VNX - Su Primastrar PDF

vnx.
su
Edition: September 2002

Release: September 2002 (01)
Publication No.: SM2A00-1X83E0E
Reference No.: 7711346631
QUICK REFERENCE INDEX
GENERAL INFORMATION
GI
MAINTENANCE
MA
ENGINE MECHANICAL
EM
PRIMASTAR
ENGINE LUBRICATION &

COOLING SYSTEMS
LC
MODEL X83 SERIES
ENGINE CONTROL SYSTEM
EC
CLUTCH
CL
MANUAL TRANSAXLE
MT
FRONT & REAR AXLE
AX
FRONT & REAR SUSPENSION
SU
BRAKE SYSTEM
BR
STEERING SYSTEM
ST
RESTRAINT SYSTEM
RS
BODY & TRIM
BT
HEATER & AIR CONDITIONER
HA
STARTING & CHARGING SYSTEMS
SC
ELECTRICAL SYSTEM
EL
WIRING DIAGRAMS
WD
NISSAN EUROPE N.V.

2002 NISSAN EUROPE N.V.
Produced in The Netherlands
Not to be reproduced in whole or in part
without the prior written permission of
Nissan Europe N.V., Paris, France.
vnx.su
FOREWORD
This manual contains maintenance and repair procedures for NISSAN
PRIMASTAR, model X83 series.
In order to assure your safety and the efficient functioning of the vehicle,
this manual should be read thoroughly. It is especially important that the
PRECAUTIONS in the GI section be completely understood before starting
any repair task.
All information in this manual is based on the latest product information
at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and the
tools and parts available. Accordingly, anyone using service procedures,
tools or parts which are not specifically recommended by NISSAN must
first completely satisfy himself that neither his safety nor the vehicles
safety will be jeopardized by the service method selected.
NISSAN EUROPE N.V.

Service Operations Section
Paris, France
France
vnx.su
This Workshop Repair Manual has been prepared by experts in repair and fault finding procedures.
The document covers the methods and the fault finding operations required in order to carry out high quality repairs
on this vehicle.
However, if a removal - refitting operation involves no special features, difficulties or special tooling, the method is not
described in this manual because it is considered very simple for a vehicle repair specialist.
The labour times are the result of time and motion studies carried out in our workshops, even though certain methods
have not been described in the Workshop Repair Manual.
UNITS OF MEASUREMENT
All dimensions are expressed in millimetres (mm) unless stated otherwise.
Tightening torques are shown in decaNewton metres (daNm).
Pressures are expressed in bar (reminder: 1 bar = 100 000 Pa).
Electrical resistance is given in ohms ().
Voltages are expressed in volts (V).
TOLERANCES
Tightening torques given without a tolerance must be accurate to within:
In degrees: 3.
In daNm: 10 %.
EQUIPMENT AND TOOLING

The repair procedures described for the vehicles in the NISSAN range require special materials and tools in certain
cases.
vnx.su
SPECIFICATIONS
101
Engine- Clutch - Gearbox
01
Engine
Vehicle type
XL0B
XL0C
Type
Capacity
(cc)
F9Q
1870
VEHICLE IDENTIFICATION
Example: XL0B
F
: Body type (van)
: Project code
0B : Engine suffix
01-1
vnx.su
Gearbox type
PK5
PK6
SPECIFICATIONS
Vehicle identification
LOCATION OF VEHICLE IDENTIFICATION PLATE
01-2
vnx.su
01
SPECIFICATIONS
LEGISLATIVE INFORMATION
1
name of Manufacturer
type-approval number
identification number
maximum weight under full load
maximum permitted gross train weight
maximum load on front axle
maximum load on rear axle
model
model code
10
exterior colour code
11
interior colour code
12
after-sales information
01-3
vnx.su
01
SPECIFICATIONS
WORKS PRODUCTION INFORMATION

1
vehicle type
equipment level
limited series specification supplement
special series specification supplement
paintwork and body colour grade
seat covers
vehicle interior colour scheme
fabrication number
technical specifications
10
main options
NOTE:
The seven characters making up the fabrication
number (8) cannot be separated.
01-4
vnx.su
01
SPECIFICATIONS
01
SIGNIFICANCE OF THE IDENTIFICATION NUMBER
10
11
12
13
14
15
16
17
Manufactuer's code:
Nissan
Chassis number
V: LUTON
Factory of
manufacture
Y: BARCELONA
Model year
See description below
Description
STRUCTURAL
DESIGN
PROJECT
N1 utility vehicles
4: NISSAN
F: VAN
E: CAB FLOOR
M1 people carriers
J: COMBI / MINIBUS
WEIGHTS
A: 1000 kg
ENGINES
Payload
categories
B: 1200 kg
A: petrol hp
A: Wheelbase 10 / Height 10
B: 1.9 l diesel 80 hp B: Wheelbase 20 / Height 10
C: 1.9 l diesel 100 hp C: Wheelbase 10 / Height 20
D: Wheelbase 20 / Height 20
WEIGHTS / NUMBER OF
SEATS
A: 1000 kg 2/9 seats (combi)
B: 1200 kg 2/9 seats (combi)
C: 1000 kg 6/8 seats (Minibus)
D: 1000 kg 2/6 seats (combi)
E: 1200 kg 2/6 seats (combi)
WHEELBASE / HEIGHT
ENGINES
A: petrol hp
B: 1.9l diesel 80 hp
C: 1.9l diesel 100 hp
01-5
vnx.su
WHEELBASES / HEIGHT
A: Wheelbase 10 / Height 10
B: Wheelbase 20 / Height 10
C: Wheelbase 10 / Height 20
D: Wheelbase 20 / Height 20
MANUAL
GEARBOX
5 gears
6 gears
MANUAL
GEARBOXES
5 gears
6 gears
SPECIFICATIONS
01
SIGNIFICANCE OF THE TECHNICAL SPECIFICATIONS
type of
transmission
A = 2 drive
wheels
STRUCTURAL
DESIGN
A = Minibus L1H1
B = Minibus L1H2
C = Minibus L2H1
D = Minibus L2H2
E = COMBI L1H1
G = COMBI L2H1
J = BUS, L1H1
N = Cabin floor
L2H1
Equipment
level
B = E1
C = E2
Steering
wheel
position
L = Left
R = Right
Country
A = All
Gearbox
R = 5 gears
S = 6 gears
Payload
categories
D = 1.200 kg
G = 1.000 kg
Project code
Engine
RA = F4R petrol 2.0 l 120 hp
TF = F9Q DIESEL 1.9 l 80 hp
TG = F9Q DIESEL 1.9 l 100 hp
TR = G9U DIESEL 2.5 l 135 hp
01-6
vnx.su
Options
package code
Model year
A = 2001
Destination code
LIFTING EQUIPMENT
102
Trolley jack - Axle stands
TROLLEY JACK AND AXLE STAND LOCATIONS
02
REAR
NOTE:
only use the underbody flange when the axle stands
are in position.
FRONT
02-1
vnx.su
LIFTING EQUIPMENT
Underbody lifts
SAFETY INSTRUCTIONS
02
2 - REMOVING AND REFITTING HEAVY

COMPONENTS
Various cases have to be considered:

IMPORTANT:
Always use a safety harness if using a two-post lift to
remove heavy components.
1 - REMOVING COMPONENTS
As a general rule, never use a two-post lift when a
four-post lift can be used.
For your safety, take care to ensure that the vehicle is

balanced when placed on a two-post lift.
If this is not possible, place the lifting pads on the jack

supports (A) as shown below:
FRONT
This is because removing heavy components (such as

the engine and transmission assembly, rear axle or
fuel tank, etc.), depending on:
the vehicle load,
its length,
the position of the lifting pads,
may cause the vehicle to become unbalanced.
It is therefore essential to put a strap around or inside
the bodywork and fix it to the arms of the lift between
the pads.
REAR
02-2
vnx.su
LIFTING EQUIPMENT
Underbody lifts
02
TOOLING REQUIRED
FITTING THE SAFETY STRAPS
Straps:
10 metres long,
25 mm wide.
Securing the vehicle with straps allows work to be

carried out beneath the vehicle free from obstruction.
The strap must be in place during any operation
involving the transfer of weight.
Straps are available under Part no.: 77 11 172 554.
Check the strap before each use.

The lift pads are placed under the vehicle facing the
supports as described above.
Lift the vehicle a few centimetres.
Protect the vehicle interior (seats, etc.).
Place the strap through under the arms of the lift and
pass twice around the vehicle, placing the strap
protectors correctly so as not to damage the bodywork
or upholstery.
Do not pull too tight.
This type of strap should only be used to immobilise a

vehicle on a two-post lift (for safety reasons, they
should not be used for any other purpose).
Use straps that are in good condition and clean (so as
not to dirty the interior or the bodywork). Avoid
damaging the vehicle by pulling the strap too tight (the
sill panels can be protected at the point where the
strap passes over them).
02-3
vnx.su
TOWING
103
All types
03
OBSERVE THE NATIONAL REGULATIONS CONCERNING TOWING FOR THE COUNTRY YOU ARE IN.
NEVER USE THE DRIVESHAFTS AS AN ATTACHMENT POINT.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or to lift the vehicle, either directly or indirectly.
FRONT
REAR (vehicle with towing equipment)
REAR (vehicle without towing equipment)
03-1
vnx.su
LUBRICANT CONSUMABLES
104
Packaging
DESCRIPTION
04
PACKAGING
GREASES
MOLYKOTE "BR2"
for main bearing journal faces, thrust pad guide tubes,
clutch fork pads, lower suspension arm bearings,
torsion bar splines, steering rack, driveshaft splines.
1 kg tin
MOLYKOTE "33 Medium"

bushes on tubular rear axle, anti-roll bar bushes.
100 g tube
ANTI-SEIZE
(high temperature grease) turbocharger etc.
80 ml tube
MOBIL CVJ 825 Black star or MOBIL EXF57C

for driveshaft seals
MULTIPURPOSE GREASE
wheel sensors.
180 g sachet
Aerosol
MECHANICAL SEALANTS
Mastic
for sealing exhaust pipe unions
1.5 kg tin
RHODORSEAL 5661
HARDENER KIT (RHODORSEAL 5661)

for bearing cap lateral seals
AUTO blue seal

sealing paste
100 g tube
Kit
100 g tube
LACQUER
"CIRCUIT PLUS"
lacquer for repairing heated screens
Bottle
BRAKES
Brake fluid
0.5 litre bottle of DOT 4
04-1
vnx.su
Packaging
DESCRIPTION
PACKAGING
MECHANICAL SEALANTS
AUTO grey seal

sealing paste
100 g tube
LOCTITE 518
for sealing the gearbox housing
Leak detector
24 ml syringe
Aerosol
ADHESIVES
"LOCTITE-FRENETANCH"
stops bolts slackening and allows them to be released
24 cc bottle
"LOCTITE - FRENBLOC"
locks bolts
24 cc bottle
"LOCTITE SCELBLOC"
for bonding bearings
24 cc bottle
"LOCTITE AUTOFORM"
for bonding the flywheel to the crankshaft
50 cc bottle
LUBRICANT CLEANING AGENTS
"NETELEC"
unseizes, lubricates
Aerosol
Carburettor cleaner
300 ml aerosol
Injector cleaner
Super-concentrated unseizing agent
"DECAPJOINT" (FRAMET) for cleaning the gasket

faces of aluminium cylinder heads
Brake cleaner
355 ml can
500 ml aerosol
Aerosol
400 ml aerosol
04-2
vnx.su
04
VALUES AND 107

SETTINGS
Capacities - Grades
07
Average capacity*
Component
After an oil change, check using the

dipstick
After replacing the oil filter
4.45 l
4.6 l
Engine (oil)
F9Q
Component
Capacity (litres)
Manual gearbox
PK5
PK6
2.7 0.15
* Check with dipstick

NOTE:
Never exceed the the maximum mark on the dipstick.
Components
Brake circuit
Capacity in litres
Standard: 0.7
Anti-lock Braking System: 1
Grade
SAE J 1703 and DOT 4
Brake fluids must be approved by the Technical Department.
Components
Capacity in litres
Grade
Fuel tank
Approximately
90
Diesel
Power assisted steering
Separate reservoir:
1.1
DEXRON II
Cooling circuit
5.40 (F4R)
6.40 (F9Q)
07-1
vnx.su
GLACEOL RX (type D)
add coolant only
VALUES AND
107SETTINGS
Dimensions
07
Dimensions in metres.
(1) unladen
(2) laden
Van
VERSION
Combi
Short
Long
Short
Long
3.098
3.498
3.098
3.498
4.782
5.182
4.782
5.182
0.833
0.833
0.851
0.851
1.615
1.615
1.630
1.630
2.232
2.232
H(1)
1.959
1.965
1.958
1.940
1.944
0.543
0.549
0.542
0.521
0.525
(2)
0.162
0.164
0.158
0.152
0.151
1.387
1.369
1.390
1.390
1.335
1.306
ZI
2.380
2.780
07-2
vnx.su
0.790
0.150
1.190
VALUES AND SETTINGS

Accessories belt tensioning
Removing/refitting the accessories belt is
straightforward. Turn the belt auto tensioner in the
direction indicated below using a 16 mm spanner.
NOTE:
Never refit a belt once removed, always replace it.
Refitting is the reverse of removal.
07-3
vnx.su
07
VALUES AND SETTINGS

Tightening the cylinder head
07
PROCEDURE FOR TIGHTENING THE CYLINDER HEAD

REMINDER:
In order to ensure that the bolts are correctly tightened, use a syringe to remove any oil which may be in the cylinder
head mounting holes.
All cylinder head bolts must always be changed after removal. There is no cylinder head retightening operation.
Preseating the gasket
Tighten all the bolts to 3 daNm, then angle tighten to 100 4 in the order shown below.
Wait 3 minutes settling time.

Tightening the cylinder head:
tightening is carried out in stages, and the following procedure is applied successively to bolts 1-2, then 3-4, 5-6,
7-8 and 9-10,
undo bolts 1-2 until they are completely free,
tighten bolts 1-2 to 2.5 daNm, then angle tighten to 213 7,
repeat the slackening and tightening operations for bolts 3-4, 5-6, 7-8 and 9-10.
There is no cylinder head retightening operation.
07-4
vnx.su
VALUES AND SETTINGS

Tyres and wheels
07
Tyre pressure when cold (in bar) (1)

Vehicle
ALL TYPES
Rim
6J16
Tyres
Front
Rear
195/65 R16 C
3.2
3.6
205/65 R16 C
3.6
4.1
215/65 R16 C
3.0
3.4
(1) With full load and on motorways.
Tightening torque of the wheel nuts: 14.2 daNm

Rim run-out: 1.2 mm
07-5
vnx.su
VALUES AND SETTINGS

Brakes
Disc thickness (in mm)
Disc thickness (in mm)
Front
Rear
Vehicle
ALL TYPES
07
Maximum disc
run-out (in mm)
Standard
Minimum
Standard
Minimum
28
24
12
10
0.07
Lining thickness (in mm) (not including mounting)

Vehicle
ALL TYPES
Front
Rear
Brake fluid
New
Minimum
New
Minimum
11.9
10.3
07-6
vnx.su
SAE J 1703
DOT 4
VALUES AND SETTINGS

Brake compensator
07
Braking pressure
Vehicle unladen.
Full fuel tank.
Driver on board.
Checking pressure (in bar)
Vehicle
Front
Rear
FL0X
> 100
44 5
JL0X
> 100
49 5
The check is carried out using two pressure gauges, one connected to the left-hand front wheel and the other
connected to the right-hand rear wheel.
NOTE:
To determine the pressure of the compensator when the vehicle is loaded, follow the procedure described in
Section 37.
07-7
vnx.su
VALUES AND SETTINGS

Underbody height
07
VEHICLE
At the front
H1 - H2 = ... mm
At the rear
H4 - H5 = ... mm
Dimension X (in mm)

Left and right
FL0X
49
14
JL0X
52
30
Tolerance: 7.5 mm
The difference between the right and left-hand sides of the same axle of a vehicle must not exceed 5 mm, the
driver's side always being higher.
Any alteration to the underbody height also requires adjustment of the brake compensator and of the headlights.
07-8
vnx.su
VALUES AND SETTINGS

Underbody height
MEASUREMENT POINTS
Measurements H1 and H4 are taken at the wheel shaft.

