Renault 2000 Megane Technical Note
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Renault 2000 Megane Technical Note

F9q 732 engine
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SPECIAL FEATURES OF F9Q 732 ENGINE
WITH HIGH PRESSURE DIRECT INJECTION
For all parts not dealt with in this Technical Note refer to Workshop Repair Manual MR 312.
77 11 292 962
"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."
Technical Note 3350A
Please observe the cleanliness advice
for any operations on this vehicle (section 13).
This Technical Note cancels and replaces Technical Note 3245A
Consult Technical Note 3341A for the diagnostic part.
XA0 5
MARCH 2000
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.
© RENAULT 2000
EDITION ANGLAISE

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  • Page 1 The methods may be modified as a result of changes introduced by the manufacturer in reference numbering system is forbidden without the prior written authority of Renault. the production of the various component units and accessories from which his vehicles are constructed."...

  • Page 2: Table Of Contents

    Contents Page Page VALUES AND SETTINGS DIESEL EQUIPMENT Capacities - Grades 07-1 Technical specifications 13-1 Accessories belt tension 07-2 Special features 13-3 Checking the accessories belt tension 07-3 Cleanliness 13-6 Tightening the cylinder head 07-5 Location of components 13-9 Tyres and wheels 07-6 Injection warning light 13-12...
  • Page 3 Contents Page STARTING - CHARGING Alternator 16-1 Starter 16-4 COOLING SYSTEM Filling - bleeding 19-1 Diagram 19-2 Thermoplunger unit 19-3 Radiator 19-4 Water pump 19-5 ENGINE MOUNTING Suspended engine mounting 19-6 Exhaust Catalytic converter 19-7 MANUAL GEARBOX Identification 21-1 Gears 21-1 Capacity - Lubricants 21-2...

  • Page 4: Values And Settings

    VALUES AND SETTINGS VALUES AND SETTINGS Capacities - Grades Capacities - Grades Capacity in Components litres Grade (approx.)* Diesel engine In case of oil European Union countries (oil) change Under no circumstances should ACEA B1 oils be used for diesel engines 4,6 (1) Other countries...

  • Page 5: Accessories Belt Tension

    VALUES AND SETTINGS WITHOUT AIR CONDITIONING Accessories belt tensioning Accessories belt tensioning ALTERNATOR AND POWER ASSISTED STEERING 98751R1 Fitting tension (in Hertz): 188 ± 5 See Technical Note 3247A for the procedure for using the tension measuring tool Mot. 1505. Crankshaft Alternator Power assisted steering pump...

  • Page 6: Checking The Accessories Belt Tension

    VALUES AND SETTINGS WITH AIR CONDITIONING Checking the accessories belt tension Checking the accessories belt tension SPECIAL TOOLING REQUIRED Mot. 1387 Tool for checking the automatic tension wheel centreline Checking the automatic tension wheel centre line Methods for using Mot. 1387 Before removing the accessories belt, check the Loosen knurled bolt (1) so that the arms (2) and (3) centreline (A) on the automatic tension wheel using...
  • Page 7 VALUES AND SETTINGS WITH AIR CONDITIONING Checking the accessories belt tension Checking the accessories belt tension Using Mot. 1387 check that you are well within Checking the centreline allows you to check if the tolerance (zone B). automatic tension system is working correctly. If the centreline is outside permitted tolerance values, check the following points: ENGINE...

  • Page 8: Tightening The Cylinder Head

    VALUES AND SETTINGS Tightening the cylinder head Tightening the cylinder head METHOD FOR TIGHTENING THE CYLINDER HEAD REMINDER: in order to tighten the bolts correctly, use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes. All the cylinder head bolts must always be changed after removal.

  • Page 9: Tyres And Wheels

    VALUES AND SETTINGS Tyres and wheels Tyres and wheels Tyre pressure when cold (in bar) (1) Type Tyres Front Rear BA05 6 J 15 185/60 R 15 JA05 6 J 15 185/60 R 15 (1) With full load and on motorways. Tightening torque for wheel nuts: 9 daN.m Rim run-out: 1.2 mm 07-6...

  • Page 10: Brakes

    VALUES AND SETTINGS Brakes Brakes at the front at the rear Type Disc thickness (in mm) Disc thickness (in mm) Drum diameter (in mm) Max. Min. Max. Min. Min. Max. (1) BA05 20.6 17.6 203.2 204.45 JA05 (1) Drum: maximum wear diameter Max.

  • Page 11: Brake Compensator

    VALUES AND SETTINGS Brake compensator Brake compensator BRAKING PRESSURE Conditions: – Full fuel tank, – Driver on board. Check pressure (1) (in bars) Type Front Rear B0A5 JA05 (1) The test is performed using two pressure gauges in an X arrangement. 07-8...

  • Page 12: Underbody Height

    VALUES AND SETTINGS Underbody height Underbody height at the front at the rear Dimension X (mm) Type H1 - H2 = ... mm H4 - H5 = ... mm D and G ± 7.5 mm ± 7.5 mm ± 0.5 mm BA05 JA05 The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed...
  • Page 13 VALUES AND SETTINGS Underbody height MEASUREMENT POINTS 99656R1 Dimension H5 is measured from the axis of the suspension bar. 88636-4R 07-10...

