection is controlled by an electric switch lever and the accelerator pedal iselectrically linked to the engine via the engine computer.
Gear change times are reduced and the driver and passengers are assured a comfortable journey.
MAINTENANCE: (to be carried out during every workshop visit).
Check:
– the hydraulic fluid level (see Tank section),
– operation of horn:
q apply the handbrake,
q start the vehicle,q select a gear (indicated by the letter "A" on the control panel),
q open the driver's door,the horn should sound.
– the start lock system:
q apply the handbrake,
q select a gear (do not depress the brake pedal),
q attempt to start the engine,
the starter should not work.
TOWING:
If the gearbox is stuck in gear:
– switch on the ignition,
– depress the brake pedal,
– select neutral,
– check that the car is in neutral (e.g. by pushing the car a little).
If neutral gear cannot be engaged, the car will have to be towed with the front wheels raised.
Always switch the engine off before towing a vehicle.
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MANUAL GEARBOX
Instructions 21
21-4
Instructions
IMPORTANT:
SEQUENTIAL GEARBOX
Clean the hydraulic unit using a compressed air cleaning product before attempting any operations.
NEVER LEAVE THE CIRCUIT OPEN
NEVER USE A HIGH PRESSURE CLEANER
THROTTLE
Under no circumstances should the throttle body be opened or removed.
HYDRAULIC UNIT
Dump the pressure in the accumulator before attempting any operations.
Always use the hydraulic unit handling frame when carrying out removal operations.
SEQUENTIAL GEARBOX COMPUTER
Switch off the ignition and wait one minute before disconnecting the computer.
18278S
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MANUAL GEARBOX
Operating principle 21
21-6
Operating principle
The hydraulic unit installed in the gearbox is made up of two actuators:
→ one to select and change gear,
→ and one to control the clutch and the hydraulic power unit.
The assembly is linked to the sequential gearbox computer and the engine computer.
The gear is selected at the gear lever:
→ in automatic mode, gear changes are controlled by the computer according to autoadaptive rules,
→ in manual mode, the driver shifts the lever to send a signal to the computer, which then implements
the gear change.
When changing gear, the sequential gearbox computer controls the engine torque so as to reduce jolts, leaving the
driver free to leave his foot on the accelerator.
The automatic mode used by the sequential gearbox is based on the design of the DP0 automatic gearbox which
uses rules which adapt themselves automatically to the driving style and road conditions.
The sequential gearbox is a manual gearbox with a hydraulic control. It has, thus, become possible to automate a
5 speed manual gearbox.
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MANUAL GEARBOX
Hydraulic unit 21
21-7
Hydraulic unit
GENERAL
18119R
1 Clutch actuator
2 Pump
3 Reservoir
4 Accumulator
5 Actuator module
6 Low pressure pipe
7 High pressure pipe
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MANUAL GEARBOX
Hydraulic unit 21
21-8
N.B.: DUMP THE ACCUMULATOR PRESSURE
USING THE DIAGNOSTIC TOOL BEFORE
ATTEMPTING ANY OPERATIONS ON THE
SEQUENTIAL SYSTEM.
The accumulator pressure is dumped using theaccumulator pressure dump command.
The buzzer sounds to indicate that procedure hasbeen completed.
To confirm that the system is depressurised, go to the
PR018 hydraulic pressure parameter to read the
value.
If there is still pressure in the system, repeat theaccumulator pressure dump procedure until the
pressure is negligible and will not pose a risk when thehigh pressure pipes are removed.
REMOVAL
The sub-frame and gearbox must be removed in order
to remove the hydraulic unit.
For information on removing the sub-frame, consult
Workshop Repair Manual 305 Section 21.
Remove the gearbox without damaging the hydraulic
unit.
Remove the gearbox hydraulic unit
Disconnect the clutch fork cable.
Disconnect the primary speed sensor connector.
Unscrew the gear change control shaft by turning it 1/4
of a turn with a screwdriver.
Locked control shaft.
The shaft grooves should be facing the mark.
Unlocked control shaft.
The shaft groove should be at a 90˚ angle to the mark.
TIGHTENING TORQUES (in daNm)
Pump assembly M8 bolts 2.4
Pump assembly M10 bolts 4.4
Actuator module nuts 2.1
Actuator module studs 0.8
High pressure pipe unions 1.4
17970S
17969R
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MANUAL GEARBOX
Hydraulic unit 21
21-9
Fit the hydraulic unit handling frame.
Undo the six mounting bolts and remove the hydraulic
unit.
REFITTING
Check that the half-moons are positioned correctly.
Position the half-moons and the circlips in the control
shaft groove.
Grease the two MOLYKOTE 33 Medium half-moons
Place the control shaft on the actuator modules in a
raised and locked position.