Measurement H2 is taken under the jacking point.
Measurement H5 is taken at the rear axle mounting shaft.
07-9
vnx.su
07
VALUES AND SETTINGS

Front axle geometry checking values
SHORT VAN
ANGLES
VALUES
POSITION OF
FRONT AXLE (mm)
235' 30'
H5 - H2 = 44
254' 30'
H5 - H2 = 30
314' 30'
H5 - H2 = 16
07
ADJUSTING
CASTOR
Not
adjustable
Max. right/left
difference = 1
CAMBER
-016' 30'
H1 - H2 = 51
-024' 30'
H1 - H2 = 64
-032' 30'
H1 - H2 = 78
Not
adjustable
Max. right/left
difference = 1
PIVOT
1133' 30'
H1 - H2 = 51
1149' 30'
H1 - H2 = 64
1204' 30'
H1 - H2 = 78
Not
adjustable
Opening
+ 010' 10'
+ 1 mm 1 mm
Unladen
Adjusted by
rotating the
track rod
sleeves
Unladen
Max. right/left
difference = 1
WHEEL ALIGNMENT
(For two wheels)
POSITION FOR TIGHTENING RUBBER BUSHES
07-10
vnx.su
VALUES AND SETTINGS

LONG VAN
ANGLES
VALUES
POSITION OF
FRONT AXLE (mm)
244' 30'
H5 - H2 = 40
303' 30'
H5 - H2 = 24
322' 30'
H5 - H2 = 9
07
ADJUSTING
CASTOR
Not
adjustable
Max. right/left
difference = 1
CAMBER
-016' 30'
H1 - H2 = 47
-024' 30'
H1 - H2 = 62
-032' 30'
H1 - H2 = 78
Not
adjustable
Max. right/left
difference = 1
PIVOT
1133' 30'
H1 - H2 = 47
1149' 30'
H1 - H2 = 62
1204' 30'
H1 - H2 = 78
Not
adjustable
Opening
+ 010' 10'
+ 1 mm 1 mm
Unladen
Adjusted by
rotating the
track rod
sleeves
Unladen
Max. right/left
difference = 1
WHEEL ALIGNMENT
(For two wheels)
07-11
vnx.su
VALUES AND SETTINGS

SHORT COMBI
ANGLES
VALUES
POSITION OF
FRONT AXLE (mm)
251' 30'
H5 - H2 = 29
306' 30'
H5 - H2 = 18
322' 30'
H5 - H2 = 8
07
ADJUSTING
CASTOR
Not
adjustable
Max. right/left
difference = 1
CAMBER
-016' 30'
H1 - H2 = 54
-024' 30'
H1 - H2 = 65
-032' 30'
H1 - H2 = 76
Not
adjustable
Max. right/left
difference = 1
PIVOT
1133' 30'
H1 - H2 = 54
1149' 30'
H1 - H2 = 65
1204' 30'
H1 - H2 = 76
Not
adjustable
Opening
+ 010' 10'
+ 1 mm 1 mm
Unladen
Adjusted by
rotating the
track rod
sleeves
Unladen
Max. right/left
difference = 1
WHEEL ALIGNMENT
(For two wheels)
07-12
vnx.su
VALUES AND SETTINGS

LONG COMBI
ANGLES
VALUES
POSITION OF
FRONT AXLE (mm)
257' 30'
H5 - H2 = 27
312' 30'
H5 - H2 = 15
328' 30'
H5 - H2 = 3
07
ADJUSTING
CASTOR
Not
adjustable
Max. right/left
difference = 1
CAMBER
-027' 30'
H1 - H2 = 51
-030' 30'
H1 - H2 = 63
-032' 30'
H1 - H2 = 76
Not
adjustable
Max. right/left
difference = 1
PIVOT
1133' 30'
H1 - H2 = 51
1149' 30'
H1 - H2 = 63
1204' 30'
H1 - H2 = 76
Not
adjustable
Opening
+ 010' 10'
+ 1 mm 1 mm
Unladen
Adjusted by
rotating the
track rod
sleeves
Unladen
Max. right/left
difference = 1
WHEEL ALIGNMENT
(For two wheels)
07-13
vnx.su
VALUES AND SETTINGS

Rear axle geometry checking values
ANGLES
07
VALUES
POSITION OF
REAR AXLE
ADJUSTING
- 045' 20'
Unladen
Not
adjustable
Unladen
Not
adjustable
HALF-LOAD
CAMBER
WHEEL ALIGNMENT
(For two wheels)

Opening
0.30' 20'
3 mm 2 mm
SHOCK
ABSORBER
CENTRE-TOCENTRE
DISTANCE
397 mm 2 mm
07-14
vnx.su
WHEELS AND
TYRES
135
Specifications
35
WHEEL RIMS
There are two types of wheel identification marking:
Engraved markings for steel rims.
Cast marking for alloy rims.
The marking gives the main dimensional specifications of the wheel rim.
The marking may be complete:
Example: 5 1/2 J 14 4 CH 36
or in abbreviated form:
Example: 5 1/2 J 14
A
Rim type
Width
(in inches)
Rim edge
profile
Nominal diameter
(in inches)
Under tyre bead
Number
of holes
Tyre bead
profile
Offset
(in mm)
5 1/2 J 14 4
CH 36
5 1/2
14
CH
36
Maximum run-out: measured on the rim edge (at G).
35-1
vnx.su
WHEELS AND TYRES

Specifications
TYRES
The identification marking can be in two forms for the
same type of tyre.
Example:
195
205
/
/
65 R
65 R
16
16
C
C
1
1
2
3
4
5
6
7
100/98
107/105
6
R
T
7
Tyre width in mm (I)

Ratio h/w
Structure suffix
Diameter in inches. Corresponds to the diameter of
the rim.
Suffix (small van type)
Load index
Speed code
Example of a structure suffix:

Suffix
Structure
None
Cross ply
Radial
Bias belted
Example of a speed suffix:

Suffix
Maximum speed (km/h)
170
180
190
200
210
240
over 240
35-2
vnx.su
35
WHEELS AND TYRES

Specifications
35

Vehicle
All types
Rim
6J16
Tyres
Front
Rear
195/65 R16 C
3.2
3.6
205/65 R16 C
3.6
4.1
215/65 R16 C
3.0
3.4

Rim run-out: 1.2 mm
35-3
vnx.su
WHEELS AND TYRES

Wheel balancing
BALANCE WEIGHTS
Only use weights supplied by the Parts Department:
secured to the metal rims by hooks (hooks

incorporated in the weight),
fitted by hooks (flat hooks) or self adhesive for alloy

wheels.
A Steel rim
B Aluminium alloy
35-4
vnx.su
35
101
FAULT FINDING GENERAL INFORMATION

General method
01
VEHICLE DESCRIPTION
PRIMASTAR is a vehicle with a multiplex network (a CAN network that links most of the main computers).
The multiplex network previously only connected the injection to the automatic gearbox.
This technology makes possible new functions such as the Electronic Stability Program.
However, it involves a great deal of information exchange between the various systems.
To run fault finding on this vehicle, select Renault Basic Vehicle in the tools menu.
This means:
that a short circuit in the multiplex network could paralyse all the vehicle functions.
that a computer or a function (1) may fail due to a fault in another computer (2).
that after a repair operation, you must ensure that the system (1) is no longer faulty.
This section describes:

the overall fault finding method,
the functions which can support faulf finding,
the main new features of the vehicle.
01-1
vnx.su

General method
01
Once the vehicle has been selected, the diagnostic tool will only allow you to
access the multiplex network diagnostic.
NOTES
Once the network diagnostic is completed, you will have access to the fault
finding functions for all the vehicle systems.
ALWAYS REPAIR NETWORK FAULTS BEFORE PERFORMING FAULT
FINDING ON THE COMPUTERS
TIP
Perform an automatic test on all the systems before selecting a particular function.
When you select a system, a help function presents the computers contributing to the
function.
FAULT CHECKING
Certain computers (notably, injection, ECUs) store parameters when a fault occurs.
This allows you to recreate the fault conditions.
CONFORMITY
CHECK
Check the states, parameters and configurations using the associated procedures.
Certain operating parameters of a system come from other computers via the multiplex network.
Example: the vehicle speed is transmitted by the ABS, sent to the instrument panel by wire then distributed
on the multiplex network and appears in the injections or variable power assisted steering fault finding.
This information appears in a different colour on the fault finding tools.
AFTER REPAIR
Click on this data to run the diagnostic for the computer

producing it.
IMPORTANT: fault finding is not possible on the instrument
panel. Do not start the connection.
Switch off the ignition, and wait for 30 seconds.

Switch on the ignition again and repeat an automatic test of all the computers to ensure
that there is no longer a fault.
01-2
vnx.su

Functions which can support fault finding
01
FAULT FINDING
NOTES
Warning: if you are unable to carry out fault finding on a computer, check the
connection between the corresponding track 7 of the diagnostic socket and the
diagnostic track in the computer.
Also check the computer supply and conformity.
AIRBAG AND
PRETENSIONERS
This computer supports fault finding with the tool and is present in the multiplex
network.
ABS EBC 430
This function only performs the wheel locking during braking.

This computer supports fault finding with the tool but is not present in the multiplex
network.
ESP EBC 430
This function also ensures the anti-skid and Electronic Stability Program (ESP).
This computer can support fault finding and is present in the multiplex network. It is
linked with the steering wheel angle sensor (cannot support fault finding).
This function is managed directly by the UCH.
IMMOBILISER
This function also includes starting of the vehicle (UCH and

Injection).
These computers support fault finding with the tool and are present in the multiplex
network.
PASSENGER
COMPARTMENT
CONNECTION UNIT
AUTOMATIC
GEARBOX
This is the same as the UCH.

Fault finding for this computer is shared between several fault finding functions (UCH
and engine immobiliser).
This function also includes fault finding on the wipers and lighting.
This computer can support fault finding and is present in the multiplex network.
01-3
vnx.su

Functions which can support fault finding
MANUAL AIR
CONDITIONING
01
On this vehicle, the heating and ventilation computer does not control the
compressor (function managed by the injection computer).
This computer cannot support fault finding with the tool and is not present in the
multiplex network.
AUTOMATIC AIR
CONDITIONING
On this vehicle, the heating and ventilation computer does not control the
compressor (function managed by the injection computer).
This computer supports fault finding with the tool but is not present on the multiplex
network.
LPG INJECTION
This is handled by a specific computer connected to the multiplex network.

Be careful: there is also a petrol injection computer.
DIESEL INJECTION
This function manages the engine, cruise control and speed limiter functions
PETROL INJECTION
This function manages the engine and the cruise control and speed limiter functions
INSTRUMENT PANEL
This computer cannot support fault finding with the tool but is present on the multiplex
network.
Important: the vehicle speed is produced by the ABS and transmitted through a
network connection to the instrument panel. The instrument panel makes this signal
on the multiplex network available to the main computers (Air bag, Injection, UCH,
etc).
CENTRAL
COMMUNICATION
UNIT
This optional computer manages the radio and navigation/networking functions.

This computer cannot support fault finding with the tool but is present on the multiplex
network.
Important: This computer has a self-test type fault finding function described in the
method.
01-4
vnx.su

New Functions
Electronic Stability Program
FUNCTION
ABS, traction control and electronic

stability programme
Function to select on the diagnostic tool
Computer
responsible for the
function
01
Anti-lock Braking System / Electronic Stability Program
Computer using
the multiplex
network
Measures vehicle performance and controls braking and engine torque to correct
skidding.
Computer
contributing data
Petrol or diesel injection.
Measures engine torque and sends it to the ABS.

Processes the torque values received from the ABS.
Computer
contributing data
Steering wheel angle sensor.
Measures the steering wheel angle sensor given by the driver and transmits it to the
ABS - ESP computer.
Important: fault finding cannot be performed on this computer but it is present on the
multiplex network.
01-5
vnx.su
Computer using
the multiplex
network
Computer using
the multiplex
network

New Functions
Air conditioning (manual or automatic)
FUNCTION
Air conditioning
Computer
responsible for the
function
01
Air conditioning.
Controls the air conditioning compressor, processes all the sensor outputs except the engine coolant
temperature and the external air temperature.
Computer
contributing data
Computer using
the multiplex
network
Authorises or inhibits the air conditioning operation.

Processes requests for set-point values for the idle speed and startup of the engine
cooling fan.
Computer
contributing data
Radio display or Central Communication Unit.
Sends the external air temperature received from the radio display or the Central
Communication Unit to the climate control unit.
01-6
vnx.su
Computer using
the multiplex
network

New Functions
Cruise control - speed limiter
FUNCTION
Petrol or diesel injection
Computer
responsible for the
function
01
Computer using
the multiplex
network
Processes the driver's commands.

Displays cruise control status on the instrument panel (via the multiplex network).
Adjusts the speed of the vehicle according to the speed set by the driver.
Computer
contributing data
Anti-lock Braking System.
Computer using
the multiplex
network
Supplies the vehicle speed.
Computer
contributing data
Instrument panel.
Computer using
the multiplex
network
Displays cruise control speed - speed limit and the cruise control - limit condition.
01-7
vnx.su

New Functions
The OBD (On Board Diagnostic: depollution)
FUNCTION
Petrol or diesel injection
Computer
responsible for the
function
01
Computer using
the multiplex
network
Injection.
The OBD function is shared by the injection ECU and the automatic gearbox ECU.
The injection ECU decides the emission control fault finding procedue to be sent to
the diagnostic tool.
The emission control faults associated with the automatic transmission are also
accessible to the injection ECU
Computer
contributing data
Automatic gearbox.
Can request emission control warning light to come on.
01-8
vnx.su
Computer using
the multiplex
network

New Functions
LPG
FUNCTION
LPG injection
Computer
responsible for the
function
01
Computer using
the multiplex
network
LPG injection.
Controls its injectors and pressure relief valve.

Measures the LPG level and sends it to the instrument panel.
Computer
contributing data
Petrol injection.
Computer using
the multiplex
network
Measures the pressures (manifold), the air temperature and flow values, and sends
them to the LPG computer.
Warning: there is a specific link between the petrol injection and LPG injection ECUs
for transmission of the Top Dead Centre signal.
Computer
contributing data
Instrument panel.
Computer using
the multiplex
network
Displays the LPG level and the change to LPG fuel combustion
01-9
vnx.su
SERVICING
104D
Service intervals
04D
SERVICE INTERVAL (every.... miles (... km))
Vehicle
Interval
PRIMASTAR
18,000 (30 000 km)
Or every two years depending on which is reached first.
04D-1
vnx.su
SERVICING
Service plans
04D
The Nissan service

The service is an important stage in the life of the vehicle. The service is based on a common set of operations
including oil changes, replacing the oil filter, checks (including fault finding checking by the computers) and topping
up (details on page 04.3).
Depending on the mileage of the vehicle, certain parts will have to be replaced (listed on page 04.4).
04D-2
vnx.su
SERVICING
Servicing programme
SERVICE OPERATIONS (PETROL AND DIESEL ENGINES)
OPERATIONS
Bodywork
Examination of underside of the car, wheel arches, doors and windows, etc...
Engine
Oil change.
Replacement of oil filter.
Visual inspection of the exhaust pipe.
Brakes
Visual inspection of the brake pads.
Visual check of the circuit seals.
Checking the level of the brake fluid / hydraulic clutch.
Check fluid levels and tightness of circuits
Hydraulic clutch.
Power assisted steering.
Front/rear screen washers.
Cooling circuit.
Steering/front and rear axle geometry
Check ball joint play - Condition of rubber gaiters.
Tyres
Check condition and pressure of tyres (including emergency spare wheel).
Visual inspection and tightness check of front and rear shock absorbers.
Equipment
Check bulbs (headlights, indicators, brake lights).
Check the condition of the vehicle battery (1).
Check the condition of the windscreen and rear-view mirrors.
Check the condition of the windscreen and rear screen wiper blades.
Delivery
Check safety and service labels are in correct positions.
Computer fault finding.
(1) if possible, this battery check will be carried out using the MIDTRONICS tool.
04D-3
vnx.su
04D
SERVICING
Servicing programme
ADDITIONAL OPERATIONS
Components to be replaced (every ... miles/km)
Engine
Spark plugs
Engine
air filter (1)
Petrol
120 000
60 000
Engine
Engine
air filter (1)
Filter in the
passenger
compartment
(if fitted)
Diesel
30 000
30 000
(1) or every 4 years whichever is reached first
04D-4
vnx.su
Filter in the
passenger
compartment
(if fitted)
30 000
04D
SERVICING
Servicing programme
04D
ADDITIONAL OPERATIONS
PETROL and DIESEL engines
Components to be replaced (every ...)
Timing belt (1)
Petrol engines: 75,000 miles (120 000 km)

Diesel engine
1.9 dCi: 95,000 miles (150 000 km) or 5 years
Accessories belt
Petrol and diesel engines: 75,000 miles (120 000 km) or 5 years
Fuel filter
75,000 miles (120 000 km)
Diesel filters
18,000 miles (30 000 km)
Check the brake shoes and remove dust