  • Page 14: Front Axle Angle Checking Values

    VALUES AND SETTINGS Front axle angle checking values Front axle angle checking values B0A5 POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 3˚22' H5 - H2 = 89 mm ± 30' 3˚52' H5 - H2 = 69 mm 4˚22' H5 - H2 = 49 mm ADJUSTABLE Max.
  • Page 15 VALUES AND SETTINGS Front axle angle checking values J0A5 POSITION OF ANGLES VALUES ADJUSTMENT FRONT AXLE CASTOR 5˚00' H5 - H2 = 23 mm ± 30' 3˚54' H5 - H2 = 65 mm 3˚19' H5 - H2 = 75 mm ADJUSTABLE Max.

  • Page 16: Rear Axle Angle Checking Values

    VALUES AND SETTINGS Rear axle angles checking values Rear axle angles checking values POSITION OF ANGLES VALUES ADJUSTMENT REAR AXLE CAMBER - 0˚50' ± 15' UNLADEN ADJUSTABLE - 1˚15' ± 15' PARALLELISM (for 2 wheels) toe-in - 0˚30' ± 20' - 3 mm ±...

  • Page 17: Engine And Peripherals

    ENGINE AND PERIPHERALS ENGINE AND PERIPHERALS Identification Identification Capacity Bore Stroke Compression Vehicle type Engine Gearbox (mm) (mm) ratio XA05 F9Q 732 1870 19/1 Repair Manual to be consulted: Mot. F9Q. 10-1...

  • Page 18: Oil Pressure

    ENGINE AND PERIPHERALS Oil pressure Oil pressure SPECIAL TOOLING REQUIRED Mot. 836-05 Boxed kit for measuring oil pressure ESSENTIAL SPECIAL TOOLING 22 mm long socket CHECKING The oil pressure should be checked when the engine is warm (approximately 80 °C). Contents of kit Mot.

  • Page 19: Engine And Transmission Assembly

    ENGINE AND PERIPHERALS Engine and transmission assembly Engine and transmission assembly SPECIAL TOOLING REQUIRED Mot. 1040-01 Dummy sub-frame for removing and refitting engine and transmission assembly Mot. 1159 Tool for maintaining engine on subframe Mot. 1202-01 Hose clip pliers Mot. 1202-02 Mot.
  • Page 20 ENGINE AND PERIPHERALS Engine and transmission assembly Remove: SPECIAL NOTES FOR VEHICLES FITTED WITH A – the battery, DRIVER'S AIRBAG – the engine undertray. WARNING Drain: – the cooling circuit through the bottom hose of the In order to eliminate any risk of damaging the radiator, rotary switch under the steering wheel, observe –...
  • Page 21 ENGINE AND PERIPHERALS Engine and transmission assembly – the closure panel for the plenum chamber. – the battery mounting, – the expansion bottle mountings and the expansion bottle, – the precatalytic converter mountings and the precatalytic converter, – the relay plate at (1) and the fuse holder (2) as well as the connectors (3) and (4), 11036R2 Remove (all types):...
  • Page 22 ENGINE AND PERIPHERALS Engine and transmission assembly – the earth strap on the bulkhead, Insert a wooden block between the gearbox and the – the mountings of the air conditioning hoses (if sub-frame. fitted) on the compressor and the condenser. Remove the nut (1), then tap it with a copper hammer NOTE: it is essential to insert plugs in the pipes and on to release the suspended engine mounting stud.
  • Page 23 ENGINE AND PERIPHERALS Engine and transmission assembly Fit tool Mot. 1040-01 under the engine sub-frame. REFITTING The alignment of the sub-frame with the body will be made easier by positioning two threaded rods Mot. 1233-01 in the two front mountings of the sub- frame on the body.

  • Page 24: Sump

    ENGINE AND PERIPHERALS Sump Sump SPECIAL TOOLING REQUIRED Mot. 1233-01 Threaded rods for lowering the sub-frame Remove: TIGHTENING TORQUES (n daN.m) – the lower ball joint mountings as well as the track rod ends, Sub-frame front mounting bolts – the sub-frame and body tie rods, Sub-frame rear mounting bolts 10.5 –...
  • Page 25 ENGINE AND PERIPHERALS Sump – the sub-frame mounting bolts, inserting the threaded rods Mot. 1233-01 as you go. Lower the sub-frame gradually using threaded rod Mot. 1233-01 until dimensions X = 9 cm are reached. 14264R1 Release the electrical harness from the sub-frame (left hand side).
  • Page 26 ENGINE AND PERIPHERALS Sump REFITTING Put a drop of RHODORSEAL 5661 at (A) (on either side of bearing N˚ 1), and at (B) (at the intersection of the crankshaft closure panel and the cylinder block). 16246R Refit the sump with a new gasket, pre-tightening it to a torque of 0.8 daN.m, then tighten it finally to a torque of 1.5 daN.m in the order recommended below.