The screwdriver slot and the shaft finger should be
facing the mark.
Fit the gasket.
Refit the hydraulic unit on the gearbox.
17968S
18011S
17972S
17970S
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MANUAL GEARBOX
Hydraulic unit 21
21-10
Remove the hydraulic unit handling frame.
Tighten the hydraulic unit mounting bolts to tightening
torque.
Using a screwdriver, press on the control shaft to clip it
onto the actuator module.
Refit the control shaft closure plate (oil the seal).
Refitting the gearbox does not pose any special
problems; refitting is the reverse of the removalprocedure.
Remove the fuel refill tank breather.
Refill the oil tank with ELF RENAULTMATIC D3 SYN
Dexron III between 32 and 38 mm above the MIN
mark.
Reprogram using the diagnostic tool, (consult theSpecial notes after replacing components in the
Hydraulic unit kit section, pages 21-36)
Topping up the reservoir
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised
(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
17970R
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MANUAL GEARBOX
Accumulator 21
21-11
Accumulator
OPERATION
The accumulator allows the pump to work
intermittently.When it is fully pressurised, it allows
three gear changes with clutch engagement/
disengagement.
Nominal operating pressures: at 20˚C: 45 bar to 55 bar
at -30˚C: 35 bar to 44 bar
N.B.:DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIALSYSTEM.
Dump the pressure in the accumulator using the
accumulator dump command (AC081).
To confirm pressure loss, go to the PR018 hydraulic
pressure parameter to read the value.
If there is still pressure in the accumulator, repeat the
accumulator dump procedure until the pressure is
negligible and will not pose a risk when the high
pressure pipes are removed.
The pressure reading should be almost zero.
REMOVAL
Disconnect the battery.
Drain the reservoir using a syringe.
Remove:
– the upper mountings of the gearbox,
– the accumulator.
REFITTING
Stick the safety label on the accumulator.
Proceed in the reverse order.
Refill the oil tank with ELFRENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MIN mark.
Reprogram using the diagnostic tool (consult theSpecial notes after replacing components in the
Accumulator system).
Topping up the reservoir
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mmabove the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition has been switched
on): The oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Accumulator 4
Lifting eye 2.1
18118S
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MANUAL GEARBOX
Pump unit 21
21-12
Pump unit
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator section)
REMOVAL
Disconnect the battery.
Drain the reservoir using a syringe.
Remove:
– the battery, – the air filter hose.
Disconnect the clutch cable.
Disconnect the injection computer.
Remove:
– the high pressure pipes,
– the low pressure pipes,
– disconnect the wiring,
– the upper mountings of the gearbox,
– the accumulator,
– Remove the three mounting bolts (C) from the pump
unit.
REFITTING
Proceed in the reverse order.
Refill the oil reservoir with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MIN mark.
Reprogram using the diagnostic tool (consult the
Special notes on reprogramming after replacing
components in the system).
Topping up the reservoir
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dumpprocedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Pump assembly M8 bolts 2.4
Pump assembly M10 bolts 4.4
High pressure pipe unions 1.4
Accumulator 4
18012R
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MANUAL GEARBOX
Pump 21
21-13
Pump
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator section)
REMOVAL
Disconnect the battery.
Drain the reservoir using a syringe.
Remove:
– the battery, – the air filter hose.
Disconnect the clutch cable.
Remove:
– the injection computer,
– the high pressure pipes, – the low pressure pipes,
– disconnect the wiring,
– the upper mountings of the gearbox,
– the accumulator, – remove the three mounting bolts (C) from the pump
unit (see previous page),
– the reservoir,
– the pump, by removing the three bolts (B).
REFITTING
Proceed in the reverse order.
Refill the oil reservoir with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MINmark.
A PressureB Suction
TIGHTENING TORQUES (in daNm)
Pump assembly M8 bolts 2.4
Pump assembly M10 bolts 4.4
High pressure pipe unions 1.4
Accumulator 4
M6 pump bolts 1
17981R1
DI2172
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MANUAL GEARBOX
Pump 21
21-14
WARNING:
The sequential gearbox pump unit relays MUST be replaced when the pump unit is replaced.
The relay may have been damaged by excessive friction.Therefore the relays must be changed in order to avoid
damaging the new pump unit.
The pump relay (A) is located in the connection unit in the engine compartment.
Re-program using the diagnostic tool, consult the Pump only in the programming section.
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump procedure. The oil level is between 32 and 38 mm above the MIN mark.
IMPORTANT:After the accumulator has been fully pressurised (15 seconds after the ignition is switched on): The oil level
will be at the MIN mark.