(drum brakes)
55,000 miles (90 000 km)
DOT 4 brake fluid only (2)
72 000 miles (120 000 km) or every 4 years
Central locking remote control unit batteries*
2 years
Air conditioning circuit*; check and top up

refrigerant fluid
4 years
Coolant
72 000 miles (120 000 km) or every 4 years
Tyre pressure monitor batteries*
10 years
Airbag and pretensioner pyrotechnic system
10 years
* if fitted
(1) Belts
The mileages and intervals for belt replacement listed above must be respected. When a drive belt needs replacing,
the customer should consult his nearest Nissan Dealer for advice on when the timing belt should be replaced
depending on his individual driving style and how he uses the car. This is particularly important when the car is being
used for:
constant door to door journeys,
urban driving,
repeated short journeys, cold engine at low temperatures,
dusty environment, unsealed roads, etc.
For replacement of the timing belt, at the service (45,000, 75,000 or 95,000 miles (75 000, 120 000 or 150 000 km)
depending on the engine). It is advisable to use the timing kit.
(2) To achieve optimization of vehicles equipped with an Electronic Stability Program, RENAULT recommends a
brake fluid with low viscosity in cold conditions (maximum 750 mm2/s at -40C).
IMPORTANT:
If there is any trace of diesel on the timing belt, it must be replaced.
04D-5
vnx.su
SERVICING
LPG special notes
04D
ADDITIONAL OPERATIONS TO BE CARRIED OUT DURING SERVICES

Servicing periods are the same for LPG-equipped cars as those for equivalent models with petrol engines.
Also:
Every 18 000 miles (30 000 km) you must:
check the safety solenoid valve,
check that the blanking cover is fitted to the safety valve.
Every 36,000 miles (60 000 km) you must:
replace the gas filter.
04D-6
vnx.su
SERVICING
Engine oil
04D
CHECKING THE OIL LEVEL

Engines in the Nissan range are designed and built to the highest technological standards, but naturally need a little
oil for optimum running.
For this reason, and to prevent any potential engine failure, the engine oil level must be regularly checked in
particular before long journeys.
It may be necessary to top up the oil between oil changes, in particular during the running in period; refill when the
oil level reaches the minimum mark on the dipstick.
The level should be checked with the car on a flat surface, with the engine stopped and cold (e.g.: before the engine
is started for the first time of the day).
When refilling, allow the oil to run through (approximately 2 minutes), before checking the level on the dipstick.
It is very important not to exceed the maximum mark on the gauge (in this case oil consumption is greater; it can
also cause engine damage).
04D-7
vnx.su
SERVICING
Engine oil
04D
The service has been designed for regular use of the vehicles.
In the event of use in certain difficult conditions:
constant door to door journeys,
urban driving,
repeated short journeys, with cold engine at low temperatures, etc.
It is recommended that your oil is changed twice as often.
Only ACEA standard oils (Association of European Automobile Manufacturers Association) may be used for a
18,000 miles (30 000 km) change interval or every two years.
Refer to the section Engine oils for more information on the viscosity grades and qualities to be used in the engines.
04D-8
vnx.su
SERVICING
Summary
Petrol Engine
04D
The following tables indicate the frequency for replacing parts in current engines.
Engine
Name
Interval
Air filter
Fuel
filter
F4R
2.0 16V
30 000
60 000
120 000
04D-9
vnx.su
Timing
belt
Accessories
belt
Filter
in the
passenger
compartment
Spark
plugs
120 000
120 000
30 000
120 000
SERVICING
Summary
Diesel engine
04D
Engine
Name
Interval
Air filter
Fuel filter
Timing belt
Accessories
belt
Filter in the
passenger
compartment
F9Q
1.9 dCi
30 000
30 000
30 000
150 000
120 000
30 000
04D-10
vnx.su
Engine oils
04D
Nissan recommends for its engines new oils that comply with ACEA (Association of European Automobile
Manufacturers) standards that must be strictly adhered to.
Petrol engine ACEA standards A1, A3 and A5
Diesel engine ACEA standards B3 and B4 only

IMPORTANT:
A1 and A5 standard lubricants (petrol only) permit a reduction in fuel consumption in comparison with other
standards (2.5 % minimum when compared with a 15W40 oil). Nissan Primastar engines benefit from this
performance.
A2 and B2 standards are not permitted.
0W30, 5W30 and 10W30 grades may not be used on diesel engines.
04D-11
vnx.su
Engine oils
SERVICING POLICY FOR 18,000 miles (30 000 km)
or 2 years
Only ACEA oils A1/A3/A5 - B3/B4 should be used. It is
essential to follow the recommendations below:
PETROL
DIESEL
0W30, 5W30 and 10W30 oil grades must never be

used in diesel engines.
* Diesel engine: to make starting from cold easier
(below -15 C), use 0W40 grade oil.
04D-12
vnx.su
04D
FLUID
105 CHANGE AND FLUID REFILLING
Engine
05
TOOLING REQUIRED
Engine drain plug spanner
DRAINING: plug (1)
FILLING: plug (2)
Topping up the engine oil is carried out using the

funnel (A); open the ends of the funnel before putting it
into position.
05-1
vnx.su
FLUID CHANGE AND FLUID REFILLING

Gearbox
TOOLING REQUIRED
Gearbox drain plug spanner
DRAINING: plug (1)

FILLING: plug (2)
05-2
vnx.su
05
FLUID CHANGE AND FLUID REFILLING

Power assisted steering
CHECKING THE LEVEL
POWER ASSISTED STEERING PUMP LEVEL
For topping up or filling, use DEXRON II.
The level, when correct, should be visible between the
MIN and MAX marks on the reservoir (1).
ALL ENGINE TYPES
05-3
vnx.su
05
ENGINE AND110
LOWER ENGINE
Identification
10
Vehicle type
Engine
Gearbox
Capacity
(cm3)
Bore (mm)
Stroke (mm)
Compression
ratio
XLOB
XLOC
F9Q 760
PK5
PK6
1870
80
93
19:1
10-1
vnx.su
ENGINE AND LOWER ENGINE

Oil consumption
10
OIL CONSUMPTION MEASUREMENT PROCEDURE

a)
Topping up to the maximum level

The operation must be carried out with the engine warm (the cooling fan having cut in) and after leaving to
stabilise for 15 minutes to allow all the oil to drain into the sump.
Check visually using the dipstick.
Top up to the maximum level.
Seal the drain plug (with a paint mark on both the filler plug and the sump drain plug) in order to be able to check
later that it has not been removed.
b)
Customer driving
Ask the customer to drive the vehicle for a period corresponding to about 1250 miles (2,000 km) or before the
minimum level is reached.
c)
Topping up to the maximum level

The operation must be carried out with the engine hot (the cooling fan having cut in) and after leaving to
stabilise for 15 minutes.
Check visually using the dipstick.
Top up to the maximum level.
Note the quantity of oil and the mileage covered since the last top-up to maximum level.
d)
Measurement of oil consumption

OIL CONSUMPTION =
Quantity of oil added (in litres)

km (in thousands)
10-2
vnx.su

Oil pressure
SPECIAL TOOLING REQUIRED
Mot. 836-05
Oil pressure measuring kit

EQUIPMENT REQUIRED
22 mm long socket
CHECKING
The oil pressure should be checked when the engine
is warm (approximately 80C).
Contents of kit Mot. 836-05.
USE
B+F
Connect the pressure gauge in place of the oil
pressure switch.
Oil pressure
1000 rpm
3000 rpm
1.2 bar
3.5 bar
10-3
vnx.su
10

Engine - Gearbox
10

Mot. 1202-01
Mot. 1202-02
Hose clip pliers
Mot. 1448
Distance pliers for cooling system

hose clips
T. Av. 476
Ball joint extractor

Disconnect the battery.
TIGHTENING TORQUES (in daNm)

Shock absorber base bolts
18
Steering ball joint nut
3.7
Suspended gearbox mounting fixing nut
6.2
Lower ball joint nut

Brake calliper mounting bolt
11
3.5
Engine tie-bar fixing bolt:
10.5
Suspended engine mounting upper

linkage mounting bolt
10.5
Driveshaft gaiter mounting bolt
Body mounting bolt for the suspended

engine mounting movement limiter
4.4
Mounting bolt on the engine for

suspended engine mounting cover
6.2
Wheel bolt
14.2
REMOVAL
Put the vehicle on four axle stands (see Section 02
Lifting equipment to correctly position the lifting jack
and axle stands) or on a lift.
During this operation (if using a lift) it is necessary
to lash the vehicle to the lift with a strap to prevent
the vehicle from toppling over.
NOTE:
Because the battery is located under the left-hand
seat, the carpet must be unclipped and removed, then
the battery cover (A) by undoing the screws.
Remove:
battery cables,
the front wheels,
the engine undertray,
battery earth strap under the body and move all
cables away from the battery,
Refer to Section 02 Underbody lift for the strap

positioning.
FOLLOW CAREFULLY THE INSTRUCTIONS
GIVEN IN SECTION 13 SPECIAL FEATURES AND
CLEANLINESS BEFORE CARRYING OUT ANY
WORK
10-4
vnx.su

Engine - Gearbox
lower gearbox soundproofing material at (1).
10
both transmission flange mounting bolts on the relay

holder bracket,
track rod end, using tool T.Av. 476,
shock absorber base mounting bolts.
Remove the driveshaft and then remove the hub unit
assembled with the driveshaft.
Left-hand side of the vehicle
Remove:
brake calliper and attach it to the suspension spring,
the wheel speed sensor,
lower ball joint nut (use an Allen key cut down to
X = 22 mm to lock the ball joint if necessary),
track rod end, using tool T. Av. 476,
driveshaft gaiter mountings,
shock absorber base mounting bolts.
Remove the driveshaft and then remove the hub unit
assembled with the driveshaft.
Drain:
the coolant circuit using filling equipment.
the cooling system through the radiator bottom hose
the gearbox and engine if necessary.
Remove:
number plate,
the direction indicators,
the radiator grille,
Right-hand side of the vehicle

Remove:
the brake calliper and attach it to the suspension
spring,
the wheel speed sensor,
lower ball joint nut (use an Allen key cut down to
X = 22 mm to lock the ball joint if necessary),
10-5
vnx.su

Engine - Gearbox
lens unit mounting screws (2).
Remove:
the bumper.
Disconnect the connectors from the lens units.

Remove the lens units, by removing the retaining
clip (3).
10-6
vnx.su
10

Engine - Gearbox
the power steering reservoir from its bracket,
the air ducts on the heat exchanger and the
mounting (4),
10
the air conditioning hose mountings (if fitted) on the

compressor and the condenser.
NOTE:
Plugs must be fitted to the hoses and the expansion
valve to prevent moisture from entering the system.
Remove:
the cooling unit,
the air filter unit air intake tube,
the preheater unit mounting (1),
the turbocharger regulation solenoid valve at (2),
the turbocharging pressure sensor (3) from its
mounting,
the impact sensor connector (6),
the expansion bottle and remove it,
the computer protection plate (A).
the bonnet catch system mountings (5) and

disconnect the cable,
the front panel,
the lower radiator mountings as well as the top hose,

the connectors on the fan assembly and the
condenser,
10-7
vnx.su

Engine - Gearbox
10
Disconnect the connectors (5) and unclip fuse

holders (6).
the mounting (9),

the clutch slave cylinder pipe by removing clip (B)
and remove it,
Remove the earth strap mountings on the gearbox and
on the left-hand side member then remove the whole
connection unit.
Disconnect:
the heater hoses at the bulkhead,
the brake servo vacuum pipe,
the fuel supply pipe (7) (fit anti-contamination
plugs) and connector (8),
the upper gearbox soundproofing material,
10-8
vnx.su

Engine - Gearbox
10
the mounting bolt (3) and undo bolt (4),
the gearbox control cables,

the heater matrix casing (C) by disconnecting the
connector (1),
the exhaust downpipe mountings.

the thermoplunger unit mounting (2) and remove the
thermoplunger unit,
Disconnect the fuel tank sender connector at (5),

unclip it from under the body and attach it to the
engine.
Attach the workshop hoist.

Support the engine and gearbox assembly using a
hoist.
the power assisted steering hoses on the steering
box (drain the power steering reservoir first).
10-9
vnx.su

Engine - Gearbox
Remove:
the power steering pipe mounting (7) and remove the
power steering pipe,
the lower crossmember (A) and front
crossmember (B),
the nut (1) and tap it with a copper hammer to release

the stud,
10
the tie-rod (2) mounting bolts, then remove the

suspended mounting movement-limiter assembly.
Using a workshop crane, remove the engine-gearbox

assembly.
REFITTING
Refit the engine-gearbox assembly following the same
method as for removal.
Refit:
the left suspended mounting,
the right suspended mounting,
the engine tie-bar.
See Section 19 Suspended engine mounting for the
tightening torques.
10-10
vnx.su

Engine - Gearbox
10
Special notes on the clutch slave cylinder when

separating the engine and gearbox
Refit the engine-gearbox assembly following the same

method as for removal.
IMPORTANT:
To prevent damage occurring to the slave cylinder,
do not coat the gearbox output shaft with
lubricant.
Refit:
the left suspended mounting,
the right suspended mounting,
the engine tie-bar.
NOTE:
To prevent leaks, replace the slave cylinder after
replacing the clutch mechanism.
See Section 19 Suspended engine mounting for the

tightening torques.
Refit in reverse order to that for removal.
Add brake fluid to the reservoir.

GIVEN IN SECTION 13 SPECIAL FEATURES FOR
THE PROCEDURE FOR STARTING THE ENGINE.
Bleed the system using bleed screw (A) located on the

union on the slave cylinder.
Perform the following operations:

fill the gearbox with oil,
fill the engine with oil, if necessary,
fill and bleed the cooling circuit (see Section 19
Filling - bleeding),
fill and bleed the power assisted steering circuit,
fill the coolant circuit using the filling equipment.
Apply Loctite FRENBLOC to the brake calliper
mounting bolts before fitting and tighten them to the
correct torque.
Depress the brake pedal several times to bring the
pistons into contact with the brake pads.
Make sure that the brake fluid reservoir is never

empty.
Top up the brake fluid.
IMPORTANT:
Tighten the bleed screw to a torque of 1 daNm.
10-11
vnx.su
ENGINE AND PERIPHERALS

110A:
Cleanness & Safety
10A
OPERATION
The Common Rail high-pressure direct injection system is a sequential diesel injection system (based on the
multipoint injection system for petrol engines).
This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and
produces high engine torque at low engine speeds thanks to a pre-injection procedure.
The low pressure pump supplies the high pressure pump via the pressure regulator filter and then the fuel filter
exclusively during the starting phase.
With a pressure between 2 and 4 bar.
The High Pressure pump generates the high pressure sent to the injector rail. The pressure regulator located on
the pump modulates the high pressure pump supply flow. The rail supplies each injector through a steel pipe.
The computer:
determines the value of injection pressure necessary for the engine to operate correctly and then controls the
pressure regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure
sensor located on the rail,
determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should
start,
controls each injector electrically and individually after determining these two values.
The injected flow to the engine is determined by:
the duration of injector control,
the injector opening and closing speed,
the needle stroke (determined by the type of injector),
the normal hydraulic flow of the injector (determined by the type of injector),
the high-pressure rail pressure controlled by the computer.
THE CLEANLINESS AND SAFETY ADVICE SPECIFIED IN THIS DOCUMENT MUST BE FOLLOWED DURING
ANY WORK CARRIED OUT ON THE HIGH-PRESSURE INJECTION SYSTEM.
10A-1
vnx.su

Cleanness & Safety
10A
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 contamination are:
damage to or destruction of the high-pressure injection system,
a component seizing or leaking.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) should get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter through to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
metal or plastic chips,
paint,
fibres:
of cardboard,
brushes,
paper,
clothing,
cloths,
foreign bodies such as hairs,
ambient air,
etc.
IMPORTANT:
it is forbidden to clean the engine using a high pressure washer because of the risk of damaging connections.
Furthermore, moisture may collect in the connectors and cause electrical connection problems.
10A-2
vnx.su

Cleanness & Safety
10A
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
Ensure that you have the plugs for the unions to be opened (bag of plugs sold by the Parts Stores Part No. 77 01 206 381).
Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is
not sufficient to make them reusable). Unused plugs must be thrown away.
Ensure that you have the resealable plastic bags for storing removed parts. Stored parts will therefore be less
subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away.
Ensure that you have lint-free cleaning towels (towels referenced 77 11 211 707). The use of a normal cloth or
paper for cleaning purposes is forbidden. These are not lint free and may contaminate the fuel circuit of the
system. Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
Use new thinner for each operation, (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 lose its hairs).
Use a brush and thinner to clean the connections to be opened.
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles have been left behind.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves, cover them with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Stores (part number 77 01 206 381). They must not, under any
circumstances, be reused.
Close the resealable bag, even if it has to be reopened shortly afterwards. Ambient air carries impurities.
All components removed from the injection system must be stored in a hermetically sealed plastic bag once the
plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
These items are likely to allow impurities to enter the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
10A-3
vnx.su

Cleanness & Safety
INSTRUCTIONS FOR FITTING THE PLUGS (part number 77 01 206 381)
10A-4
vnx.su
10A

Cleanness & Safety
10A
POST-REPAIR CHECK
Re-prime the circuit. To do this, turn the low-pressure pump over by switching on the ignition several times, or turn
the low-pressure pump over with the diagnostic tool using the "Actuator Commands" menu.
After any operation, check that there are no diesel leaks. Run the engine at idle speed until the engine
cooling fan starts up, then accelerate several times with no load.
IMPORTANT: the engine must not run with diesel containing more than 10% diester.
The system injects the diesel fuel into the engine at a pressure of up to 1350 bar. Before any intervention, check
that the injector rail is depressurised.
It is absolutely vital that you observe the tightening torque:
of the high-pressure pipes,
of the cylinder head injector,
of the pressure sensor.
When the high-pressure pump, injectors and high pressure supply, output and return unions are removed
or repaired, all openings should be fitted with new blanking plugs of the correct size to prevent
contamination entering.
WARNING:
ALL PIPES REMOVED MUST BE REPLACED.
When replacing the high pressure pipe, follow the method below:
remove the high pressure pipe, holding the filter rod on the injector with a lock-wrench,
fit anti-contamination plugs,
loosen the high pressure rail,
fit the new high pressure pipe,
offer up the unions by hand until they touch,
tighten the high pressure rail mountings to torque,
torque-tighten the union at the injector side,
tighten the high pressure rail connection to torque.
Dismantling the interior components of the pump is prohibited.