  • Page 27: Top And Front Of Engine

    TOP AND FRONT OF ENGINE TOP AND FRONT OF ENGINE Timing belt Timing belt SPECIAL TOOLING REQUIRED Mot. 1054 TDC setting pin Mot. 1387 Tool for checking the automatic tensioner centreline Mot. 1453 Engine support tool Mot. 1505 Tool for measuring belt tension Mot.
  • Page 28 TOP AND FRONT OF ENGINE Timing belt Special features of vehicles fitted with air Remove: conditioning: – the suspended mounting cover and its movement limiter. Before removing the accessories belt, check the – the bolt (1), and slacken engine tie-bar bolt (2), centreline of the automatic tensioner (see without removing it.
  • Page 29 TOP AND FRONT OF ENGINE Timing belt Remove the timing gear cases. 12518R Release the tension wheel, then remove the timing belt. Check that the tension wheel and pulleys turn freely without play. NOTE: Slackening the tension wheel bolt by more than one turn may cause it to come loose.
  • Page 30 TOP AND FRONT OF ENGINE Timing belt REFITTING Apply a pretensioning torque using Mot. 1543 (fitted with cover N˚ 3) by using a torque wrench adjusted to Engine cold (ambient temperature). a torque of 1.1 daN.m on the edge of the belt to be measured.
  • Page 31 TOP AND FRONT OF ENGINE Timing belt Fit the reading head of Mot. 1505 and carry out the The belts on vehicles fitted with air conditioning are measurement, then adjust the tension using the bolt tensioned by bringing the automatic tensioner plate to in contact with the belt until pretension value a stop at bolt (B), without forcing it, using a 9.35 mm T1 = 68 ±...

  • Page 32: Cylinder Head Gasket

    TOP AND FRONT OF ENGINE Cylinder head gasket Cylinder head gasket SPECIAL TOOLING REQUIRED Mot. 251 -01 Dial gauge support Mot. 252 -01 Pressure plate to measure piston protrusion Mot. 1054 TDC setting pin Mot. 1159 Tool for holding engine on subframe Mot.
  • Page 33 TOP AND FRONT OF ENGINE Cylinder head gasket Fit tool Mot. 1159 between the sub-frame and the cylinder block. NOTE: cut the base of Mot. 1159 by 30 mm. 99023R2 99024R2 Remove the engine mountings Mot. 1453. 11-7...
  • Page 34 TOP AND FRONT OF ENGINE Cylinder head gasket Remove: – the air filter assembly and the air inlet pipe, – the air ducts (A) and (B), – the injector connectors and the heater plugs, – the connectors (1) and (2), –...
  • Page 35 TOP AND FRONT OF ENGINE Cylinder head gasket – the brake servo vacuum pipe, – the fuel pipes (4) (fit cleanliness plugs) and the wiring – the pipes on the cylinder head water outlet unit and mounting (5), the sensor connections (1), 16179R 16870R5 –...
  • Page 36 TOP AND FRONT OF ENGINE Cylinder head gasket – the low pressure pump connector, – the bolts (1) and (2), – the alternator mounting bolts and remove the alternator, then remove the bolts (3). PRF1103 16156R2 Loosen the exhaust pipe clamp mounting. –...
  • Page 37 TOP AND FRONT OF ENGINE Cylinder head gasket CLEANING Checking piston protrusion It is very important not to scratch the gasket faces Clean the piston heads in order to eliminate any traces of any aluminium component. of deposits. Use the Décapjoint product to dissolve any part of the Turn the crankshaft in its operating direction, to bring piston n °...
  • Page 38 TOP AND FRONT OF ENGINE Cylinder head gasket REFITTING (special notes) Fit the cylinder head gasket. This is centred by two dowels. Bring the pistons to mid-stroke position to prevent them from coming into contact with the valves as the cylinder head is tightened.

  • Page 39: Fuel Mixture

    FUEL MIXTURE FUEL MIXTURE Air intake Air intake AIR INTAKE CIRCUIT DIAGRAM Air-air exchanger Air filter Flow meter Inlet manifold Turbocharger Air inlet 12-1...

  • Page 40: Turbocharging

    TURBOCHARGING TURBOCHARGING Pressure regulating valve Pressure regulating valve The LDA (A) of the pressure regulation valve is controlled by a solenoid valve (B) which is controlled by the injection computer. This solenoid valve varies the underpressure as a function of the engine operating ranges, which allows the turbocharging pressure to be regulated.

  • Page 41: Pressure Adjustment

    TURBOCHARGING Pressure adjustment Pressure adjustment TURBOCHARGING PRESSURE LIMITATION Calibration values VALVE (WASTEGATE) NB: the limitation valve operates in the opposite Underpressure Rod movement way to the usual fittings. values (mm) The absence of control pressure causes a turbocharging pressure limitation. 120 mb Between 1 and 4 mm 400 mb...

  • Page 42: Turbocharger

    TURBOCHARGING Turbocharger Turbocharger SPECIAL TOOLING REQUIRED Elé. 1294 -01 Tool for removing windscreen wiper arms REMOVAL TIGHTENING TORQUES (in daN.m) NOTE: to slacken the turbocharger mounting nuts Turbo mounting nuts (1) more easily on the exhaust manifold, it is useful to Oil inlet connection (4) spray a releasing agent on the nuts when still hot, just before removal.
  • Page 43 TURBOCHARGING Turbocharger From above Remove: – the turbo oil inlet connection (4), Remove (for the Scénic): – the two air intake and outlet ducts connected to the – the windscreen wiper arms using tool Elé. 1294-01, turbo, – the scuttle panel, –...
  • Page 44 TURBOCHARGING Turbocharger REFITTING Special precautions For refitting operations, use the same procedure as for Before refitting, make sure that the lubrication is removal in reverse. correct for the turbocharger bearings. To do this activate the starter motor having first IMPORTANT: you must change the copper gasket at disconnected the high pressure manifold regulator the turbo oil inlet connection.