18228R
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MANUAL GEARBOX
Reservoir 21
21-15
Reservoir
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator section)
REMOVAL
Disconnect the battery.
Drain the reservoir using a syringe.
Remove:
– the low pressure pipes,
– the high pressure pipes, – the gearbox mounting bracket,
– the accumulator,
– the reservoir mounting bolts (A).
A Suction
B Return
REFITTING
Proceed in the reverse order.
Refill the oil tank with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MIN mark.
Reprogram using the diagnostic tool (consult the
Special notes after replacing components in thereservoir system).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mmabove the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised
(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Accumulator 4
High pressure pipe unions 1.4
Lifting ring mounting nut 2.1
18012R1
DI2173
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MANUAL GEARBOX
Clutch module 21
21-16
Clutch module
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIALSYSTEM. (Consult the Accumulator) section
REMOVAL
The pump unit must be removed in order to remove
the clutch module.
For information on removing the pump unit, consultpage 21-12.
Remove:
– the reservoir,
– the pump, by removing the three bolts (B).
Remove:
– the sleeve stop,
– the dust seal,
– the clutch position sensor, taking care not to displace
the clutch cylinder.
Remove: – the piston spring assembly,
– the potentiometer control (A),
– the piston brace (B) using a screwdriver,
– the clutch cable (C).
TIGHTENING TORQUES (in daNm)
Accumulator 4
High pressure pipe unions 1.4
Lifting ring mounting nut 2.1
Pump assembly M8 bolts 2.4
Pump assembly M10 bolts 4.4
M6 pump bolts 1
17981R1
17980S
17983R
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MANUAL GEARBOX
Clutch module 21
21-17
Remove the clutch module sleeve with the seal.
REFITTING
IMPORTANT:
The piston seals have special lips and must be fitted
the right way round.
Check that the piston seals are in good condition.
Refit:
– the clutch cable in the piston (C),
– the brace (B),
– the potentiometer control (A).
Refit:
– the spring, – the sleeve (A) by pressing the spring and observing
the direction of fitting so as not to cut the piston seal.
18007S
17982S
17985R
17986R
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MANUAL GEARBOX
Clutch module 21
21-18
Refit the sleeve (B) ensuring you observe the direction
of fitting so as not to damage the lip seal.
Refit:
– the cylinder liner-piston assembly in the clutch
module.
– the seal.
Clip the potentiometer to its control.
Screw the potentiometer to the clutch module,
compressing the spring.
Refit:
– the dust seal,
– the sleeve stop.
Proceed in the reverse order to removal to complete
the operation.
Refill the oil reservoir with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MIN mark.
Reprogram using the diagnostic tool (consult the
Special notes after replacing components in the clutch
cylinder system).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mmabove the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
17983-1R
17984S1
17980S
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MANUAL GEARBOX
Actuator module 21
21-19
Actuator module
KEY
1 Clutch operation solenoid valve
2 Engagement solenoid valve
3 Selection solenoid valve
4 Engagement position sensor
5 Selection position sensor
6 Pressure sensor
7 High pressure filter
17979R
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MANUAL GEARBOX
Actuator module 21
21-20
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator) section
REMOVAL
Disconnect the battery.
Drain the reservoir using a syringe.
Remove:
– the battery,
– the air filter hose, – the injection computer,
– the clutch cylinder connections, – the connector mounting plate (A).
Remove:
– the lifting ring mounting bracket (B),
– the accumulator (C),
– the high pressure pipes,
– the low pressure pipes,
– the reservoir,
– the left headlight,
– the wheel,
– the left wheel arch liner,
– the earth strap on the gearbox.
Fit the engine support Mot. 1453.
Uncouple the gearbox mounting from its housing.
Lower the gearbox as far as possible.
Remove the control shaft closure panel.
TIGHTENING TORQUES (in daNm)
Actuator module studs 0.8
Actuator module nut 2.1
Solenoid valve bolts 0.4
Control shaft closure panel bolts 0.6
High pressure pipe unions 1.4
Accumulator 4
18118R
96107R
17975S
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MANUAL GEARBOX
Actuator module 21
21-21
Unscrew the gear change control shaft by turning it 1/4
of a turn with a screwdriver.
Remove the hydraulic unit.
REFITTING
Check that the half-moons are positioned correctly.
Position the half-moons and the circlips in the controlshaft groove.
Grease the two MOLYKOTE 33 Medium half-moons
Place the control shaft on the actuator modules in a
raised and locked position.
The screwdriver slot and the shaft finger should befacing the mark.
Fit the gasket.
Refit the actuator module on the gearbox.
17969R
18011S
17972S
17970S
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MANUAL GEARBOX
Actuator module 21
21-22
Tighten the actuator module on the gearbox to the
correct tightening torque.