The fuel return pipe fitted to the injectors must be replaced when it is removed.
The diesel temperature sensor cannot be removed. It is part of the fuel return rail.
Loosening a high pressure pipe connection when the engine is running is prohibited.
10A-5
vnx.su

Foreword
USING THE MANUAL
There are two main sections in this manual:
technical specifications,
overhauling the engine.
UNITS OF MEASUREMENT
All dimensions are given in millimetres (mm) (unless
stated otherwise).
Tightening torques are expressed in
decaNewton.metres (daN.m).
Reminder: 1 daNm = 1.02 m.kg.
Pressures in bar
Reminder: 1 bar = 100,000 Pa.
TOLERANCES
Tightening torques given without a tolerance must be
accurate to within:
in degrees ( 3),
in daN.m ( 10%).
10A-6
vnx.su
10A

Engine identification
10A
The engine identification is stamped on the cylinder

block.
It includes:
A: the engine type
B: the engine approval letter
D: the identification of RENAULT
E: the engine suffix
F: the engine fabrication number
G: the engine assembly plant
Engine
Suffix
Compression
Ratio
Bore (mm)
Stroke (mm)
Cubic capacity
(cc)
F9Q
718, 732, 733, 738,

740, 746, 748, 750,
751, 752, 754, 756,
760, 762, 772, 790
19:1
80
93
1870
10A-7
vnx.su

Tightening torques (in daN.m or in degrees)
10A
UPPER ENGINE
Description
Tightening torques
Cylinder head cover bolts
Cam shaft line beam bolt
Camshaft pulley bolt
High pressure pipe nuts
2.5
Common rail mounting bolt
2.2
Cylinder head bolts
Inner timing housing bolt
Valve timing cover bolt
Heater plug
1.5
Lifting bracket fastening bolt (timing end)
Lifting bracket fastening bolt (engine flywheel end)
1.3
Injector clamp bolts
Vacuum pump mounting bolts
2.3
Suspended mounting bolt
3.5
High pressure pump mounting bolt
Rear high pressure pump support bolts and nuts
3
1.5 plus an angle of 60 10
High pressure pump pulley nuts

Thermostat mounting bolt
0.8
Camshaft sensor bolts
0.9
Exhaust gas recirculation valve mounting bolt
0.9
Inlet - exhaust manifold nuts
2.8
Thermal unit mounting bolt
0.8
* See procedure.
10A-8
vnx.su

10A
LOWER ENGINE
Description
Tightening torques
Oil pressure sensor
3.8
Oil level sensor
3
2 plus an angle of 115 15
Crankshaft accessories pulley bolt

Bolts on crankshaft bearing caps (tightening order: 34251)
Con rod head cap bolts
Oil pump bolts
2.4
Crankshaft closure panel bolt
1.4
Oil sump bolts (see tightening sequence)
1.5
F9Q engine flywheel bolt
Clutch bolts
Bolt of F9Q water pump
Timing tensioner plate bolts
Timing tensioner nut
Coolant inlet pipe mounting bolt
Coolant pipe mounting bolt
Multifunction support bolts
Power assisted steering pump bolt
2.5
Air conditioning compressor bolts
2.5
FLEXIBLE engine flywheel bolts
10A-9
vnx.su

Description
10A
Tightening torques
Alternator bolts
2.5
Accessories tensioner roller bolts on cylinder block
2.5
Oil decanter bolts
Top dead centre plug
Turbocharger mounting nuts
2.4
Turbo oil inlet union (cylinder block end)
2.3
Turbo oil inlet union (pipe end)
2.4
Turbo oil inlet union (turbocharger end)
2.6
Mounting bolts on turbocharger oil return pipe (turbocharger end)
1.2
Light-off catalyst mounting nuts to turbo
2.5
Exhaust stay bolt:

M8
M10
2.4
4.3
Anti-emulsion plate mounting bolts
2.4
Auto tensioner mounting bolts
4.3
10A-10
vnx.su

Specifications
CYLINDER HEAD
Cylinder head tightening procedure
REMINDER:
to obtain correct tightening of the bolts, remove any oil from the cylinder head
securing holes using a syringe.
All cylinder head bolts must always be changed after removal. There is no
cylinder head retightening operation.
Tighten all the bolts to 3 daN.m, then angle tighten to 100 4, in the
sequence shown below.
Wait 3 minutes settling time.

Cylinder head tightening is carried out in stages, and the following procedure
is applied successively to bolts 1-2 then 3-4, 5-6, 7-8 and 9-10
Loosen bolts 1-2 until they are completely free.
Tighten bolts 1-2 to 2.5 daNm, then angle tighten to 213 7.
Repeat the loosening and tightening operations for bolts 3-4, 5-6, 7-8 and
9-10.
There is no cylinder head retightening operation.
10A-11
vnx.su
10A

Specifications
10A
Thickness of the cylinder head gasket

The thickness of the cylinder head gasket is measured
at (A):
thickness of the gasket when tightened:
1.32 0.05 mm.
Measure the piston protrusion.

Checking piston protrusion
The protrusion must be: 0.56 0.06 mm.
Clean the piston heads in order to eliminate any traces

of deposits.
Turn the crankshaft one turn in its operating direction
to bring piston No. 1 close to top dead centre.
Fit tool Mot. 251-01 equipped with a gauge on support
plate Mot. 252-01, and find top dead centre.
NOTE:
All measurements are to be carried out in the
longitudinal axis of the engine, in order to eliminate
any errors due to piston tilting.
WARNING:
the gauge detector must not be in the valve clearance.
10A-12
vnx.su

Specifications
Height of the cylinder head (in mm)
Valves
H = 162.75 1.75
Stem diameter (in mm)

Inlet:
Exhaust:
10A
6.985 0.011
6.971 0.011
Face angle
Inlet and exhaust::
90
Head diameter (in mm)

Inlet:
Exhaust:
35.325 0.125
32.625 0.125
Valve length (in mm)

Inlet:
Exhaust:
110.99 0.20
110.79 0.20
Max. valve lift (in mm)

Inlet:
Exhaust:
8.866
10.344
Gasket face deformation (in mm): 0.05
Protrusion of valves in relation to the cylinder

head gasket face (in mm)
NO REGRINDING IS AUTHORISED
Inlet and exhaust:
0.09 0.12
Valve clearance settings (in mm)

Inlet:
Exhaust:
10A-13
vnx.su
0.20 0.05
0.40 0.05

Specifications
Valve seats
Valve guides
Seat angle ()
Length (in mm)
Inlet and exhaust:
89.5
Inlet and exhaust:
Mating surface width X (in mm)

Inlet and exhaust:
38.25 0.15
Guide external diameter (in mm)

1.8
Normal:
Seat external diameter (D) (in mm)

Inlet:
Exhaust:
10A
+0.068
12 +0.05
Guide internal diameter (in mm)
36.975 0.008
33.597 0.008
Inlet and exhaust

+0.12
Not machined:
6.3 0
Machined*:
+0.022
0
* This dimension is measured with the guide fitted in

the cylinder head.
Diameter of the guide housing in the cylinder head
(in mm)
Normal:
-0.02
12 -0.05
The inlet and exhaust guides have valve stem seals

which must be replaced each time the valves are
removed.
Diameter of the seat housing in the cylinder head
(in mm)
Inlet:
36.9
+0.007
-0.023
Exhaust::
33.5
+0.029
0
10A-14
vnx.su

Specifications
It is essential to fit the valve stem seals using tool
Mot. 1511 or other suitable equipment.
Angle of the inlet and exhaust guides (in degrees)

Inlet and exhaust:
NOTE:
Do not lubricate the valve stem seals before fitting
them.
Tool Mot. 1511 consists of:
four cores (1),
four pushrods (2),
one guide tube (3),
one sleeve (4).
= 90
Position of the inlet and exhaust valve guides

(in mm)
Inlet and exhaust:
10A-15
10A
vnx.su
A = 81.05 0.4

Specifications
Valve springs
10A
Checking the valve clearance

46 2
Place the valves of the cylinder concerned at the "end

of exhaust - beginning of inlet" position and check the
clearance (X).
27 daN
61.4 daN
37.5
27.5
NOTE:
Dimension (Y) corresponding to the tappet thickness
class (at the Parts Stores there are 25 classes).
Close-wound coils (in mm):
25.07 0.1
Diameter of wire (in mm):
3.90 0.03
Internal diameter (in mm):
21.5 0.1
External diameter (in mm):
29.5
Free length (in mm):

Length under load (in mm):
Pistons
External diameter of tappet (in mm):
34.975 0.01
Diameter of the housing in the cylinder head
(in mm):
35
+0.039
0
1
3
4
2
4
2
1
3
Compare the values recorded with the values

specified, then replace the tappets which are not within
tolerance.
Clearance, when the engine is cold, in mm:
Inlet:
Exhaust:
10A-16
vnx.su
0.20 0.05
0.40 0.05

Specifications
The camshaft must be removed to replace the tappets.
10A
Note dimension (Y) and repeat the operation for the

tappets where the valve clearance is not within
tolerance.
Determining dimension (Y).

Set up the following assembly using Mot. 252-01 and
Mot. 856-02, then calibrate the gauge.
Refer to the "Replacement parts catalogue" for the

vehicle concerned to select the various thicknesses of
the tappet(s).
Camshaft
End play (in mm)
0.045 to 0.135
Number of bearings
Timing diagram
*
**
Raise the gauge extension (without modifying the

position of the magnetic support/gauge assembly),
then slide in the tappet to be measured.
10A-17
vnx.su
Inlet opening retardation *

Inlet closing retard
Exhaust opening advance
Exhaust closing advance **
-3
21
46
-5
If the inlet opening delay is negative, valve

opening can be found after top dead centre.
If the exhaust closing advance is negative, valve
closing can be found before top dead centre.

Specifications
10A
PISTONS
Fitting the gudgeon pin in the con rod and in the piston.
The gudgeon pin is retained by circlips.
These engines are fitted with KOLBENSCHMIDT
pistons.
Piston marking
1
2
3
4
5
6
7
8
Cylinder block top dead centre fixed mark

Flywheel top dead centre moving mark
Flywheel bottom dead centre moving mark
Inlet opening retardation
Exhaust closing advance
Inlet closing retardation
Exhaust opening advance
Direction of engine rotation (flywheel end)
1
2
3
4
5
6
7
10A-18
vnx.su
Direction of fitting of the piston: towards the

flywheel
Height between the gudgeon pin and the top of the
piston (see table on following page)
Used by the supplier only
Used by the supplier only
Piston axis of symmetry
Gudgeon pin hole axis
Offset between the hole of the pin (6) and the axis
of symmetry of the piston (5): 0.5 mm

Specifications
Table of gudgeon pin heights
10A
Rings
Mark on piston*
Pin height (mm)
47.046
47.088
47.130
47.172
47.214
Three rings (thickness in mm)

-0.01
Compression ring
2.5 -0.03
Sealing
-0.01
-0.03
Scraper
-0.01
-0.03
The rings are supplied ready adjusted.
The tolerance on the pin heights is 0.02 mm.

* The different gudgeon pin heights are exclusively
reserved for the engine assembly plant.
The Parts Stores will only supply piston classes
(height) L, M, N.
NOTE:
if the engine is fitted with a K class piston, an L class
piston must be fitted as a replacement,
if the engine is fitted with a P class piston, an N class
piston must be fitted as a replacement,
Measuring the piston diameter
The piston diameter is measured at height A = 39 mm.
Piston diameter (in mm): 79.866 0.0075
T = Top
Clearance at the gap
10A-19
vnx.su
Rings
Clearance at the gap

(in mm)
Compression
0.2 to 0.35
Sealing
0.7 to 0.9
Scraper
0.25 to 0.5

Specifications
10A
Gudgeon pin (in mm)
CON RODS
All types except F9Q 750 and 756
The con rods are DIVISIBLE.
Length:
59.7 to 60
External diameter:
27.995 to 28
Internal diameter:
13.8 to 14.1
F9Q 750 and 756

Length:
59.5 to 60
External diameter:
27.995 to 28
Internal diameter:
12.8 to 13.1
WARNING:
The bolts must be sealed with engine oil under the
heads and on the threads when the con rods are
fitted in the engine.
Positioning of the con rod heads on the body is
ensured by roughnesses on the crack.
The occurrence of impacts or a foreign body
between the body-head mating surfaces will lead
to rapid failure of the con rod.
Lateral play of the con rod big end (in mm):
0.22 to 0.482
Diametral play of the con rod big end (in mm):
0.027 to 0.086
Centre-to-centre distance between the con rod big end
and small end (in mm):
139
Diameter of the big end (in mm):
+0.019
51.587 0
Diameter of the small end (in mm):
(without ring) 30.24
(with ring)
+0.025
0
+0.025
28 +0.013
NOTE:
the con rod small end bushings cannot be replaced.
10A-20
vnx.su

Specifications
IMPORTANT:
Do not use a sharp point to mark
the bearing caps in relation to
their con rods to avoid starting a
crack in the rod.
Use a permanent marker pen.
The maximum weight difference for
the con rod, piston and gudgeon
pin assemblies for the same engine
must be 23 grams.
10A-21
vnx.su
10A

Specifications
Direction of fitting of the con rod in relation to the
piston
10A
CRANKSHAFT
Number of main journals
Place the "" (1) engraved on the piston head

downwards and the machined flat (2) of the con rod
head upwards.
Lateral crankshaft play (in mm):

0.067 to 0.233
Diametral crankshaft play (in mm):
0.027 to 0.086
Diameter of the main bearing journals
Main bearing journal diameters are shown on the
crankshaft by paint marks.
Paint mark
Blue
Red
Journal
diameter
(in mm)
54.785
inclusive to
54.795
exclusive
54.795
inclusive to
54.805
exclusive
Diameter of the crankpins (in mm):

48.01 0.01
The lateral shims are located on bearing No. 2.
NO REGRINDING IS AUTHORISED
Direction for fitting the circlips on the piston

Fit the circlips on the piston as shown below.
10A-22
vnx.su

Specifications
BEARING SHELLS
Crankshaft bearing shells
The engine is fitted with bearing shells without a
locator notch.
The crankshaft bearing shells are fitted on the cylinder

block and on the bearings using tool Mot. 1493.
10A-23
vnx.su
10A

Specifications
Direction of fitting:
the cylinder block bearings are
fitted with grooved bearing
shells,
the bearing caps are fitted with

non-grooved bearing shells.
10A-24
vnx.su
10A

Specifications
Con rod bearing shells
The engine is fitted with bearing shells without a
locator notch.
The bearing shells are fitted using Mot. 1492 and

Mot. 1492-01.
10A-25
vnx.su
10A

Specifications
PREPARING THE ENGINE TO BE SET ON THE
STAND
10A
the turbocharger oil supply pipe,

the three turbocharger mounting nuts on the exhaust
manifold.
Before the engine is mounted on the stand

Mot. 792-03, the engine's electrical harness must be
removed and the engine oil drained.
Remove:
the stay between the cylinder block and the light-off
catalyst,
the turbocharger oil return pipe,
10A-26
vnx.su

Specifications
10A
Change to the cylinder block

To optimise the acoustics, a change has been made to the cylinder block mating face.
Conventional cylinder block with a small mating
face
New cylinder block with a large mating face
10A-27
vnx.su