  • Page 45: Air-Air Exchanger

    TURBOCHARGING Air-air exchanger Air-air exchanger REMOVAL If the vehicle is fitted with fog lights. It is necessary to remove the bumper to access the air- Disconnect: air exchanger. – the battery, – the fog light wiring harness connector (E) located in To do this, remove: the front section of the left-hand front wheel arch.
  • Page 46 TURBOCHARGING Air-air exchanger – the central mounting bolt (torx 40). – the flexible air inlet and outlet ducts on the exchanger (1), 98836-1R1 94965R Remove the two side positioning centring fittings on the bumper in relation to the wing. – three mounting bolts, Remove: –...

  • Page 47: Manifolds

    FUEL MIXTURE FUEL MIXTURE Manifolds Manifolds Remove (for the Scénic): TIGHTENING TORQUES (in daN.m) – the windscreen wiper arms, – the scuttle panel, Manifold mounting stud – the bulkhead panel, Manifold mounting stud – the air unit, – the turbocharger. EGR valve mounting bolt REMOVAL NOTE: Removal of the manifolds requires that you...
  • Page 48 FUEL MIXTURE Manifolds Remove the EGR solenoid valve pipe and the lifting bracket (4). 16157R 12-10...
  • Page 49 FUEL MIXTURE Manifolds Remove the nuts securing the manifolds. Manifolds If replacement of the inlet manifold is planned, remove the EGR valve (consult section 14 "Antipollution" for the method). REFITTING Proceed in the reverse order to removal. Change the manifold gasket and take care to replace it properly. 12-11...

  • Page 50: Priming Catalytic Converter

    FUEL MIXTURE Priming catalytic converter Priming catalytic converter Remove (for the Scénic) : TIGHTENING TORQUES (in daN.m) – the windscreen wiper arms using tool Elé. 1294-01, – the scuttle panel, Priming catalytic converter mounting nuts (pre-catalytic converter) Lower mounting bolt Priming catalytic converter stay bolt 11020R –...

  • Page 51: Priming Catalytic Converter

    FUEL MIXTURE Priming catalytic converter REFITTING Fit the priming catalytic converter (or pre-catalytic converter) to the turbocharger. Fit: – the pre-catalytic converter stay, – the mounting nuts. Tighten all the nuts and mounting bolts. Refit the exhaust downpipe. Replace the seals. 12-13...

  • Page 52: Diesel Equipment

    DIESEL EQUIPMENT DIESEL EQUIPMENT Specifications Specifications Engine Depollution Vehicle Gearbox Cubic standard Bore Stroke Compres- Catalytic capacity Type Index (mm) (mm) sion ratio converter ◊ C103 XA05 1 870 19/1 Euro 2000 ENGINE SPEED (rpm) SMOKE DENSITY Max. - under IDLING SPEED Max.

  • Page 53: Specifications

    DIESEL EQUIPMENT Specifications DESCRIPTION MAKE/MODEL SPECIAL NOTES MAGNETTI Resistance: ≈ 2.050 Ω at 25 ˚C Diesel temperature sensor MARELI Resistance: 800 ± 80 Ω Engine speed sensor Atmospheric pressure sensor Integrated in the computer Camshaft sensor ELECTRIFIL Hall effect sensor Resistance : 4 KΩ...
  • Page 54 DIESEL EQUIPMENT Special notes Special notes The common rail direct high pressure injection system aims to deliver a certain quantity of diesel to the engine at a specific time. DESCRIPTION The system consists of: – a low pressure pump (1) (located between the induction unit and the fuel filter), –...
  • Page 55 DIESEL EQUIPMENT Special notes OPERATION The common rail direct high pressure injection system is a sequential diesel injection system (based on the operation of multipoint injection for petrol engines). This new injection system reduces operating noise, lowers the quantity of polluting gas and particles and produces significant engine torque at low engine speeds thanks to a pre-injection procedure.
  • Page 56 DIESEL EQUIPMENT Special notes POST-REPAIR CHECK A fuel cock is fitted to the fuel filter at the level of the diesel return pipe leading to the tank. It should be in open position for normal operation. However, to carry out a circuit reignition after an intervention, a filter change or a fuel fault, you should: –...

  • Page 57: Cleanliness

    DIESEL EQUIPMENT Cleanliness Cleanliness CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks relating to contamination The system is very sensitive to contamination. The risks caused by the introduction of pollution are: – damage to or destruction of the high pressure injection system, –...
  • Page 58 DIESEL EQUIPMENT Cleanliness INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle. For each operation, use a clean brush which is in good condition (the brush must not shed its bristles). Clean using the unions to be opened and the parts to be removed using thinner and tweezers.
  • Page 59 DIESEL EQUIPMENT Cleanliness 13-8...

  • Page 60: Location Of Components

    DIESEL EQUIPMENT Location of components Location of components Injection computer Cylinder marking sensor Solenoid injector Rail pressure sensor Flow meter with air temperature sensor EGR valve Turbocharger pressure sensor Preheating unit Turbocharging pressure regulator (solenoid) Accelerator pedal potentiometer Engine speed sensor and coolant temperature sensor Fuel pressure regulator Fuel temperature sensor (depending on version) High pressure pump...
  • Page 61 DIESEL EQUIPMENT Location of components 16192R High pressure pump Common injection rail Injector Pressure regulator Pressure sensor Water temperature sensor 13-10...
  • Page 62 DIESEL EQUIPMENT Location of components EGR solenoid valve Turbo regulation solenoid Turbocharger pressure sensor Preheating unit 16181R 16869R3 Cylinder marking sensor Injection computer Turbocharger Fuel filter Priming catalytic converter Repriming fuel cock 16870R2 16155R2 13-11...