Using a screwdriver, press on the control shaft to clip it
onto the actuator module.
Connect: – the actuator earth wire,
– the connections.
Refit: – the control shaft closure panel (oil the seal).
– the gearbox mounting on its housing.
Remove the engine support tool Mot. 1453.
Refitting does not present any specific problems and
should be performed in the reverse order to removal.
Refill the oil reservoir with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MIN mark.
Reprogram using the diagnostic tool, (consult the
Special notes after replacing components in the
selection cylinder, engagement cylinder system
section).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dumpprocedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised
(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
17970R
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MANUAL GEARBOX
Solenoid valves 21
21-23
Solenoid valves
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator) section
Follow the instructions on pages 21-4.
REMOVAL
Disconnect:
– the battery, – the hydraulic unit wiring harness connector.
Remove: – the air filter sleeve,
– the sleeve mounting,
– the computer,
– the gearbox mounting (B), – the accumulator (C),
– the hydraulic unit wiring harness connector (A).
Disconnect the connectors of the solenoid valves
concerned.
Disconnect the solenoid valves in order of removal.
A Clutch operation solenoid valveB Selection solenoid valve 4
C Selection solenoid valve 3D Engagement solenoid valve 1
REFITTING
Proceed in the reverse order.
Refill the oil reservoir with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and38 mm above the MIN mark.
Reprogram using the diagnostic tool, (consult theSpecial notes after replacing components in the
solenoid valves operations section).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mmabove the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Accumulator 4
High pressure pipe unions 1.4
Lifting ring mounting nut 2.1
Solenoid valve bolts 0.4
18118R
17978R
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MANUAL GEARBOX
Solenoid valves 21
21-24
Engagement solenoid valve 2:
REMOVAL
The gearbox must be lowered in order to remove
engagement solenoid valve 2.
Remove:
– the battery,
– the air filter sleeve,
– the injection computer,
– the left headlight,
– the wheel,
– the left wheel arch liner,
– the earth strap on the gearbox.
Fit the engine support Mot. 1453.
Uncouple the gearbox mounting from its housing.
Lower the gearbox as far as possible.
Disconnect the engagement solenoid valve 2
connector (D).
Remove the engagement solenoid valve 2 (D).
REFITTING
Proceed in the reverse order.
Refill the oil reservoir with ELF
RENAULTMATIC D3 SYN Dexron III between 32 and
38 mm above the MIN mark.
Reprogram using the diagnostic tool, (consult the
Special notes after replacing components in the
solenoid valves operations section).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mmabove the MIN mark.
IMPORTANT:After the accumulator has been fully pressurised
(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
17975S
17978R5
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MANUAL GEARBOX
Engagement position sensor 21
21-25
Engagement position sensor
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator) section
Removal of the engagement position sensor does notrequire removal of the actuator module.
REMOVAL
Operating from underneath, remove the accelerator
pedal potentiometer and its mounting.
Disconnect the engagement position connector (A).
Remove the engagement position sensor (A).
REFITTING
Proceed in the reverse order.
Reprogram using the diagnostic tool, (consult the
Special notes after replacing components in the
engagement position sensor operations section).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Engagement position sensor bolts 0.4
Actuator module nuts 2.1
Lifting ring mounting nut 2.1
High pressure pipe unions 1.4
Accumulator 4
17974-1S
17978R2
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MANUAL GEARBOX
Selection position sensor 21
21-26
Selection position sensor
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIAL
SYSTEM. (Consult the Accumulator) section
The car must be in 1st gear before the selection
position sensor is removed.
REMOVAL
Disconnect the battery.
Remove:
– the air filter sleeve, – the sleeve mounting.
Disconnect the hydraulic unit wiring harness
connector (A).
Remove the hydraulic unit wiring harness connector mounting (A).
Disconnect the selection position connector (B).
Remove the selection position connector (B).
REFITTING
Check that the selection sensor can rotate freely.
Proceed in the reverse order to removal to complete
the operation.
Reprogram using the diagnostic tool, (consult the
Special notes after replacing components in the
selection position sensor operations section).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dumpprocedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Engagement position sensor bolts 0.4
Solenoid valves 0.4
Lifting ring mounting nut 2.1
High pressure pipe unions 1.4
Accumulator 4
18118R1
17978R3
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MANUAL GEARBOX
Clutch position sensor 21
21-27
Clutch position sensor
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIALSYSTEM. (Consult the Accumulator) section
REMOVAL
Remove:
– the gearbox mounting.
Disconnect the clutch position sensor connector.
Remove the clutch position sensor (A).
REFITTING
Proceed in the reverse order.