Specifications
10A
Conventional cylinder block with

a small mating face
Fit rods (B), (N), (P) Mot. 995 onto
the cylinder block such that they fit
into holes (26, 12, 25) in the plate
(Mot. 792-03).
New cylinder block with a large mating face
Change to DESVIL engine mountings head used in

engine repair. Replacement of head TS 126 (1) with
head TS 127 (2).
Fit rods (B), (N1), (P) Mot. 1575 onto the cylinder
block such that they fit into holes (26, 12, 25) in the
plate (Mot. 792-03).
Special feature of this new head:

axis of rotation permanently lubricated,
variable locking of the head.
IMPORTANT:
The clamping bolt (3) must be fully undone to
release the head when there is no longer an engine
resting on the support.
10A-28
vnx.su

Specifications
10A
CONSUMABLES
Type
Quantity
Cleaner
Component concerned
Cleaning parts
DECAPJOINT or equivalent
Coat
Cleaning gasket faces
RHODORSEAL 5661
Coat
Crankshaft bearing cap
Loctite 518
Coat
Cam shaft line beam
Loctite FRENETANCH
Tube of RHODORSEAL 5661
1 - 2 drops
Manifold studs, coolant pump bolt
Bead
WARNING
Crankshaft closure plate
FITTING THREAD INSERTS

Threaded holes on all engine component parts can be
repaired by using thread inserts except on the
camshaft line beam and the cylinder head cover.
IMPORTANT:
The cleanliness rules described at the start of
this document must be strictly complied with
when working on the fuel supply system.
PARTS TO BE REPLACED AFTER REMOVAL:
all the gaskets,

flywheel bolts,
metal oil return pipe from the decanter,
crankshaft bearing bolts,
camshaft pulley bolt,
crankshaft pulley bolts,
con rod cap bolt,
injector holder copper washers,
diesel return pipe,
pipe plugs,
coolant circuit rigid hose,
belts,
timing gear tension wheel,
the piston base cooling jets.
10A-29
vnx.su

Standard replacement
PREPARING THE USED ENGINE FOR RETURN
The engine should be cleaned and drained (oil and
water).
Leave on the used engine or include in the return box:
the oil filter,
the oil pressure switch,
the water pump,
the high pressure pump,
the rail,
the injectors
the heater plugs,
the oil trap,
the dipstick,
the vacuum pump,
the flywheel,
the clutch
Remember to remove:
all coolant pipes,
the inlet and exhaust manifolds,
the alternator,
the power-assisted steering pump,
the air conditioning compressor,
the multifunction support,
the oil level sensor,
the cylinder head coolant outlet unit.
The used engine should be secured to the base under
the same conditions as the overhauled engine:
plastic plugs and covers fitted,
cardboard cover over the assembly.
10A-30
vnx.su
10A

Essential special tooling
Illustration
10A
Part No.
Method
Part Store
reference
Emb. 880
00 00 088 000
Pin extractor.
Mot. 11
00 01 072 500
Crankshaft bearing extractor.
Mot. 251-01
00 00 025 101
Gauge stand; used with Mot. 252-01.
Mot. 252-01
00 00 025 201
Thrust plate for measuring the protrusion

of cylinder liners, used with Mot. 251-01.
Mot. 445
00 00 044 500
Oil filter wrench.
Mot. 582-01
00 00 058 201
Flywheel immobilisation segment.
Mot. 591-02
00 00 059 102
Magnetised flexible shaft for angular

wrench for tightening cylinder head.
Mot. 591-04
00 00 059 104
Angular wrench for tightening cylinder

head, 1/2" drive with index.
10A-31
vnx.su
Description

Illustration
10A
Part No.
Method
Parts Store
reference
Description
Mot. 799-01
00 00 079 901
Tool for immobilising pinions for the toothed

timing belt
Mot. 988-02
00 00 098 802
Tool for fitting the camshaft seal at the

timing end.
Mot. 990-03
00 00 099 003
Tool for fitting crankshaft seal, timing end.
Mot. 991-01
00 00 099 101
Tool for fitting crankshaft seal, flywheel end.
Mot. 1054
00 00 105 400
TDC setting rod.
Mot. 1200-01
00 00 120 001
High pressure pump pin immobiliser.
Mot. 1200-02
00 00 120 002
Injection pump pulley immobiliser.
10A-32
vnx.su

Illustration
10A
Part No.
Method
Parts Store
number
Mot. 1281-01
00 00 128 101
Oil filter cap.
Mot. 1335
00 00 113 500
Tool for removing valve stem seals.
Mot. 1387
00 00 138 700
Tool for checking the accessories belt

tension.
Mot. 1423
00 00 142 300
Tool for removing the silicon crankshaft

bearing cap.
Mot. 1485
Mot. 1485-01
00 00 148 500
00 00 148 501
Tool for removing piston coolers.
Mot. 1492
00 00 149 200
Tool for fitting con rod bearing shells.
Mot. 1492-01
00 00 149 201
Adaptation kit for fitting the separable con

rod bearing shells.
Mot. 1566
00 00 156 600
Tool for removing high pressure pipes
10A-33
vnx.su
Description

Illustration
10A
Part No.
Method
Parts Store
number
Mot. 1493
00 00 149 300
Tool for fitting crankshaft bearing shells.
Mot. 1505
00 00 150 500
Device for checking the belt tension.
Mot. 1511
00 00 151 100
Tool for fitting valve stem seals.
Mot. 1516
00 00 151 600
Tool for refitting piston coolers orientated

at 5.
Mot. 1516-01
00 00 151 601
Plate for refitting piston coolers orientated

at 3 (addition to Mot. 1516).
Mot. 1525
00 00 152 500
Tapered hub pump pin extractor.
Mot. 1525-01
00 00 152 501
Fitting clips for Mot. 1525 for

F9Q Common Rail engines.
Mot. 1543
00 00 154 300
Timing belt pretensioning tool.
Mot. 1516-02
00 00 151 602
Plate for refitting piston coolers (orientated

at 0) (addition to Mot. 1516).
10A-34
vnx.su
Description

Illustration
10A
Part No.
Method
Parts Store
number
Mot. 1551
00 00 155 100
Tool for fitting the oil return pipe.
Mot. 1573
00 00 157 300
Cylinder head support.
Rou. 15-01
00 01 331 601
Internal shaft protector 16 mm.
Mot. 1575
00 00 157 500
Engine mounting pin "N1" (addition to

Mot. 792-03 for Desvil engine stand).
Mot. 445-01
00 00 044 501
Replacement strap for Mot. 445.
Mot. 792-03
00 00 079 203
Engine support plate for Desvil engine stand

(with pins from A to W).
Mot. 995
00 00 099 500
Set of two pins adaptable to engine

mounting plate Mot. 792-03.
10A-35
vnx.su
Description

Illustration
10A
Part No.
Method
Parts Store
number
Mot. 1569
00 00 156 900
Cone for fitting the pistons in the cylinder

block.
Mot. 1577
00 00 157 700
Lip seal extractor 28 mm to 50 mm.
Mot. 1578
00 00 157 800
Mot. 1579
00 00 157 900
Mot. 1635
00 00 163 500
Tool for fitting elastomer crankshaft seal,

flywheel end.
Mot. 1636
00 00 163 600
Tool for fitting elastomer crankshaft seal,

timing end.
Mot. 1592
00 00 159 200
Flexible end piece for taking pressure at end

of compression.
Mot. 1676
00 00 167 600
Accessories belt tensioner.
Mot. 1677
00 00 167 700
Flywheel immobilisation segment for cylinder

block large face.
10A-36
vnx.su
Description

Essential equipment
10A
Description
Standard 22 mm long socket 1/2" (12.7 mm squared) for removing the oil pressure
gauge.
Standard 1/2" 8 / 12 / 14 female torx socket (12.7 mm squared).

Angular tightening tool from:
STAHLWILLE part number 540 100 03 for example,
FACOM part number DM2360 for example,
SAM part number 1 SA, for example.
FACOM tool for fitting the valve stem seals, part number DM6J4, for example.
Gun for using tube of RHODORSEAL 5661.
Wrench for removing high pressure pipes, e.g. FACOM part number DM 19
Articulated wrench for removing and refitting the heater plugs, e.g. FACOM part number
B10R10A.
Clamp for internal circlips.
Valve spring compressor.
10A-37
vnx.su

Essential equipment
10A
Description
"Crowfoot" end-piece for torque-tightening high pressure pipes, e.g. FACOM part
number 18.17.
Crankshaft bearing puller, e.g. FACOM part number U49 A D5.
"Crowfoot" end-piece for torque-tightening high pressure pipes, e.g. FACOM part
number 19.17.
10A-38
vnx.su

Overhauling the engine
10A
REMOVING THE UPPER ENGINE

Engine fitted with a water pump
driven by the timing belt.
Remove:
the exhaust gas recirculation
pipe,
the ring for lifting the engine at the
timing end,
the intake and exhaust manifolds.
Remove the accessories drive belt by turning the

spanner to the right to loosen the belt.
Remove the Top Dead Centre pin plug.
10A-39
vnx.su

Timing adjustment
Rotate the crankshaft in clockwise
direction at the timing end.
When the mark (1) on the camshaft
pulley appears in the window (2) of
the timing cover, push in the Top
Dead Centre pin Mot. 1054 to pin
the crankshaft (the mark on the
camshaft pulley must be located
approximately in the centre of the
window).
Remove the timing housing.

NOTE:
Use a pencil to mark the lower
timing housing opposite the mark on
the camshaft pulley.
10A-40
vnx.su
10A

Remove the crankshaft accessories
pulley by blocking the flywheel using
Mot. 582-01 or Mot. 1677.
10A-41
vnx.su
10A

Relax the tensioner by loosening
the nut (3), then remove the timing
belt.
Remove the cylinder marking

sensor.
10A-42
vnx.su
10A

Remove:
the cylinder head bolts,
the cylinder head.
10A-43
vnx.su
10A

STRIPPING THE CYLINDER HEAD
Place the cylinder head on cylinder head support
Mot. 1573.
Pay strict attention to the instructions regarding
cleanliness (see start of document)
Remove the rear high pressure pump support.
10A-44
vnx.su
10A

Remove the diesel return pipe.
Fit the cleanliness blanking
plates on the high pressure pump
and the injectors.
Remove the high-pressure diesel

pipes using Mot. 1566.
Fit the cleanliness blanking
plates on the high pressure pump
and the injectors.
10A-45
vnx.su
10A

Remove:
the two common rail bolts (1),
the injector mounting bracket
bolts (2),
the injectors, fitting cleanliness
blanking plates on the injector
noses,
flame arrestor washers.
10A-46
vnx.su
10A

Place in position on the high-pressure pump pulley tool
Mot. 1200-01 or Mot. 1200-02.
10A
Remove the high pressure pump pulley nut.

Fit extractor Mot. 1525, fitted with Mot. 1525-01 clips,
on the high pressure pump pulley, to separate the
pulley from the high pressure pump shaft.
10A-47
vnx.su

Remove:
the high pressure pump pulley,
the high pressure pump by withdrawing the studs (3)
depending on the version.
10A
Remove:
the cylinder head suspended mounting support,
the camshaft pulley bolt by locking the pulley using

Mot. 799-01.
On other versions, the three mounting nuts (20) on the
high pressure pump must be removed.
10A-48
vnx.su

Remove:
the inner timing cover,
the vacuum pump,

the thermostatic unit,
the ring for lifting the engine at the flywheel end,

the pre-post heating plugs using a 10 mm articulated
wrench,
the cylinder head cover.
10A-49
vnx.su
10A

Remove:
the cam shaft line beam
10A
the tappets, noting their position.

Compress the valve springs using the valve lifter.
Remove:
the keys,
the upper cups,
the springs,
the valves.
the camshaft,
NOTE:
Before removing the valves and the valve stem
seals, it is vital that you measure position H of one
of the old seals in relation to the cylinder head
using Mot. 1511 or using a FACOM tool with part
number DM6J4.
10A-50
vnx.su

Fit the pushrod of Mot. 1511 on the valve stem seal.
10A
Insert sleeve (1) in the guide tube, until the sleeve

comes into contact with the pushrod.
Then block the sleeve using the wheel (2).
Remove the guide tube plus sleeve assembly, being
careful not to loosen the tumblewheel.
Withdraw the pushrod.
Remove:
the valve stem seals using pliers Mot. 1335,
the lower cups.
NOTE:
The internal diameter of the pushrod must be
identical to that of the valve. Moreover, the
pushrod must come into contact with the metallic
upper section of the valve stem seal.
Fit the guide tube above the pushrod until it comes into
contact with the cylinder head.
10A-51
vnx.su

10A
CLEANING
It is very important not to scratch the mating surfaces of any aluminium components.
Wear gloves whilst carrying out this operation.
Use "Dcapjoint" product or equivalent to dissolve any part of the gasket remaining stuck.
Apply the product to the section to be cleaned.
Wait for about ten minutes, then remove using a wooden spatula.
Do not allow this product to drip on to the paintwork.
Great care should be taken when performing this operation, to prevent foreign objects entering the pipes
taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover) and the oil return
pipes.
CHECKING THE GASKET FACE
Check for mating surface bow using a ruler and a set of shims.
Maximum bow 0.05 mm.
NO REGRINDING OF THE CYLINDER HEAD IS PERMITTED
CHECKING THE CAMSHAFT END PLAY
Refit the camshaft.
Refit the camshaft line beam by tightening the bolts to a torque of 2 daN.m.
Check the end play, which must be between 0.045 and 0.135 mm.
Remove the camshaft line beam and the camshaft.
Check that the cylinder head lubrication ducts, camshaft bearings, and tappets are not obstructed.
Replace worn parts.
10A-52
vnx.su

REBUILDING THE CYLINDER HEAD
Fit new valves, grind them gently into their respective
seats.
10A
Place the barrel of the Mot. 1511 tool over the valve
stem (the internal diameter of the barrel must be
identical to the diameter of the valve stem).
Clean all the parts thoroughly, mark them for

identification purposes, then carry out the refitting
operation.
Lubricate the inside of the valve guide.
Fit the valve spring collar rings.
The valve stem seals must be fitted using tool
Mot. 1511 or with the FACOM tool, part number
DM6J4.
Keep the valve pressed against its seat.

Place the valve stem seal (not lubricated) over the tool
barrel.
NOTE:
Do not lubricate the valve stem seals before fitting
them.
Fitting new valve stem seals.
Place the valve in the cylinder head.
10A-53
vnx.su

10A
Push the valve stem seal past the tool barrel, then
withdraw the barrel.
NOTE:
The internal diameter of the pushrod must be
identical to the diameter of the valve stem.
Moreover, the lower part of the pushrod must be in
contact with the upper section of the valve stem
seal.
Place the pushrod over the valve stem seal.
Place the guide tube and sleeve assembly over the

pushrod.
10A-54
vnx.su

Push the valve stem seal down by tapping the top of
the sleeve with the palm of your hand until the guide
tube touches the cylinder head.
10A
Place the valves of the cylinder concerned at the "end

of exhaust - beginning of inlet" position and check the
clearance (X).
NOTE:
Dimension (Y) corresponds to the tappet thickness
class (there are 25 classes in the Parts Store).
1
3
4
2
4
2
1
3
Repeat these operations for all the valves.
Compare the values noted with the specified values.
Position the springs.
Clearance, when the engine is cold, in mm:

Inlet
0.20 0.05
Exhaust
0.40 0.05
Position the upper cups.

Compress the springs.
Remove:
the cam shaft line beam
the camshaft,
the tappet(s) not within tolerance.
Fit the pins.