  • Page 63: Injection Warning Light

    DIESEL EQUIPMENT Injection warning light Injection warning light Vehicles using the high pressure diesel system are fitted with two injection warning lights used during the preheating phase and in case of an injection fault (or engine overheating). WARNING LIGHT PRINCIPLE When ignition is switched on, the preheating light is lit during the preheating phase and then goes out (see section 13 "Pre-postheating control").

  • Page 64: Immobiliser Function

    DIESEL EQUIPMENT Immobiliser function 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.

  • Page 65: Injection Programming/ Air Conditioning

    DIESEL EQUIPMENT Injection/air conditioning programming Injection/air conditioning programming INJECTION COMPUTER/AC COMPUTER CONNECTION The compressor is of the variable cubic capacity type. The injection calculator and the air conditioning calculator are linked by two leads: – The power absorbed information tells the injection computer the output absorbed by the compressor. It is possible to see the output absorbed using the diagnostic tool.
  • Page 66 DIESEL EQUIPMENT Injection/air conditioning programming COMPRESSOR OPERATION PROGRAMMING During certain stages of operation, the diesel injection computer stops the compressor from functioning. Engine start programming The compressor is prevented from operating for 5 seconds after the engine has started. Recovery of performance When the position of the accelerator pedal is changed significantly and if the engine speed is less than 3000 rpm, the compressor is prevented from operation for 5 seconds.

  • Page 67: Idle Speed Correction

    DIESEL EQUIPMENT Idle speed correction Idle speed correction IDLING SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE CORRECTION OF THE IDLING SPEED WHEN THE POTENTIOMETER IS FAULTY If the accelerator pedal potentiometer is faulty, idling speed is held at 1200 rpm. If the information from the accelerator pedal position potentiometer and the brake switch information does not correspond, the speed is changed to 1250 rpm.

  • Page 68: Pre-Postheating Control

    DIESEL EQUIPMENT Pre-postheating control Pre-postheating control The pre-postheating function is controlled by the preheating unit. OPERATING PRINCIPLE FOR PRE-POST HEATING Starting The plugs remain supplied while the starter is "Preheating" on ignition being activated. Variable preheating "Postheating" while the engine is running The warning light lighting time and the supply to heater plugs time depends on the During this phase the plugs are supplied...

  • Page 69: Heater Plugs

    DIESEL EQUIPMENT Heater plugs Heater plugs The resistance of a heater plug is 0.6 Ω. TIGHTENING TORQUES (in daN.m) Heater plug Plugs may be removed without having to open the high pressure circuit. REMOVAL Unclip the plug connector. Clean the plug exterior to avoid any dirt entering the cylinder.
  • Page 70 DIESEL EQUIPMENT Thermal plunger Thermal plunger The three thermal plungers are located on a water unit Control strategy fixed under the manifold at the engine - gearbox joint. When the thermal plungers are operating the idling The objective of the system is to reheat the coolant. speed is brought to 900 rpm.
  • Page 71 DIESEL EQUIPMENT Thermal plunger If the battery voltage is > 13.5 volts if not then Thermal plungers One thermal plunger not supplied supplied If after 20 seconds the battery voltage is > 13.5 volts if not then Thermal plungers Two thermal plungers not supplied supplied If after 20 seconds...

  • Page 72: Low Pressure Pump (Supercharging Pump)

    DIESEL EQUIPMENT Low pressure pump (supercharging pump) Low pressure pump (supercharging pump) The supercharging pump is an electric pump located in IMPORTANT : the engine compartment. A fuel cock (R) is fitted to the fuel filter at the level of REMOVAL the return pipe leading to the tank.

  • Page 73: Fuel Filter

    DIESEL EQUIPMENT Fuel filter Fuel filter The fuel filter is located in the engine compartment. It is contained in an unremovable cartridge. This cartridge contains a regulating valve which limits the flow of diesel circulating to the engine. To replace the filter it is therefore necessary to replace the whole unit. REMOVAL REFITTING It is vital that you respect the position of the...