Reprogram using the diagnostic tool, (consult the
Special notes after replacing components in the
"clutch position sensor operations" section).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Clutch position sensor bolts 0.4
Pump assembly M8 bolts 2.1
Pump assembly M10 bolts 4.4
High pressure pipe unions 1.4
Lifting ring mounting nut 2.1
Accumulator 4
17980R
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MANUAL GEARBOX
Pressure sensor 21
21-28
Pressure sensor
N.B.:
DUMP THE ACCUMULATOR PRESSURE USING
THE DIAGNOSTIC TOOL BEFORE ATTEMPTING
ANY OPERATIONS ON THE SEQUENTIALSYSTEM. (Consult the Accumulator) section
REMOVAL
Drain the reservoir using a syringe.
Disconnect the pressure connector (C).
Remove the pressure sensor (C) using a thin 14 mm
spanner.
REFITTING
Proceed in the reverse order.
Refill the oil tank with ELF RENAULTMATIC D3 SYN
Dexron III oil.
Reprogram using the diagnostic tool (consult the
Special notes after replacing components in the
"pressure sensor" system).
Topping up the reservoir.
The reservoir marker is at MIN.
At rest: carry out the accumulator pressure dump
procedure. The oil level is between 32 and 38 mm
above the MIN mark.
IMPORTANT:
After the accumulator has been fully pressurised
(15 seconds after the ignition is switched on): The
oil level will be at the MIN mark.
TIGHTENING TORQUES (in daNm)
Position sensor bolts 0.4
Actuator module nut 4.4
Lifting ring mounting nut 2.1
High pressure pipe unions 1.4
Accumulator 4
17978R4
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MANUAL GEARBOX
Speed sensor 21
21-29
Speed sensor
After the gearbox speed sensor has been replaced, the car must be driven to switch off the fault warning light and
erase the computer memory.
The computer will only erase the fault if it receives a speed signal from the sensor.
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MANUAL GEARBOX
Computer 21
21-30
Computer
LOCATION
It is located in the engine compartment on the front
right wheel arch.
The connector is split into two sections (52 track
+ 28 track).
REMOVAL - REFITTING
Switch off the ignition and disconnect the battery
before operating on the computer.
IMPORTANT:
Reprogram the computer after it has been replaced.
17976S
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MANUAL GEARBOX
Computer 21
21-31
TRACK ASSIGNMENT
52 track connector
1
2
3
26
27
28
29
31
32
33
36
38
39
4041
42
43
44
45
49
50
51
52
---
---
→
←
---
---
→
→
→
→←
←
←
←
← →
→
→
→
→←
→←
←
←
←
POWER EARTH 1
POWER EARTH 2
SELECTION SOLENOID VALVE 4 CONTROLCHANGING UP SIGNAL
+ BATTERY
+ AFTER IGNITION
SELECTION SOLENOID VALVE 3 CONTROL
PUMP UNIT SOLENOID RELAY
ENGAGEMENT SOLENOID VALVE 1 CONTROL
DIAGNOSTIC SOCKET: CAN L
VEHICLE SPEED SIGNAL
INPUT BOX SPEED SENSORENGAGEMENT POSITION SENSOR SIGNAL
PRESSURE SENSOR SIGNALFAULT WARNING LIGHT
STARTER SOLENOID VALVE RELAY
CLUTCH SOLENOID VALVE CONTROL
ENGAGEMENT SOLENOID VALVE 2 CONTROL
DIAGNOSTIC SOCKET: CAN H
DIAGNOSTIC LINE K
INPUT BOX SPEED SENSOR
SELECTION POSITION SENSOR SIGNALENGAGEMENT POSITION SENSOR SIGNAL
28 track connector
65
66
67
68
69
71
7273
7476
7778
80
---
---
←
←
←
←
→
---
←
←
←
←
→
GEAR LEVER EARTH
SENSORS EARTH
STABLE POSITION SIGNAL (STAND-BY)
CHANGING DOWN SIGNAL
BRAKE PEDAL SWITCH
HANDBRAKE SWITCH
INSTRUMENT PANEL SIGNALSENSORS SUPPLY
CHANGING TO NEUTRAL SIGNALKEY AFTER STARTING SIGNAL
AUTO MODE CONTACTDOOR SWITCH
HORN CONTROL
←
→
INPUT
OUTPUT
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MANUAL GEARBOX
Relay 21
21-32
Relay
LOCATION
The system activates two relays:
– the starter authorisation relay (A), located near to buzzer (B) under the dashboard,
– The pump relay (C), located in the connection unit in the engine compartment.
REMOVAL - REFITTING
Switch off the ignition and disconnect the battery before operating on the system.