Check the valve protrusion which should be
0.09 0.12 mm.
Check and adjust the valve clearance
Refit the tappets.
Refit the camshaft.
Refit the camshaft line beam by tightening it to a
torque of 2 daN.m.
10A-55
vnx.su

Determining dimension (Y).
Set up the following assembly using Mot. 252-01 and
Mot. 856-02, then calibrate the gauge.
10A
Note dimension (Y) and repeat the operation for the

tappets where the valve clearance is not within
tolerance.
Then select the various thicknesses of the tappet(s) by
referring to the "Replacement parts catalogue" for the
vehicle concerned.
Lubricate the camshaft bearings.
Degrease the mating faces, which they must be
clean, dry and free from grease (in particular, avoid
finger marks).
Fit the camshaft.
Raise the gauge extension (without modifying the

position of the magnetic support/gauge assembly),
then slide in the tappet to be measured.
10A-56
vnx.su

Using a stipple roller, apply Loctite 518 to the gasket
face of the camshaft line beam until it turns "reddish"
in colour.
10A
Degrease the mating faces of the cylinder head

cover and the camshaft line beam. They must be
clean, dry and free from grease (in particular, avoid
finger marks).
Refit the new seal on the cylinder head cover.
Refit the cylinder head cover by tightening the bolts in
the specified sequence:
tighten bolt (1) to a torque of 1.2 daN.m,
tighten bolts (2) and (3) to a torque of 1.2 daN.m,
retighten bolt (1) to a torque of 1.2 daN.m.
NOTE:
Using a cloth, remove any LOCTITE 518 in the five
camshaft line beam bearings.
Place one or two drops of LOCTITE FRENETANCH
on the five beam mounting bolts on the inlet and
exhaust manifold end.
Tighten the camshaft line beam to a torque of
2 daN.m, in the specified sequence.
10A-57
vnx.su

Refit:
the thermostatic support fitted with a new seal by
tightening the bolts to a torque of 0.8 daN.m,
the vacuum pump by tightening the bolts to a torque
of 2.3 daN.m,
10A
the inner timing housing by placing a drop of

LOCTITE FRENETANCH on the bolts, then
tightening them to a torque of 1 daN.m,
the camshaft seal (timing end) using Mot. 988-02.

the engine lifting ring (flywheel end) by tightening the
bolts to a torque of 1.3 daN.m,
the pre-postheating plugs using an articulated
wrench of 10 mm by tightening them to a torque of
1.5 daN.m,
10A-58
vnx.su

Refit:
the camshaft pulley by blocking it using Mot. 799-01,
and tightening the bolt to a torque of 6 daN.m,
10A
the high pressure pump by tightening the studs to a

torque of 3 daN.m,
the high pressure pump pulley, locking it using tool

Mot. 1200-01 or Mot. 1200-02. Tighten the nut to a
torque of 1.5 daN.m plus an angle of 60 10.
the cylinder head suspended mounting, tightening

the bolts to a torque of 3.5 daNm,
10A-59
vnx.su

Change the washer (1) under the injectors.
10A
Tighten the injector flanges to a torque of 2 daN.m.

Refit the high pressure pipes.
NOTE:
In order to refit the high pressure pipes correctly, it
is vital that the following fitting sequence be
complied with.
Refit:
the injectors,
the injector brackets without blocking them,
the two rail bolts without blocking them,
the new diesel return pipe.
Tighten:
the high pressure pipe nuts at the injector end to a
torque of 2.5 daN.m,
the high pressure pipe nuts at the rail end to a
torque of 2.5 daN.m,
the rail tightening bolts to a torque of 2.2 daN.m,
the pump/rail high pressure pipe to a torque of
2.5 daN.m.
Bring the support into contact with the rear of the pump
using the two nuts (1).
Tighten the two bolts (2), then the two nuts (1) to a
torque of 3 daN.m.
10A-60
vnx.su

REMOVING THE LOWER ENGINE
Engine fitted with a water pump
driven by the timing belt.
Remove:
the power-assisted steering
pump,
the accessories tensioner roller
by removing bolt (1),
the alternator.
10A-61
vnx.su
10A

Remove:
the multifunction mounting.
10A-62
vnx.su
10A

Remove:
the oil decanter,
the oil filter,
the oil heat exchanger,
the oil pressure sensor,
the oil level sensor,
the coolant hose,
the pump inlet pipe.
10A
the clutch
Checking the flywheel and the friction face

It is essential to change the flywheel is the contact
surface is "bluish" or if the friction face is "worn out".
Position the immobilising tool Mot. 582-01 or
Mot. 1677.
Remove the flywheel mounting bolts (these bolts
must be replaced).
Remove the flywheel.
10A-63
vnx.su

Special notes concerning engines fitted with a
flexible flywheel:
10A
the oil pump and the anti emulsion panel,
Under no circumstances should the bolts (A) be

removed.
the timing tensioner plate,

the coolant pump.
Remove:
the engine oil sump,
10A-64
vnx.su

Remove the timing crankshaft sprocket.
If necessary, use the locally manufactured tool (see
drawing on following page) with the thrust plate
Rou. 15-01.
10A-65
vnx.su
10A

Drawing of locally manufactured tool (dimensions in mm)
A Two holes, 6.5 mm

B Bolts, 12 mm - pitch 1.75 mm
C One hole, 13 mm
D Nut, 12 mm - pitch 1.75 mm weld-on
10A-66
vnx.su
10A

Remove:
The crankshaft closure plate,
the oil pump chain and the drive sprocket.
10A-67
vnx.su
10A

REMOVING THE LOWER ENGINE
IMPORTANT:
Do not use a sharp point to mark
the bearing caps in relation to
their con rods to avoid starting a
crack in the rod.
Use a permanent marker pen.
10A-68
vnx.su
10A

Remove the bearing caps and the
connecting rod/piston assemblies.
NOTE:
It is essential to mark the position
of the crankshaft shells, as the
category may be different for
each bearing.
Remove:
the crankshaft bearing caps,
oil return tube (1) from the
decanter by tapping (A).
10A-69
vnx.su
10A

Extraction of bearing No. 1, fitted with bars of injected
silicon paste, is made easier by using Mot. 1423.
10A
FITTING THE CON ROD BEARING SHELLS

On the con rod body:
Remove the crankshaft.

Slide the shell support (1) of Mot. 1492-01 into the
groove (2) on the base of tool Mot. 1492.
EXTRACTING THE GUDGEON PINS

NOTE:
It is essential to mark the connecting rod to match
it to its piston, because the piston height classes
in the same engine may be different (see Technical
Specifications section).
Fit the guide (3) of Mot. 1492-01 onto the base (as
shown in the diagram).
To extract the gudgeon pin, remove the circlips using

internal circlip pliers, then release the pin.
10A-70
vnx.su

10A
Lay the body of the con rod on the base of the tool (as
Bring the shell support up against the base of the con

rod body.
Ensure that the lower part (4) of the small end of the
con rod is in contact with the guide pin.
Remove the con rod body support and repeat the

operation for the remaining con rod bodies.
Fit the shell (5) on the shell support, then push it in the
direction of the arrow (as shown in the diagram).
On the con rod cap
10A-71
Fit the con rod cap as shown in the diagram.
vnx.su

Push the guide (in the direction of the arrow) until the
con rod cap is in contact with the pins (6) at the base of
the tool.
10A
Bring the shell support up against the base of the con

rod cap.
Remove the con rod cap support and repeat the
operation for the remaining con rod caps.
Fit the shell (7) on the shell support, then push it in the
direction of the arrow (as shown in the diagram).
10A-72
vnx.su

10A
"CON RODS / PISTON" ASSEMBLY
FITTING THE RINGS
NOTE:
You must ensure that you match the con rods to
the piston and cylinder as previously determined.
The rings set to their original adjustment must be free

within their channels.
Ensure the rings are fitted in the correct orientation.
Direction of fitting of the con rod in relation to the

piston
Place the "" (1) engraved on the piston head
downwards.
Place the machined flat (2) of the con rod head
upwards.
T = Top
Fit the rings such that the gaps are equally spaced
around the piston.
Direction for fitting the circlips on the piston

Fit the circlips on the piston as shown below.
10A-73
vnx.su

10A
PISTON BASE COOLING JETS
Replacement of the piston base cooling jets
There are various orientations for piston cooling jets

(0, 3 and 5).
REMOVAL
To be sure of obtaining the correct cooling jet

orientation when refitting, their orientation must be
marked before they are removed.
To remove the piston base cooling jets (1), they must

be drilled with a 7 mm diameter drill. This is necessary
in order to remove the spring stop (2) and the spring
(3).
To do that, use tools Mot. 1516, Mot. 1516-01 and

Mot. 1516-02.
Then, try to fit one of the three plates of these tools.
Each plate corresponds to a precise cooling jet
orientation.
Orientation of cooling
jets (in degrees)
Tools to be used for

removal (marking the
orientation) then for
refitting (application of
the correct orientation)
Mot. 1516-02
Mot. 1516-01
Mot. 1516
NOTE:
Do not remove the ball (4), to prevent swarf
entering the cooling circuit.
10A-74
vnx.su

Remove the swarf using a brush.
Screw Mot. 1485 or Mot. 1485-01 into the drilled out

jets using a 6 mm Allen key which you slide inside the
tool.
10A-75
vnx.su
10A

Screw the Emb. 880 inertia extractor to the Mot. 1485 or Mot. 1485-01 tool and extract the jet.
Fitting piston base cooling jets

It is essential that the cooling jets be fitted with tool
Mot. 1516 and plates Mot. 1516-01 and Mot. 1516-02.
10A-76
vnx.su
10A

10A
Fitting the jets for cylinders 1 and 3
Tighten the two bolts (1), the remove the guide rod.
Locate the plate (3) of the Mot. 1516-01 tool on the

cylinder block (as shown in the illustration below)
without tightening the two bolts (1) of the Mot. 1516
tool.
Insert the cooler into the pushrod.

NOTE:
Check that the jet is correctly oriented, with the
end of the jet (4) directed towards the centre of the
cylinder.
Position the guide rod (2) of tool Mot. 1516 in the plate
(3) and the end of the guide rod in the cooler hole to
centre the plate (3).
Fit the pushrod in place and instead of the guide rod.

With a hammer, tap the pushrod until the shoulder (5)
of the pushrod comes into contact with the plate (3).
10A-77
vnx.su

10A
Fitting the jets for cylinders 2 and 4
Tighten the two bolts (1), the remove the guide rod.
Locate the plate (3) of the Mot. 1516-01 tool on the

cylinder block (as shown in the illustration below)
without tightening the two bolts (1) of the Mot. 1516
tool.
Insert the cooler into the pushrod.

NOTE:
Check that the jet is correctly oriented, with the
end of the jet (4) directed towards the centre of the
cylinder.
Position the guide rod (2) of tool Mot. 1516 in the plate
(3) and the end of the guide rod in the cooler hole to
centre the plate (3).
Fit the pushrod in place and instead of the guide rod.

With a hammer, tap the pushrod until the shoulder (5)
of the pushrod comes into contact with the plate (3).
10A-78
vnx.su

Orientation of the piston base cooling jets (see
diagram below).
A: Orientation of the coolers of cylinders 2 and 4

B: Orientation of the coolers of cylinders 1 and 3
10A-79
vnx.su
10A

REFITTING THE LOWER ENGINE
10A
Slide the pipe (2) into the groove of the base of the
tool.
Clean the cylinder block.

Clean the crankshaft by passing a wire through the
lubrication channels.
Fitting the metal oil return pipe from the decanter
The pipe is fitted using Mot. 1551.
Fit the snap fastener on the pipe collar.

Fit the base (1) of Mot. 1551 on the cylinder block (as
10A-80
vnx.su

Tap the snap fastener using a hammer until the
shoulder (3) of the snap fastener touches the base of
the tool (1).
10A
Fitting the bearings in the cylinder block

Position tool Mot. 1493 on the cylinder block.
Fit the grooved bearing shell in tool Mot. 1493, then

press at (A) until the bearing shell is touching tool
Mot. 1493 at (B).
10A-81
vnx.su

10A
Fitting the bearing shells in the bearings
Replacement of the crankshaft bearing
Position tool Mot. 1493 on the bearing.
The crankshaft bearing is extracted using Mot. 11.
Fit the non-grooved bearing shell in tool Mot. 1493,

then press at (C) until the bearing shell is touching tool
Mot. 1493 at (D).
10A-82
vnx.su

Refit:
the lateral crankshaft shims,
the crankshaft.
Oil the main journal bearings with
engine oil.
Refit the crankshaft bearing caps
except cap N 1 (the caps are
numbered from 1 to 5 and position
these numbers opposite the oil
filter side).
Tighten the bolts to a torque of

2 daN.m plus an angle of 62 4
(tightening order 3 4 2 5 1).
10A-83
vnx.su
10A

Check the lateral clearance of the crankshaft which
should be between 0.067 and 0.233 mm.
10A
Coat the lower surfaces of the cylinder block at (26)

with a thin layer of RHODORSEAL 5661.
Check that the crankshaft rotates freely.
Install the crankshaft bearing cap and tighten it to a

torque of 2 daN.m plus an angle of 62 4.
Mix 45 ml of RHODORSEAL 5661 (approximately half
of a 100 gram tube) with half of the tube of hardener
using the mixing stick to obtain a uniform, slightly pink
mixture.
Fitting bearing N 1 with silicon injection

IMPORTANT:
the mixture must be injected within approximately
5 minutes to prevent it from polymerising in the
syringe.
Clean the surfaces thoroughly at (25) of the cylinder
block and the crankshaft cap, using a cloth soaked in
cleaning thinner.
Allow to dry.
10A-84
vnx.su

10A
Insert the mixture into the syringe and inject it into the
grooves of the crankshaft bearing cap.
Using a cloth, wipe off the excess mixture, both inside

and outside the cylinder block.
Allow the mixture to flow out slightly on either side of

the grooves of the crankshaft bearing cap, to ensure
that the injected mixture has totally filled the sealing
groove.
Allow to dry for a few moments and cut the excess off
the gasket face.
10A-85
vnx.su

Fitting the pistons
The pistons are fitted using cone Mot. 1569.
Oil the pistons.

Fit the piston in the cone and allow the piston skirt to
protrude from the cone by approx. 1 to 2 cm.
10A-86
vnx.su
10A

Fit the piston-con rod assembly,
fitted with the cone, on the cylinder
block, paying attention to the
direction (the V towards the
flywheel). Then press the pistoncon rod assembly into the jacket.
Fit the con rods onto the oiled big
end journals of the crankshaft.
Fit the con rod caps, ensuring they

are correctly matched (marks made
when dismantling).
10A-87
vnx.su
10A

Tighten the new bolts of the con rod
caps to a torque of 2 daN.m, then
tighten to an angle of 40 6.
Check the lateral clearance of the

con rod head, which should be
between 0.22 and 0.482 mm.
10A-88
vnx.su
10A

10A
Checking piston protrusion
Measure the piston protrusion.
Clean the piston heads in order to eliminate any traces

of deposits.
The protrusion must be: 0.56 0.06 mm.
Turn the crankshaft one turn in its operating direction

to bring piston No. 1 close to top dead centre.
NOTE:
To prevent any risk of piston/valve interference
when the engine is running, the piston protrusion
value must be less than 0.67 mm.
Fit tool Mot. 252-01 on the piston.

Refit the oil pump chain.
Fit tool Mot. 251-01 equipped with a gauge on its base
plate Mot. 252-01, and find top dead centre of the
piston.
NOTE:
All measurements are to be carried out in the
longitudinal axis of the engine, in order to eliminate
any errors due to tilting of the piston.
WARNING:
the gauge detector must not be in the valve clearance.
10A-89
vnx.su

10A
Crankshaft closure panel sealing
Oil pump chain guide
There are two possible solutions:

Either it is sealed with RHODORSEAL 5661; the
band (1) must be 1.75 mm wide and be applied as
shown in the drawing below.
Be careful not to obstruct the pipes (C).
There are likewise two possible solutions:

For engines equipped with a water pump driven by
the timing belt (water pump moved).
In this case, check presence of oil pump chain guide.
Or it is performed with a seal consisting of a steel

sheet coated with elastomer on both sides.
NOTE:
This type of seal projects from the plate. It should
in no case be cut out, because the two projecting
tabs provide sealing when the sump is fitted.
10A-90
For engines equipped with a water pump driven by

the accessories belt (water pump not moved).
In this case, the oil pump chain guide is no longer of
any use.
vnx.su

Refit the closure panel, tightening the bolts to a torque
of 1.4 daN.m.
10A-91
vnx.su
10A

REFITTING THE LOWER ENGINE
10A
If sealing of the closure panel has been performed with

RHODORSEAL 5661:
Apply a drop of RHODORSEAL 5661 to (A) (on
either side of bearing No. 1), and at the intersection
of the crankshaft closure panel and the cylinder block
at (B).
Engine fitted with a water pump driven by the

timing belt.
NOTE:
Put a drop of Loctite FRENETANCH on bolts (1).
Refit:
the water pump fitted with a new seal, tightening the
bolts to a torque of 1 daN.m,
the tensioner support plate, tightening the bolts to a
torque of 1 daN.m,
If sealing of the closure panel has been performed with

the gasket consisting of a steel sheet coated with
elastomer:
Apply a drop of RHODORSEAL 5661 to (A) (on
either side of bearing No. 1).
NOTE:
For side (B), sealing will be implemented by the
plate gasket. This type of gasket projects from the
plate and it should in no case be cut out, because
the two projecting tabs provide sealing when the
sump is fitted.
the anti-emulsion plate,

the oil pump, tightening the bolts to a torque of
2.4 daN.m,
10A-92
vnx.su

10A
Refit the sump with a new gasket, pre-tightening it to a

torque of 0.8 daN.m, then finally tightening it to a
torque of 1.5 daN.m in the recommended order.
Fitting the crankshaft seal gaskets
The alignment of the cylinder block and the sump must

be complied with on the flywheel side to prevent the
clutch housing from being damaged when fitting the
gearbox.
Change of material on the engine elastomer seals

(fitted on the crankshaft).
GENERAL INFORMATION
Fitting and removing the new type elastomer seal from

the engine requires new tools and precautions
compared to the old type seal.
The old and new type of seal can both be used on the
same engine. They are not interchangeable. Old
type seals must be replaced with old type seals
(still available from the Parts Department), and a new
type seal with a new type seal.
An old type seal can be replaced with a new type seal
in the case of a crankshaft replacement. This is
possible if the engine is fitted with one during its
lifetime in series production.
10A-93
vnx.su

Old and new seals are easily recognized.
The old elastomer seal is fitted with a spring (1) and
has a "V"-shaped sealing lip (2).
The new elastomer seal has a flat sealing lip (3) and a
protector (4) which also assists in fitting the seal to the
engine.
10A-94
vnx.su
10A

Tooling required for fitting old type elastomer
seals.
Engine type
F9Q
Tool for the crankshaft seal

Timing end
Flywheel end
Mot. 990-03
Mot. 991-01
Tooling required for fitting new type elastomer

seals.
Engine type
F9Q

Timing end
Flywheel end
Mot. 1636
Mot. 1635
Tooling required for removing new type elastomer

seals.
Engine type
F9Q

Timing end
Flywheel end
Mot. 1577
Mot. 1579
10A-95
vnx.su
10A

Method for removing elastomer seals
10A
Screw extractor tool into the seal using hexagon bar

(4).
This procedure is applicable for crankshaft seals.