  • Page 74: High Pressure Pump

    DIESEL EQUIPMENT High pressure pump High pressure pump IT IS PROHIBITED TO REMOVE THE INTERIOR OF THE PUMP. SPECIAL TOOLING REQUIRED Mot. 1054 TDC setting pin Mot. 1200-01 Pump-pulley retaining tool Mot. 1383 Tool for removing high pressure pipes Mot. 1525 Pulley extractor Mot.
  • Page 75 DIESEL EQUIPMENT High pressure pump REMOVAL Remove the nut from the high pressure pump pulley. Fit the extractor Mot. 1525 fitted with the adaptor YOU SHOULD FOLLOW THE CLEANNESS Mot. 1525-01 on the pulley pump then disassemble INSTRUCTIONS CLOSELY the unit. Disconnect the battery.
  • Page 76 DIESEL EQUIPMENT High pressure pump REFITTING Refitting is the reverse of removal. NOTE: be careful not to place the high pressure pipe under stress. Undo the high pressure rail. Offer up the high pressure pipe nuts on the pump and rail side. Tighten the high pressure rail.
  • Page 77 DIESEL EQUIPMENT High pressure pump Reprime the circuit: – close the fuel cock (R), – start the low pressure pump while switching on the ignition several times, – start the engine, – OPEN THE FUEL COCK (R) (the valve is open when the two coloured lines are aligned).
  • Page 78 DIESEL EQUIPMENT Injector rail Injector rail SPECIAL TOOLING REQUIRED Mot. 1294 -01 Tool for removing windscreen wiper arms Mot. 1383 Tool for removing high pressure pipes ESSENTIAL SPECIAL TOOLING "Low torque" torque wrench TIGHTENING TORQUES (in daN.m) High pressure pipe nut 2.5±0.2 Injection rail mounting bolt 2.2±0.2...
  • Page 79 DIESEL EQUIPMENT Injector rail REMOVAL YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY Disconnect: – the battery, – the pressure sensor (1), – the injectors, – the cylinder marking sensor. Undo and remove the diesel HP pipes. Insert the plugs to maintain cleanness. Gently remove the injection rail.
  • Page 80 DIESEL EQUIPMENT Injector rail REFITTING Position the injection rail and finger-tighten the mounting bolts (the rail should be floating). Position all the HP pipes and finger-tighten them. Tighten: – all the HP injection pipe connections (on the injector side (1) then on the injection rail side (2).
  • Page 81 DIESEL EQUIPMENT Injector rail NOTE: it is imperative that you replace the fuel return pipe (5) placed on the injectors during removal. 16192-1R 13-30...
  • Page 82 DIESEL EQUIPMENT Injector rail Reprime the circuit using a fuel cock (R) placed on the diesel filter (depending on version). 16870R3 NOTE: certain vehicles are not fitted with a fuel cock. In this case, ignore the repriming procedure. After any intervention, check that there are no leaks in the diesel circuit.

  • Page 83: Injectors

    DIESEL EQUIPMENT Injectors Injectors IT IS FORBIDDEN TO REMOVE THE INTERIOR OF AN INJECTOR OR TO SEPARATE THE INJECTOR HOLDER FROM THE PIPE. SPECIAL TOOLING REQUIRED Elé. 1294 -01 Tool for removing windscreen wiper arms Mot. 1383 Tool for removing high pressure pipes TIGHTENING TORQUES (in daN.m) 2 ±...
  • Page 84 DIESEL EQUIPMENT Injectors REMOVAL If necessary, remove: – the bulkhead panel using tool Elé. 1294-01, – the scuttle panel, – the air unit. YOU SHOULD FOLLOW THE CLEANNESS INSTRUCTIONS CLOSELY NOTE: the injectors may be replaced individually. Remove the HP pipe using the tool Mot. 1383. Insert the plugs to maintain cleanness.
  • Page 85 DIESEL EQUIPMENT Injectors CLEANING REFITTING It is absolutely forbidden to use the following when Change the washer beneath the injector. cleaning the injector: – a metallic brush, – an emery cloth, – an ultrasound cleaner. To clean the nose of the injector, let it soak in degreaser, then wipe is with a lint-free cloth.
  • Page 86 DIESEL EQUIPMENT Injectors NOTE: be careful when refitting that you do not stress the HP pipe. Remove the injection rail. Fit: – the injector, – the diesel return pipe. 16192-1S 13-35...
  • Page 87 DIESEL EQUIPMENT Injectors Fit the high pressure pipe. Loosen the high pressure pump/rail pipe. Tighten to torque: – the injector, – the injector side connections, then the injection rail connections, – the rail. – the pump/rail pipe (high pressure pump side under pressure). 16192S NOTE: it is essential that you replace the fuel return pipe placed on the injectors during removal.

  • Page 88: Checking Diesel Pressure And Flow

    DIESEL EQUIPMENT Checking diesel pressure and flow Checking diesel pressure and flow It is possible to check the pressure and flow in the low pressure fuel circuit. The low pressure is delivered by the supercharging pump (electric pump located under the diesel filter designed to feed the high pressure pump).

  • Page 89: Pressure Sensor

    DIESEL EQUIPMENT Pressure sensor Pressure sensor TIGHTENING TORQUES (In daN.m or/and°) 3.5 ± 0.5 Pressure sensor IMPORTANT: before any intervention, connect the after-sales diagnostic tool, query the injection computer and check that the injection rail is not under pressure. Take note of the fuel temperature. PRESSURE SENSOR (1) REFITTING Replace the seal.

  • Page 90: Pressure Regulator

    DIESEL EQUIPMENT Pressure regulator Pressure regulator TIGHTENING TORQUES (In daN.m or/and °) 0.9 ± 0.1 Regulator bolt IMPORTANT: before any intervention, connect the after-sales diagnostic tool, query the injection computer and check that the injection rail is not under pressure. Take note of the fuel temperature. PRESSURE REGULATOR (2) REFITTING Change the seals.

  • Page 91: Accelerator Potentiometer

    DIESEL EQUIPMENT Accelerator potentiometer Accelerator potentiometer TRACK ASSIGNMENT Track Description Signal track 2 Signal track 1 5 volt supply track 2 Track 1 earth Track 2 earth 5 volt supply track 1 15760S 15760S NOTE: a fault on one of the tracks for the accelerator pedal position potentiometer leads to idling speed or modified operation.