18228-1R
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MANUAL GEARBOX
Fuses 21
21-33
Fuses
LOCATION
The system is supplied via three fuses:
– the + after ignition 3A fuse (A), located on the passenger compartment fuse plate, connected to pin 28 on the
sequential gearbox computer connector.
– the + battery 20A fuse (B), located on the engine compartment connection unit, connected to pin 27 on thesequential gearbox computer connector.
– the + battery 30A fuse (C), located on the engine compartment connection unit supplying the system pump unit.
REMOVAL - REFITTING
Switch off the ignition and disconnect the battery before operating on the system.
18228-2R
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MANUAL GEARBOX
Harness 21
21-34
Harness
It is integrated to the hydraulic unit and unites the eleven connectors of the various system components.
The earths of the five solenoid valves are united on one terminal, a fixed plate on the hydraulic unit.
The pump unit earth is fixed to the clutch cylinder body.
The connection to the car wiring harness is made through a 24 track SICMA connector located on top of the system.
ALLOCATION OF CONNECTOR TRACKS
A8
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
C7
C8
→
→
→
→
→
→
---
←
←
←
←
---
←
→
PUMP UNIT CONTROL +
CLUTCH SOLENOID VALVE CONTROL+
ENGAGEMENT SOLENOID VALVE 2 CONTROL +
SELECTION SOLENOID VALVE 3 CONTROL +
ENGAGEMENT SOLENOID VALVE 1 CONTROL +
SELECTION SOLENOID VALVE 4 CONTROL +EARTHS FOR:
- ENGAGEMENT SENSOR
- SELECTION SENSOR- CLUTCH SENSOR
- PRESSURE SENSOR
ENGAGEMENT SENSOR SIGNAL
SELECTION SENSOR SIGNAL
CLUTCH SENSOR SIGNAL
PRESSURE SENSOR SIGNAL
GEARBOX INPUT SPEED SENSOR EARTH -
GEARBOX INPUT SPEED SENSOR SIGNAL+CONTROL+:- ENGAGEMENT SENSOR
- SELECTION SENSOR
- CLUTCH SENSOR
- PRESSURE SENSOR
←
→
INPUTOUTPUT
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MANUAL GEARBOX
Gear lever 21
21-35
Gear lever
USING THE GEAR LEVER
JoyStick gear levers have only one stable position.
All manoeuvres start from this position, also called
STAND-BY.
– move the lever forwards (+): to change to a higher gear,
– move backwards (-): to change to a lower gear,
– move right (N): to change to neutral,
– move right and then backwards (R): to change to
reverse.
Button (A) switches the automatic mode on or off,
according to the driver's requirements.
The gear selected is displayed on the instrument
panel. The R symbol on the gear lever base remindsthe driver that reverse gear has been selected.
OPERATION
The sequential gearbox is electrically controlled.
Contacts at the bottom of the control module sendelectronic signals to the gearbox computer when the
gear lever positions is changed.
16671S
17977R
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MANUAL GEARBOX
Gear lever 21
21-36
REMOVAL
Disconnect the battery.
Remove:
– the gear lever console cover,
– the gear lever console.
Disconnect the gear lever electrical connection.
Remove the two LED supply wires for display R on the
gear lever electrical connector (tracks 6 and 7).
Remove the supply wires for the automatic or
sequential selector push button on the gear lever
electrical connector (tracks 8 and 9).
Allocation of the connector pins (ten tracks):
Unclip the washer from the gear lever base.
Pull upwards to remove the gear lever knob (follow the
direction of the arrow).
Remove the four mounting bolts from the gear lever
base plate.
Change the faulty part.
REFITTING
Refitting does not present any specific problems and
should be performed in the reverse order to removal.
18006R
Track 1
Track 2Track 3
Track 4
Track 5Track 6
Track 7Track 8
Track 9
Track 10
:
::
:
::
::
:
:
Gear lever earth
Change up signalChange down signal
Stable position signal (STAND-BY)
Change to neutral signalEarth
Change to reverse signalEarth
Change to automatic mode signal
Not connected
SE2037
18006-1R
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MANUAL GEARBOX
Special notes for replacing system components 21
21-37
Special notes for replacing system components
HYDRAULIC UNIT KIT/COMPUTER/GEARBOX/REPROGRAMMING
A)
B)
C)
D)
E)
F)
G)
Switch on the ignition
Restart all programming procedures: RZ002 Programming.
Command name: VP008 Programming selection zone/engagement.Wait until the end of the procedure
Switch off the ignition.Wait 1 minute
Switch on the ignition (the buzzer sounds if there is a fault)
Check programming OK: status ET061 Range good; if Range complete or status ET063 Solenoid valve
point zero are displayed, repeat procedure (B).
Engagement of all gear positions (signal OK on control panel display)
Shift the gear lever to neutral
Start the engineWait 10 seconds (until clutch biting point is programmed) without changing gear.