Extract the seal by tightening threaded rod (5).
Fit the extractor tool onto the shaft by adjusting
plungers (1) to the shaft diameter with knurled backplate (2).
Tighten knurled back-plate (3) until it locks on knurled

back-plate (2) to keep the plungers correctly adjusted
on the shaft.
10A-96
vnx.su

10A
Method for fitting new type elastomer seals.
Crankshaft elastomer seal (timing end)
IMPORTANT:
This type of seal is extremely FRAGILE. Only
touch the protector part (1) when handling the
gasket. It is strictly forbidden to touch the seal (2).
This is to ensure that there will be no oil leaks
once the gasket is fitted on the engine.
Screw the threaded rod (22) of Mot. 1636 into the

crankshaft.
This new seal must be fitted using the tooling

mentioned previously.
Fit spacer (23) of Mot. 1636 to the crankshaft.
10A-97
vnx.su

Fit the protector complete with the seal onto the
spacer, taking care not to touch the seal.
10A
Tighten the nut until the cover touches the spacer.
Fit cup (24) and nut (25) (putting threaded hole (26) of
the nut on the side facing away from the engine) of
Mot. 1636.
10A-98
Remove the nut, the cup, the protector, the spacer and
the threaded rod.
vnx.su

Crankshaft elastomer seal, flywheel end
10A
Fit cup (28) and nut (29) (putting the threaded hole
(30) of the nut on the side facing away from the
engine) of Mot. 1635.
Install tool Mot. 1635 on the crankshaft, attaching it

with bolts (27).
Tighten the nut until the cup makes contact with the
base plate of Mot. 1635.
Fit the protector complete with the seal onto tool

Mot. 1635, being careful not to touch the seal.
10A-99
vnx.su

10A
The method for fitting old type seals remains

unchanged.
Lock the flywheel with tool Mot. 582-01 or Mot. 1677

depending on the cylinder block (large or small side).
Fitting old type crankshaft seal gaskets

Flywheel side, use tool Mot 991-01,
Refit the flywheel, tightening the new bolts to a torque

of 2 daN.m, then tighten to an angle of 70 7.
If the flywheel is flexible, tighten the new type bolts
to a torque of 3 daN.m et then turn them through
an angle of 35 6.
Flexible flywheel:
Timing side, use tool Mot. 990-03.
NOTE:
Under no circumstances should bolts (A) be removed.
10A-100
vnx.su

Refit the clutch, tightening the bolts to a torque of
2 daN.m.
Withdraw the flywheel immobiliser Mot. 582-01 or

Mot. 1677.
10A-101
vnx.su
10A

Refit:
the oil decanter fitted with a new seal by tightening
the bolts to a torque of 1 daN.m,
the oil heat exchanger,
the oil filter,
the oil pressure sensor by tightening to a torque of
3.8 daN.m,
the oil level sensor by tightening it to a torque of
3 daN.m,
the coolant pipe by tightening the bolt to a torque of
4 daN.m,
the coolant pump inlet pipe fitted with a new seal, by
tightening the bolts to a torque of 1 daN.m,
10A-102
10A
the multifunction support by tightening the bolts to a

torque of 5 daN.m,
vnx.su

Refit:
tightening the bolts to a torque of
2.5 daN.m,
the alternator, tightening the bolts

to a torque of 2.5 daN.m.
10A-103
vnx.su
10A

Refit:
the power assisted steering pump
by tightening the bolts to a torque
of 2.5 daN.m,
the accessories roller tensioner
by tightening the bolts to a torque
of 2.5 daN.m.
10A-104
vnx.su
10A

REFITTING THE UPPER ENGINE
10A
Check that the tensioner is securely positioned on the

pin (1).
Refitting the cylinder head

Position the pistons at mid-stroke.
Fit the cylinder head gasket using the centring sockets
of the cylinder block.
Tighten the cylinder head (see the Cylinder head
characteristics).
Timing adjustment
Check that pin Mot. 1054 is in place.
The notch (4) in the crankshaft must be located in the
middle of the two grooves (2) on the crankshaft closure
housing. The mark (3) of the crankshaft timing
sprocket should be moved to the left by one notch of
the engine vertical axis.
Fit the timing belt, aligning the marks on the belt with
the marks on the camshaft and crankshaft sprockets
(77 teeth between the two marks on the belt).
10A-105
vnx.su

Place the tensioner against the belt
by tightening bolt (2) on the
tensioner mounting.
10A-106
vnx.su
10A

Remove pin Mot. 1054.
Fit the crankshaft accessories
pulley bolt.
IMPORTANT:
If the bolt is not fitted with a washer,
fit the washer R1 (4) included in the
tool kit Mot. 1543.
Do not forget to remove it again
when fitting the crankshaft pulley.
10A-107
vnx.su
10A

Fit Mot. 1543 and the cover
numbered 1 on the crankshaft
accessories pulley bolt.
Apply pre-tension between the

crankshaft timing sprocket and the
tensioner using the tool Mot. 1543
and the cover 1, adjusting the
torque wrench to a torque of
1.1 daNm.
10A-108
vnx.su
10A

10A
Fit the sensor of Mot. 1505 between

the crankshaft sprocket and the
tensioner.
Tension the belt by turning bolt (2)
until the recommended fitting value
95 Hz 3 Hz is obtained.
Tighten the tensioner to a torque of
1 daN.m.
Turn the crankshaft over four times.
Check
Refit pin Mot. 1054 and set the timing to its setting point, (begin to press on the pin a half-tooth before alignment
of the mark on the camshaft pulley and that made by the operator on the lower timing housing, to avoid it
falling into a crankshaft balance hole).
Remove the pin Mot. 1054.
Apply pretension between the crankshaft timing sprocket and the tensioner using the tool Mot. 1543 and the
cover 1, adjusting the torque wrench to a torque of 1.1 daN.m.
Position the sensor of Mot. 1505.
Check that the tension value is 90 Hz 3 Hz, otherwise readjust it.
Tighten the tensioner nut to a torque of 5 daN.m.
NOTE:
It is essential to tighten the tensioner nut to torque to avoid any loosening which may cause damage to the
engine.
IMPORTANT:
Remove the washer R1 included in the tool kit Mot 1543 before fitting the crankshaft pulley.
10A-109
vnx.su

Refit the camshaft sensor.
Install the flywheel immobiliser Mot. 582-01 or

Mot. 1677.
10A-110
vnx.su
10A

Refit the crankshaft accessories
pulley by tightening the bolt to a
torque of 2 daN.m, then angle
tighten to 115 15.
Withdraw the flywheel immobiliser
Mot. 582-01 or Mot. 1677.
Refit the timing housing.
10A-111
vnx.su
10A

Refit the accessories belt.
Turn the wrench in a clockwise
direction to fit the belt.
The engine must be turned
through two revolutions to
position the belt correctly.
10A-112
vnx.su
10A

Special notes concerning engines fitted with an
auto tensioner.
Position the apertures of the tension wheel end piece
on the engine mounting and screw up without
tightening the two bolts.
Keep the tension wheel in high position.

Install the belt, ending with the tension wheel.
10A-113
vnx.su
10A

Exert merely pressure with the thumb on the end of the
tension wheel to position said wheel.
While maintaining this light pressure with the thumb,
tighten the two mounting bolts to a torque of
2.5 daN.m.
The tension wheel is now tightened in position.

Tensioning of the tension wheel.
Depending on ease of access to the engine, place tool
Mot. 1676 on the belt strand:
alternator-compressor or
crankshaft-fixed roller.
Once the belt has been centred on the tool's rollers,
take a ratchet spanner and apply a rotation movement
to tension the belt.
10A-114
vnx.su
10A

Maintain the force created by belt torsion until the
tension wheel's pretensioning torque plate can be
withdrawn manually.
Apply tension to the tension wheel while gradually

relaxing the force.
The tension wheel is now ready to operate.
10A-115
vnx.su
10A

REFITTING THE UPPER ENGINE
Refit the inlet and exhaust manifolds
fitted with new seals, tightening the
nuts to a torque of 2.8 daN.m.
Refit the engine lifting ring,
tightening the bolts to a torque of
2 daN.m.
Refit the exhaust gas recirculation
pipe.
Remove the engine from the stand
Mot. 792-03.
10A-116
vnx.su
10A

10A
Refit the turbocharger, tightening the nuts to a torque

of 2.4 daN.m.
Refit the turbocharger oil return pipe fitted with new

seals, then tighten the bolts to a torque of 1.2 daN.m.
Refit the turbocharger oil supply pipe, tightening the

couplings at the cylinder block end to a torque of
2.3 daN.m and at the turbocharger end to a torque of
2.4 daN.m.
Refit the exhaust stay by tightening the M8 bolt to a

torque of 2.4 daN.m and bolt M10 to a torque of
4.3 daN.m.
10A-117
vnx.su
111 TOP AND FRONT OF ENGINE

Timing belt tension wheel
11

Mot. 1054
TDC setting pin
Mot. 1453
Engine support tool
Mot. 1505
Tool for checking belt tension
Mot. 1543
Tool for pre-tensioning the belt

EQUIPMENT REQUIRED
Angular torque wrench
14 Torx socket
REFITTING
TIGHTENING TORQUE (In daNm and/or)

Tension wheel nut
Tension wheel plate bolt
Crankshaft pulley bolt
2+11515
Suspended engine mounting

upper linkage mounting bolt
10.5
Body mounting bolt for the

suspended engine mounting
movement limiter
4.4

6.2
Wheel bolt
Refit:
tension wheel plate by tightening the bolts to a torque
of 1 daNm,
the timing belt (see Section 11 Timing belt).
14
REMOVAL
Put the vehicle on a two-post lift.
Remove:
the timing belt (see Section 11 Timing belt),
both tension wheel plate bolts.
11-1
vnx.su
TOP AND FRONT OF ENGINE

Timing belt
11

Mot. 1054
TDC setting pin
Mot. 1505
Tool for checking belt tension
Mot. 1543
Mot. 1367-02
Engine support tool

EQUIPMENT REQUIRED
Angular torque wrench
14 Torx socket

Tension wheel nut
2+11515

10.5

movement limiter
4.4

6.2
Wheel bolt
NOTE:
As the battery is situated under the left-hand seat, the
carpet must be removed by unclipping it, then
removing the battery flap (A) by undoing the bolts.
14
REMOVAL
Lifting methods for the correct positions of the lifting
jack and axle stands) or on a lift.
Remove the engine undertray and the left-hand side

protection.
11-2
vnx.su

Timing belt
Fit engine support tool Mot. 1367-02 between the
lower crossmember and the sub-frame.
11
Unclip the wiring from the engine mounting and move

it out of the way.
Unclip the power steering reservoir from its support
and remove.
Remove:
the accessories belt (see Section 07 Accessories
belt tension),
tie-rod (1) mounting bolts, then remove the
suspended mounting movement-limiter assembly,
Bring the top part of the tool (A) into contact with the
sump.
Adjust the position of section (A) on the sump using
the mountings (B).
Lift the engine slightly at point (C), then tighten
nuts (D).
the Top Dead Centre pin plug.
11-3
vnx.su

Timing belt
Timing adjustment
Turn the crankshaft in a clockwise direction (timing
end). When the mark (1) on the camshaft pulley
appears in the window (2) of the timing cover, push in
the Top Dead Centre pin Mot. 1054 to pin the
crankshaft (the mark on the camshaft pulley must be
located approximately in the centre of the window).
11-4
vnx.su
11

Timing belt
Remove:
the accessories belt tensioner (3),
the crankshaft accessories pulley by locking the flywheel,
timing cover from underneath the car (lower the engine using the engine
support tool Mot. 1453).
NOTE:
Use a pencil to mark the lower timing housing opposite the mark on the
camshaft pulley.
11-5
vnx.su
11

Timing belt
Loosen the tensioner by loosening the nut (5), then remove the timing belt.
11-6
vnx.su
11

Timing belt
REFITTING
11
The crankshaft groove (4) should be located at the

centre of the two ribs (2) on the crankshaft closure
housing, mark (3) on the crankshaft timing sprocket
should be offset one tooth to the left of the vertical axis
of the engine.
TENSIONING PROCEDURE
Engine cold (ambient temperature).
Check that the tensioner is securely positioned on the
pin (1).
Check that pin Mot. 1054 is in place.
11-7
vnx.su

Timing belt
Fit the new timing belt by aligning the belt markings with those of the
camshaft and crankshaft sprockets.
Place the tensioner against the belt by tightening bolt (2) on the tensioner
mounting.
11-8
vnx.su
11

Timing belt
Fit the crankshaft accessories pulley together with washer R1 (4) which is
included in the kit with tool Mot. 1543.
NOTE:
Do not forget to remove it again when fitting the crankshaft pulley.
11-9
vnx.su
11

Timing belt
Fit Mot. 1543 and the cover
numbered 1 on the crankshaft
accessories pulley bolt.
Apply pre-tension between the

crankshaft timing sprocket and the
tensioner using tool Mot. 1543
and the cover 1, adjusting the
torque wrench to a torque of
1.1 daN.m.
11-10
vnx.su
11

Timing belt
Connect the sensor of Mot. 1505.
Tension the belt by turning bolt (2) until the recommended fitting value
95 3 Hz is obtained.
Tighten the tensioner to a torque of 1 daN.m.
Turn the crankshaft two revolutions.
11-11
vnx.su
11

Timing belt
Refit the pin Mot. 1054 and set the timing to its setting
point, (begin to press on the pin half a tooth before
alignment of the mark on the camshaft pulley and
that made by the operator on the inner timing
housing, to prevent it falling into a crankshaft
balance hole).
Apply pre-tension between the crankshaft timing
sprocket and the tensioner using the tool Mot. 1543
and the cover 1, adjusting the torque wrench to a
torque of 1.1 daN.m.
Position the sensor of Mot. 1505.
Check that the tension value is 90 3 Hz. If not,
readjust it.
Tighten the tension wheel nut to a torque of 5 daNm.
NOTE:
It is essential to tighten the tensioner nut to torque to
avoid any loosening which may cause damage to the
engine.
IMPORTANT:
Remove the numbered washer R1 included in tool kit
Mot. 1543 before fitting the crankshaft pulley.
The crankshaft accessories pulley bolt MUST be
tightened to a torque of 2 daNm plus an angle of
115 15.
Refit the right-hand suspended engine mounting (see
Section 19 Suspended engine mounting for the
tightening torques).
11-12
vnx.su
11

Cylinder head gasket
11

Mot. 1054
TDC setting pin
Mot. 1202-01
Hose clip pliers
Mot. 1202-02
Mot. 1448
Distance pliers for cooling system

hose clips
Mot. 1505
Belt tension measuring tool
Mot. 1543

EQUIPMENT REQUIRED
14 Torx socket
High pressure pipe wrench (e.g. Facom DM19
wrench)
Angular tightening wrench

Tension wheel nut
Tension wheel plate bolt
2+11515

10.5

movement limiter
4.4

6.2
Wheel bolt
14
REMOVAL
Lifting methods for the correct positions of the lifting
jack and axle stands) or on a lift.
NOTE:
As the battery is located beneath the left seat, the
carpet must be removed from the floor by unclipping it,
then remove the battery flap (A) by loosening the bolts.