  • Page 92: Management

    DIESEL EQUIPMENT Coolant temperature management Coolant temperature management CCTM OPERATION The injection computer controls, as a function of the coolant temperature: – the injection system, – the engine cooling fan relays: the fan is kept at a low speed if the coolant temperature exceeds 99 ˚C and stops when the temperature drops below 96 ˚C, the fan is kept at a high speed if the coolant...

  • Page 93: Computer

    DIESEL EQUIPMENT Computer Computer TRACK ASSIGNMENT Connector A THROTTLE POTENTIOMETER SUPPLY (TRACK 2) → OBD WARNING LIGHT → COOLANT TEMPERATURE WARNING OUTPUT → PREHEATING WARNING LIGHT OUTPUT ← IMMOBILISER INPUT → FAULT WARNING LIGHT OUTPUT ← POWER CONSUMED ← THROTTLE POTENTIOMETER INPUT (TRACK 2) ←...
  • Page 94 DIESEL EQUIPMENT Computer Connector C TURBOCHARGER PRESSURE SENSOR EARTH FLOW METER EARTH → LOW SPEED FAN RELAY CONTROL OUTPUT → ELECTRIC FUEL PUMP CONTROL OUTPUT → HIGH SPEED FAN RELAY CONTROL OUTPUT DIESEL PRESSURE SENSOR EARTH CAMSHAFT POSITION SENSOR EARTH →...

  • Page 95: Antipollution

    ANTIPOLLUTION ANTIPOLLUTION Oil vapour rebreathing Oil vapour rebreathing CIRCUIT DIAGRAM DI1322 A Oil vapour rebreathing pipe for the bottom of engine 13042R 1 Engine B Oil vapour rebreathing pipe for the top of engine 2 Oil separator 3 Air filter unit C Oil separator 4 Inlet manifold D Oil vapour rebreathing pipe linked to the intake...

  • Page 96: Exhaust Gas Recirculation

    ANTIPOLLUTION Exhaust gas recirculation Exhaust gas recirculation CIRCUIT DIAGRAM Engine Injection computer Inlet manifold Exhaust manifold EGR solenoid valve Water temperature sensor REMOVING THE VALVE The EGR valve is an interference fit in the intake manifold. To facilitate its replacement it is preferable to remove the manifolds. PURPOSE OF THE EGR SYSTEM The recirculation of the exhaust gases is used to reduce the nitrogen oxide (NOx) content of the exhaust gases.

  • Page 97: Exhaust Gas Recirculation

    ANTIPOLLUTION Exhaust gas recirculation OPERATING PRINCIPLE The electric EGR valve is supplied for 40 seconds on each return to idling speed if the air temperature is The valve is controlled by an RCO signal issued by the greater than 15 ˚C. injection computer.

  • Page 98: Starting - Charging

    STARTING - CHARGING STARTING - CHARGING Alternator Alternator IDENTIFICATION Type Engine Alternator Current SG 10 B010 120 A SG 10 B011 XA0 5 F9Q 732 A13VI252 80 A A11VI88 75 A CHECKING After 15 minutes warming up at a voltage of 13.5 volts. Rpm.

  • Page 99: Alternator

    STARTING - CHARGING Alternator SPECIAL TOOLING REQUIRED Mot. 1273 Tool for checking belt tension REMOVAL Special features of vehicles fitted with air conditioning: Put the vehicle on a 2 post lift. Before removing the accessories belt, check the Disconnect the battery as well as all electrical centreline of the automatic tensioner (see connections on the alternator.
  • Page 100 STARTING - CHARGING Alternator REFITTING (special notes) Refit in reverse order to removal. The belts on vehicles fitted with air conditioning are tensioned by bringing the automatic tensioner plate to a stop at bolt (B), without forcing it, using a 9.35 mm square.

  • Page 101: Starter

    STARTING - CHARGING Starter Starter IDENTIFICATION Type Engine Starter motor XA0 5 F9Q 732 MITSUBISHI M1T85781 16-4...
  • Page 102 STARTING - CHARGING Starter REMOVAL Remove (all types): – the turbocharging air ducts between the exchanger Put the vehicle on a 2 post lift. and the engine, – the pre-catalytic converter mountings to the turbo. Disconnect the battery. Loosen the exhaust pipe clamp mounting. Remove (for the Scénic): –...

  • Page 103: Cooling System

    COOLING SYSTEM COOLING SYSTEM Filling and bleeding Filling and bleeding There is no heater matrix water control valve. Water flow is continuous in the heater matrix, which contributes to the cooling of the engine. FILLING It is essential to open the bleed screw on the cylinder head coolant pipe housing outlet.

  • Page 104: Diagram

    COOLING SYSTEM Diagram Diagram 3 mm ∅ restriction Engine 6 mm ∅ restriction Radiator "Hot" container with degassing after thermostat Oil/water exchanger Heater matrix 10 Water pump Thermostat mounting 11 Thermostat Thermoplunger mounting (if fitted) 12 Bleed screw The expansion bottle valve rating is 1.2 bar (colour: brown).