Check programming OK: status ET062 Biting point done if not, repeat procedure D.
Start the engine at half load 5 or 6 times until clutch temperature status PR095 is below 180 ˚C (for clutchprogression programming)
Switch off the ignition.
Wait 1 minute
Switch on the ignition
Check programming OK: status ET065 Progression done and check again if the Progression signal varies.If not, repeat procedure E.
Command name: CF321 Gearbox type, options: short or long gearbox.
Check that the Gearbox type information is correct.
Switch off the ignition.
ENGAGEMENT POSITION SENSOR/SELECTION POSITION SENSOR
A)
B)
C)D)
Switch on the ignition
Ensure there is no fault
Command name: VP008 programming selection zone/engagement.
Wait until the end of the procedure
Switch off the ignition.Wait 1 minute
Switch on the ignition (the buzzer sounds if there is a fault)
Check programming OK: status ET061 Range good; if Range zone or status ET063 Solenoid valve point
zero are displayed, repeat procedure (B).
Engagement of all gear positions (signal OK on control panel display)Switch off the ignition.
CLUTCH POSITION SENSOR/CLUTCH
A)
B)C)
D)
Switch on the ignition
Ensure there is no fault
Command name: RZ003 Biting point programming.Put the gear lever in neutral
Start the engine
Wait 10 seconds (until clutch biting point is programmed) without changing gear.
Check programming OK: status ET062 biting point done if not, repeat procedure C.Start the engine at half load 5 or 6 times until the "clutch temperature" status PR095 is below 180 ˚C (for
progression clutch programming).
Switch off the ignition.Wait 1 minute
Switch on the ignition
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MANUAL GEARBOX
Special notes for replacing system components 21
21-38
E)
Check programming OK: status ET065 Progression done and check again if the Progression signal
varies. If not, repeat procedure D.
Switch off the ignition.
PRESSURE SENSOR
A)
B)
Switch on the ignition
Ensure there is no fault
Command name: AC011 bleed hydraulic pressure unit.
Wait until the end of the procedure
Switch off the ignition.
SELECTION SOLENOID VALVE/ENGAGEMENT SOLENOID VALVE
A)
B)
C)
D)
Switch on the ignition
Ensure there is no faultCommand name: AC011 bleed hydraulic pressure unit.Wait until the end of the procedure
Switch off the ignition.
Engagement of all gear positions (signal OK on control panel display)
Switch off the ignition.
CLUTCH SOLENOID VALVE
A)
B)
C)
D)
Switch on the ignition
Ensure there is no fault
Open the hydraulic unit bleed screwCommand name: AC008 bleed clutch circuit phase 1.
Close the bleed screw as soon as the fluid is running clear air bubblesWait until the end of the procedure (duration 6 minutes)
Command name: AC008 bleed clutch circuit phase 2.
Wait until the end of the procedure (duration 8 minutes)
Command name: AC011 bleed hydraulic pressure unit.
Wait until the end of the procedure
Switch off the ignition.
SELECTION CYLINDER/ENGAGEMENT CYLINDER/TANK/ACCUMULATOR/PUMP ONLY
A)
B)
C)
D)
E)
Switch on the ignition
Ensure there is no faultCommand name: AC011 bleed hydraulic pressure unit.
Wait until the end of the procedure
Command name: VP008 Programming selection zone/engagement.Wait until the end of the procedure
Switch off the ignition.
Wait 1 minute
Switch on the ignition (the buzzer sounds if there is a fault)Check programming OK: status ET061 Range good; if Range done or status ET063 Solenoid valve point
zero are displayed, repeat procedure C.Engagement of all gear positions (signal OK on control panel display)
Switch off the ignition.
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MANUAL GEARBOX
Special notes for replacing system components 21
21-39
CLUTCH CYLINDER/FLUID LEAK DURING CLUTCH CABLE REPLACEMENT
A)
B)
C)
D)
E)
F)
Switch on the ignition
Ensure there is no faultOpen the hydraulic unit bleed screw
Command name: AC008 bleed clutch circuit phase 1.
Close the bleed screw as soon as the fluid runs clear of air bubbles
Wait until the end of the procedure (duration 6 minutes)
Command name: AC009 bleed clutch circuit phase 2.
Wait until the end of the procedure (duration 8 minutes)
Command name: RZ003 Biting point programming.
Put the gear lever in neutralStart the engine
Wait 10 seconds (until clutch biting point is programmed) without changing gear
Check programming OK: status ET062 biting point done if not, repeat procedure E.
Switch off the ignition.
HIGH PRESSURE PIPE
A)
B)
3)
Switch on the ignition
Ensure there is no fault
Open the hydraulic unit bleed screw
Command name: AC008 bleed clutch circuit phase 1 Close the bleed screw as soon as the fluid runs clear of air bubbles
Wait until the end of the procedure (duration 6 minutes)
Command name: AC009 bleed clutch circuit phase 2
Wait until the end of the procedure (duration 8 minutes)Switch off the ignition.
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MECHANICAL ELEMENT CONTROLS
Master cylinder 37
37-1
137MECHANICAL ELEMENT CONTROLS
Master cylinder
REMOVAL
Disconnect the battery.
Remove:
– the battery mounting,
– the battery,
– the plastic protector for the computer,
Disconnect and remove the computer.
Drain the brake reservoir using a syringe.
Remove the reservoir, taking care to not spill any
brake fluid. Use a cloth.
Remove:
– the two brake pipes, (mark them).
– the master cylinder mountings.
In the passenger compartment, unscrew the 4 brakeservo mountings.
Pivot the brake servo downwards to release the
master cylinder.
REFITTING
Check the length of the pushrod.
Dimension X = 22.3 mm.
Depending on model, adjust using pin (P).
TIGHTENING TORQUES (in daNm)
M 10 X 100 1.3
Master cylinder bolts 1.5
Brake servo bolts 2
94693S
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MECHANICAL ELEMENT CONTROLS
Master cylinder 37
37-2
N.B.: these vehicles have a master cylinder which is
integral to the brake servo. Sealing of the brake servo
is directly linked to that of the master cylinder. During
any operation, a new seal (A) must be fitted.
Fit the master cylinder in alignment with the brake
servo so that pushrod pin (P) enters the master
cylinder housing correctly.
Reconnect:
– the pipes, ensuring they are in the positions
marked before removal,
– the compensation reservoir by pressing down on it to
click it into the master cylinder,
Bleed the brake circuit.
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MECHANICAL ELEMENT CONTROLS
Brake servo 37
37-3
Brake servo
The brake servo cannot be repaired. Operations are
only allowed on: – the air filter,
– the non-return valve.
Disconnect the battery.
REMOVAL
Remove the master cylinder (follow the proceduredescribed on the previous page).
Using tool Elé. 1294-01 remove the two windscreenwiper mounting nuts.
Remove:
– the air inlet pipe,
– the three wiper motor mounting bolts.
– the wiper motor, – the non-return valve on the brake servo,
– the front left lens unit.
Fit the engine support tool Mot. 1453.
Remove the gearbox mounting bolts.
Fit the two Tav. 1233-01 8 mm diameter tools.
SPECIAL TOOLING REQUIRED
Elé. 1294 -01 Windscreen wiper arm
removing tool
Mot. 1453 Engine support
2 x Tav. 1233-01 Front subframe holding screw
TIGHTENING TORQUES (in daNm)
M 10 X 100 1.3
Master cylinder bolts 1.5
Brake servo bolts 2
Gearbox mounting nuts 4.5
Sub-frame bolt 6.5
Upper windscreen wiper nut 1.6
Lower windscreen wiper nut 1.2
17975S
17967S
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MECHANICAL ELEMENT CONTROLS
Brake servo 37
37-4
Remove:
– the shaft from the yoke connecting the brake pedal to
the push rod after having removed the clip,
– the brake servo mounting bolts,
– the steering shaft yoke nut,
– the two engine tie-bar bolts.
Gradually lower the engine and transmission assembly
and the sub-frame, to allow the release of the brake
servo.
REFITTING
Proceed in the reverse order to removal.
Before refitting, check that:
Dimension L = 94.5 mm
can be adjusted using pushrod C (see diagram)
Dimension X = 22.3 mm
can be adjusted using pushrod P (see diagram)
Fit the master cylinder in place (consult the advice in
the relevant section).
Bleed the brake circuit.
94692R
94693S
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MECHANICAL ELEMENT CONTROLS
Air filter - Brake servo non-return valve 37Air filter - Brake servo non-return valve
REPLACING THE AIR FILTER
There is no need to remove the brake servo to replace
the air filter (F).
Under the pedal mounting, use a screwdriver or a
metal hook to remove the worn filter (F).
Cut the new filter at A (see diagram) and fit it aroundthe rod, then press it into position, checking that it fills
the opening completely to prevent any non-filtered air
from passing through
REPLACING THE NON-RETURN VALVE
This operation may be carried out on the vehicle.
REMOVAL
Disconnect the brake servo vacuum inlet pipe.
Pull and turn the non-return valve to release it from the
rubber sealing washer.
REFITTING
Check the condition of the rubber sealing washer and
the non-return valve.
Replace any faulty parts.
Refit the assembly into position.
75564G
74883S