  • Page 105: Thermoplunger Unit

    COOLING SYSTEM Thermal plunger unit Thermal plunger unit SPECIAL TOOLING REQUIRED Mot. 453 -01 Hose clamp pliers set Mot. 1202 Hose clip pliers Mot. 1448 Long nose pliers for hose clips TIGHTENING TORQUES (in daN.m) Thermal plungers REMOVAL Put the vehicle on a 2 post lift. Disconnect the battery.

  • Page 106: Radiator

    COOLING SYSTEM Radiator Radiator SPECIAL TOOLING REQUIRED Mot. 1202 -01 Hose clip pliers Mot. 1202 -02 Mot. 1448 Long nose pliers for hose clips REMOVAL REFITTING Put the vehicle on a two post lift. Refitting is the reverse of removal. Disconnect the battery.

  • Page 107: Water Pump

    COOLING SYSTEM Water pump Water pump SPECIAL TOOLING REQUIRED Mot. 1202 -01 Hose clip pliers Mot. 1202 -02 Mot. 1448 Long nose pliers for hose clips Cleaning TIGHTENING TORQUES (in daN.m) It is very important not to scratch the gasket faces. Water pump bolts Use the Décapjoint product to dissolve any part of the gasket which remains attached.

  • Page 108: Engine Mounting

    ENGINE MOUNTING ENGINE MOUNTING 1319 Manual gearbox Suspended engine mountings Suspended engine mountings TIGHTENING TORQUE (daN.m) 17518R4 19-6...

  • Page 109: Exhaust

    EXHAUST EXHAUST 1419 Catalytic converter Catalytic converter TIGHTENING TORQUES (in daN.m) Engine tie bar bolt Steering shaft yoke bolts Engine sub-frame bolts – front ∅ 10 – rear ∅ 12 10.5 Three point flange nuts Sub-frame - side member tie rod bolts Disconnect the battery and put the vehicle on a two post lift.

  • Page 110: Manual Gearbox

    MANUAL GEARBOX MANUAL GEARBOX Identification Identification "SCENIC" vehicles, F9Q high pressure engines, are equipped with JC5 manual gearboxes. The Workshop Repair Manual "JB gearbox. JC" deals with the complete repair of this component. 14834-1R A mark (1), located on the gearbox casing, indicates: A Type of gearbox B Gearbox index C Manufacturing number...

  • Page 111: Capacity - Lubricants

    MANUAL GEARBOXES MANUAL GEARBOXES Capacities - Lubricants Capacities - Lubricants CAPACITY (in litres) 5 gear box Viscosity grade TRX 75W 80W CHECKING THE LEVEL 92081S Filling is by overflow 21-2...

  • Page 112: Air Conditioning

    AIR CONDITIONING AIR CONDITIONING General General CONSUMABLES – Oil for DELPHI HARRISON compressor: ± 15 PLANETELF PAG 488: 220 cm (to be ordered from ELF). – Refrigerant: R134a: 780 g ± 35 (Mégane) R134a: 680 g ± 35 (Scénic) – Compressor: DELPHI HARRISON V5 62-1...

  • Page 113: Compressor

    AIR CONDITIONING SCENIC Compressor Compressor REMOVAL REFITTING Drain the R134a refrigerant circuit (refer to the Refitting is the reverse of removal. procedure described in the "Air conditioning" manual). Tighten the R134a refrigerant pipes retaining bolt on Disconnect the battery. the compressor to 3 daN.m. Remove: Fill the R134a refrigerant circuit using the filling –...

  • Page 114: Dehydration Canister

    AIR CONDITIONING SCENIC Dehydration canister Dehydration canister REMOVAL Drain the R134a refrigerant circuit using the filling equipment (refer to the procedure described in the "Air Conditioning" manual). Remove: – the right hand mudguard, – the mounting bolts which secure the pipes to the dehydration canister, –...

  • Page 115: Condenser

    AIR CONDITIONING SCENIC Condenser Condenser REMOVAL Place the vehicle on a lift. Drain the R134a refrigerant circuit (refer to the procedure described in the "Air conditioning" manual). Remove: – the six mounting bolts of the upper cross member, 98838S – the two lower mounting bolts of the condenser on the fan unit, then the two upper bolts, –...

  • Page 116: Pressure Relief Valve

    AIR CONDITIONING SCENIC Pressure relief valve Pressure relief valve TIGHTENING TORQUES (in daN.m) Pressure relief valve retaining bolt Pipe retaining bolt REPLACEMENT Drain the R134a refrigerant circuit using the filling equipment (refer to the procedure described in the "Air Conditioning" manual). Remove the right hand cowl vent grille.
  • Page 117 AIR CONDITIONING SCENIC Connecting pipes Connecting pipes Disconnect the battery. Drain the R134a refrigerant circuit using the filling equipment (refer to the procedure described in the "Air Conditioning" manual). LOW PRESSURE PIPE HIGH PRESSURE PIPE BETWEEN THE COMPRESSOR AND THE CONDENSER REMOVAL REMOVAL Remove the right hand cowl vent grille.
  • Page 118 AIR CONDITIONING SCENIC Connecting pipes Disconnect the battery. Drain the R134a refrigerant circuit using the filling equipment (refer to the procedure described in the "Air Conditioning" manual). HIGH PRESSURE PIPE BETWEEN THE HIGH PRESSURE PIPE BETWEEN THE DEHYDRATION CANISTER AND THE PRESSURE DEHYDRATION CANISTER AND THE CONDENSER REDUCING VALVE REMOVAL...

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MeganeScenic

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