GIVEN IN SECTION 13 "SPECIAL FEATURES"
AND "CLEANLINESS" BEFORE CARRYING OUT
ANY WORK
Drain the cooling circuit through the lower radiator

hose.
11-13
vnx.su

Remove:
the heater casing (B) by disconnecting the
connector (1),
11
the turbocharger pipe (C),

the connector (3) as well as the injector and preheater plug connectors,
thermoplunger unit mounting (4),
fuel return pipe at (5) (fit anti-contamination
plugs),
the air filter unit,

the vacuum pipes (2),
the hoses on the cylinder head water outlet housing

as well as the coolant temperature sensor connector,
the brake servo vacuum pipe,
11-14
vnx.su

11
the air pipe (A) as well as the turbocharger air outlet

pipe, then move it out of the way,
the stays (5) and (6), then the catalytic converter (7),
fuel pipe (1) (fit anti-contamination plugs) and

connector (2),
the connectors (3) and Top Dead Centre sensor

at (4),
the oil return pipe (1),

mounting (2), having loosened the pipe at (3), then
remove the oil supply pipe at (4) and move it aside
towards the bulkhead,
the exhaust downpipe mountings,

the cylinder head bolts,
the cylinder head.
11-15
vnx.su

CLEANING
REFITTING
It is very important not to scratch the gasket faces

of any aluminium component.
Special notes
11
Fit the cylinder head gasket. This is centred by two

dowels.
Use the Dcapjoint product to dissolve any remains of

the gasket still adhering.
Bring the pistons to mid-stroke position to prevent

them from coming into contact with the valves as the
cylinder head is tightened.
Wear gloves whilst carrying out the following

operation.
Apply the product to the part to be cleaned, wait
approximately ten minutes, then remove it using a
wooden spatula.
Centre the cylinder head on the dowels.
Please take great care during this operation to

prevent any foreign bodies from entering the oil
galleries (channels located in the cylinder block
and in the cylinder head).
Tighten the cylinder head using an angular tightening

wrench (see Section 07 Tightening the cylinder
head).
Lubricate the threads and under the heads of the

mounting bolts.

CHECKING THE GASKET FACE
Refit the timing belt (see procedure described in

Section 11 Timing belt).
Check for mating surface bow using a ruler and a set

of shims.
Fill and bleed the cooling system (see Section 19

Filling and Bleeding).
Maximum deformation: 0.05 mm.

No regrinding of the cylinder head is permitted.
11-16
vnx.su
ENGINE MOUNTING
Suspended engine mountings
19
4.4
10.5
6.2
6.2
10.5
8.5
4.4
6.2
4.4
4.4
4.4
18
* Order of tightening: tighten bolt (1) then (2) and (3).
19-6
vnx.su
COOLING SYSTEM
119
Specifications
19
VOLUME AND GRADE OF COOLANT

Engine
F9Q 760
Volume (in litres)
Grade
Special notes
GLACEOL RX (type D)
only use coolant liquid
6.4
Protection down to - 20 2C for

temperate and cold countries.
Protection down to - 37 2C for very
cold countries.
THERMOSTAT
Engine type
Starts to open at (C)
Fully open at (C)
Travel (mm)
F9Q 760
83
101
7.5
19-1
vnx.su
COOLING SYSTEM
Filling and bleeding
FILLING
It is essential to open the bleed screws on the
coolant reservoir cylinder head housing outlet.
Fill the circuit through the expansion bottle opening.
Close the bleed screws as soon as the liquid starts to
flow in a continuous stream.
Start the engine (2 500 rpm).
Adjust the level by overflow for a period of about
4 minutes.
Close the bottle.
BLEEDING
Allow the engine to run for about 20 minutes at
2 500 rpm, until the engine cooling fan starts up (time
necessary for automatic degassing).
Check that the liquid level is at or near the Maximum
mark.
NEVER OPEN THE BLEED SCREW WHEN THE
ENGINE IS RUNNING.
RE-TIGHTEN THE EXPANSION BOTTLE CAP
WHILE THE ENGINE IS WARM.
19-2
vnx.su
19
COOLING SYSTEM
Checking
19

M.S. 554-01
Adapter for M.S. 554-07
M.S. 554-06
Adapter for M.S. 554-07
M.S. 554-07
Kit for testing cooling circuit

sealing
1 - Testing the circuit sealing
2 - Checking the valve calibration.
Replace the expansion bottle valve with adapter

M.S. 554-01.
If liquid passes through the expansion bottle valve, the

valve must be replaced.
Connect this to tool M.S. 554-07.
Fit tool M.S 554-06 on pump M.S. 554-07 and fit both
onto the valve to be checked.
Warm up the engine then switch it off.

Increase the pressure, which should stabilise at the
valve calibration pressure with a test tolerance of
0.1 bar.
Pump to pressurize the circuit.

Stop pumping at 0.1 bar less than the valve is
calibrated.
Valve calibration value:

The pressure should not drop; if it does, look for the
leak.
Slowly unscrew the union of tool M.S. 554-07 to
decompress the cooling circuit, then remove tool
M.S. 554-01 and refit the expansion bottle valve with a
new seal.
19-3
vnx.su
Engines
Colour of valve
Valve calibration
(in bar)
All types
Brown
1.2
COOLING SYSTEM
Diagram
1
2
3
4
5
6
7
8
9
10
11
Engine
Radiator
Hot bottle with degassing after thermostat
Heater matrix
Thermostat mounting
Thermoplunger mounting (if fitted)
16 mm restriction
Coolant/oil heat exchanger
Coolant pump
Thermostat
Bleed screw
The expansion bottle valve calibration is 1.2 bar (colour brown).
19-4
vnx.su
19
COOLING SYSTEM
Coolant pump
F9Q ENGINE
19

Mot. 1202-01
Hose clip pliers
Mot. 1202-02
Mot. 1448
Distance pliers for hose clips

REFITTING
TIGHTENING TORQUE (in daNm)

Coolant pump bolt
0.9
NOTE:
put a drop of Loctite FRENETANCH on bolts (3)
and (4).
REMOVAL
Remove the engine undertray.
Drain the cooling circuit through the lower radiator
hose.
Remove:
the coolant pump.
Refit:
the coolant pump fitted with a new seal by tightening
the bolts to a torque of 0.9 daNm,
the timing belt (see method described in Section 11
Timing belt).
Fill and bleed the cooling circuit (see Section 19
Filling and bleeding).
19-5
vnx.su
F9Q ENGINE
FUEL MIXTURE
112
Air intake
AIR INTAKE CIRCUIT DIAGRAM
1
2
3
4
5
6
Air-to-air intercooler
Air filter
Flowmeter
Inlet manifold
Turbocharger
Air inlet
12-1
vnx.su
12
F9Q ENGINE
FUEL MIXTURE
Air filter
FILTER ELEMENT REPLACEMENT
Remove the three screws on the air filter cover to gain

access to the filter element.
12-2
vnx.su
12
F9Q ENGINE
FUEL MIXTURE
Manifolds
Disconnect:
airflow sensor connector (3),
turbocharger air intake pipe (4).

Manifold mounting stud
0.8
Manifold mounting nut
2.8
Exhaust gas recirculation valve

mounting bolt
0.8
12
Remove:
air filter unit mounting nuts (5), then remove it,
REMOVAL
NOTE:
To remove the manifolds it is necessary to remove the
turbochargers (see Section 12 Turbocharging
turbocharger). The two manifolds cannot be removed
separately.
the turbocharger (see Section 12 Turbocharging:
turbocharger).
Disconnect the heater unit connector (1).

Remove the heater unit mounting bolt and three nuts
(2), then remove the unit.
12-3
vnx.su
F9Q ENGINE
FUEL MIXTURE
Manifolds
Disconnect:
manifold pressure signal pipe (6),
manifold air intake pipe (7),
the electrical exhaust gas recirculation valve (8).
Remove the electrical exhaust gas recirculation
valve mounting bolt (9) and remove the valve.
12-4
vnx.su
12
F9Q ENGINE
FUEL MIXTURE
Manifolds
Remove the exhaust gas recirculation pipe and the lifting lug.
12-5
vnx.su
12
F9Q ENGINE
FUEL MIXTURE
Manifolds
Remove:
nuts securing the manifolds,
the manifolds.
REFITTING
Proceed in the reverse order to removal.
Replace the manifold, taking care to replace it correctly, and the exhaust gas recirculation valve seal.
12-6
vnx.su
12
F9Q ENGINE
FUEL MIXTURE
Air flowmeter
REMOVAL
12
both airflow sensor mounting screws (6) on the air

filter unit,
the airflow sensor.
Disconnect:
the battery,
heater unit connector (1).
Remove the heater unit mounting bolt and three nuts
(2), then remove the unit.
Disconnect:
REFITTING
Proceed with refitting in the reverse order to removal
Remove:
air filter unit mounting screws (5), then remove it,
12-7
vnx.su
FUEL MIXTURE
Air flowmeter
F9Q ENGINE
TRACK ALLOCATION
Connector for air flowmeter with integrated air
temperature sensor.
Track
Description
Air temperature
Earth
5 V reference
+ battery
Air flowmeter signal
Earth
Air temperature sensor resistance (between tracks 1

and 2): approximately 2170 at 20 C.
12-8
vnx.su
12
F9Q ENGINE
TURBOCHARGING
Pressure regulating valve
The diaphragm (A) of the pressure regulation valve is

controlled by a solenoid valve (B) which is managed by
the injection computer. This solenoid valve varies the
vacuum according to the engine operating range,
which enables the turbocharging pressure to be
regulated.
12
The solenoid valve, closed in the rest position, is

supplied after the engine is started following a delay
according to the coolant temperature.
X
Y
The pressure regulation valve is open in rest position.
The engine operates as normally aspirated.
12-9
vnx.su
Timed period (seconds)

Temperature (C)
F9Q ENGINE
TURBOCHARGING
Turbocharger pressure adjustment
TURBOCHARGER PRESSURE CONTROL VALVE

(WASTEGATE)
12
Calibration value
NOTE:
The limiter valve functions in the opposite way to
conventional assemblies.
The absence of control pressure limits the
turbocharging pressure.
Check that there are no leaks between the vacuum
pump and the control valve.
Vacuum value
(mbar)
Rod movement (mm)
120
between 1 and 4
400
between 10 and 12
> 450
Rod at stop
On the vehicle itself
Calibration pressure check
It may be necessary to adjust the wastegate rod length

(A) (if the pressure is not within tolerance) when
checking the calibration pressure.
Operation on the vehicle.
Loosen the lock nut (1).
Use a magnetic base fitted with a gauge which should

be positioned at the end of the wastegate rod
(inserted as close as possible to the centre line of the
wastegate).
Carry out the adjustment by tightening or loosening the

adjusting wheel (2) half a turn at a time until the correct
calibration pressure is obtained.
A vacuum is applied gradually to the wastegate using

pressure gauge Mot. 1014.
NOTE:
Check the calibrating pressure after retightening the
locknut (1).
Confirm the repair with a road test, checking
parameters Wastegate opening cyclic ratio and
Turbocharging pressure on the diagnostic tools.
12-10
vnx.su
F9Q ENGINE
TURBOCHARGING
Turbocharger
12

Turbocharger mounting nut
2.4 1
Oil inlet union on the turbocharger
2.4 4
Engine oil supply connection
2.6 0.2
Oil return union bolt
1.2 0.1
Catalytic converter mounting nuts on

the turbocharger
2.6 0.2
REMOVAL
NOTE:
To loosen the turbocharger mounting nuts on the
exhaust manifold, it helps to spray some unlocking fluid
onto the nuts while they are still warm, just before
removal.
both exhaust system mounting nuts (6) and allow it to

rest on the engine sub-frame.

Disconnect:
airflow meter connector (3),
Remove:
air filter unit mounting screws (5), then remove it,
12-11
vnx.su
F9Q ENGINE
TURBOCHARGING
Turbocharger
Remove:
the catalytic converter mounting stays (1) and (2),
the nuts (3) securing the catalytic converter to the
turbocharger,
the catalytic converter.
Remove:
turbocharger oil supply pipe (5),
turbocharger oil return pipe (6),
three turbocharger mounting nuts (7),
the turbocharger.
Disconnect:
wastegate diaphragm control pipe (4),
the turbocharger air intake and outlet pipes.
12-12
vnx.su
12
F9Q ENGINE
TURBOCHARGING
Turbocharger
REFITTING
12
Special precautions
For refitting operations, use the reverse procedure to

removal.
Before refitting, check that the turbocharger

bearings are correctly greased. To do this,
activate the starter motor having first
disconnected the high pressure regulator
connector (to prevent the engine from starting)
(clear the computer memory). Sufficient oil should
arrive via the oil pressure pipes (place a container
underneath). If this is not the case, change the
lubrication pipe.
Ensure that no foreign bodies enter the turbine or
compressor during the refitting operation.
If there has been a fault in the turbocharger, check
that the air-to-air intercooler is not full of oil. If the
air-to-air intercooler is full of oil, it must be
removed, flushed with a cleaning agent and then
left to drain properly.
Check that the turbocharger oil return pipe is not
partially or completely blocked by scale. Also
check that it is perfectly sealed. If not, replace it.
IMPORTANT:
It is essential to replace the leather seal on the
turbocharger oil inlet union and the oil return pipe seal.
IMPORTANT:
Before starting the engine, leave the pressure regulator
connector on the high pressure pump disconnected.
Then run the starter motor until the oil pressure warning
light goes out (do this for a few seconds).
Reconnect the regulator, preheat and start the engine.
Run the engine at idle speed and check that there are
no leaks at the oil connections.
Clear the fault and check the turbocharging pressure
solenoid valve sensor.
12-13
vnx.su
F9Q ENGINE
TURBOCHARGING
Air-to-air intercooler
REMOVAL
Remove the retaining clip screw (1).
Disconnect:
air-to-air intercooler air intake pipe (2),
air-to-air intercooler air outlet pipe (3),
REFITTING
Remove:
air-to-air intercooler mounting bolts (4),
air-to-air intercooler.
12-14
vnx.su
12
DIESEL EQUIPMENT
113
Specifications
F9Q ENGINE
13
Engine
Vehicle
XLOC
XLOB
Gearbox
PK5 and
PK6
Type
Suffix
Bore
(mm)
Stroke
(mm)
Cubic
capacity
(cm3)
Compression
ratio
Emission
control
standard
F9Q
760
80
93
1870
19 / 1
EU 00
ENGINE SPEED (rpm)
FUME OPACITY
Idle speed
Maximum - no load
Maximum - full
load
Homologation
value
Maximum maximum
800 50 rpm
4160 150 rpm
3700 100 rpm
1.7 m-1 (50%)
3 m-1 (70%)
Description
High-pressure pump
Booster pump (low-pressure)
Make/Type
Special notes
BOSCH CR / CP3
BOSCH EKP3
Pressure from 250 to 1350 bar

Pressure 2.5 bar maximum
Flow: 80 to 100 l/h minimum
Diesel pressure sensor
BOSCH
Screwed to the injection rail

Resistance: tracks 1,2 and 1,3 = 4,3 M
tracks 2, 3 = 1050
Injectors
BOSCH
Solenoid injector
Resistance: < 2
Maximum pressure 1600 bar
Pressure regulator
Incorporated in the high-pressure pump (not

removable)
Resistance: approximately 5 at 20 C
Injection computer
Accelerator pedal sensor
BOSCH EDC 15
HELLA
128-track computer
Dual track potentiometer
Track 1 resistance: 1200 480
Track 2 resistance: 1700 680
Pre/postheating unit
NAGARES BED/7
Engine speed sensor
MGI
With pre/post-heating function controlled by the

injection computer
Resistance: 800 80 at 20 C
13-1
vnx.su
F9Q ENGINE
Description
Preheater plugs
Air intake temperature sensor
Diesel temperature sensor
Atmospheric pressure sensor

Camshaft sensor
DIESEL EQUIPMENT
Specifications
Make/Type
13
Special notes
BERU or CHAMPION
Resistance: 0.6 connector disconnected
SIEMENS
Incorporated in the air flowmeter

Resistance = approximately 2170 at 20 C
MAGNETTI
MARELLI and
ELTH
Resistance = approximately 2050 at 25 C
Incorporated into the computer
ELECTRICIFIL
Hall effect sensor
Turbocharging pressure
sensor
DELCO
Resistance: 4 k across tracks A and C

Resistance: 5 k across tracks B and C
Resistance: 9 k across tracks A and B
Turbocharger control solenoid

valve
BITRON
Resistance: 16.5 1 at 25 C
Air flowmeter
Exhaust gas recirculation

system solenoid valve
SIEMENS
Air flowmeter with integrated air temperature

sensor
Track 1: air temperature
Track 2: earth
Track 3: 5 V reference voltage
Track 4: + battery
Track 5: airflow signal
Track 6: earth
PIERBURG/SIEBE
13-2
vnx.su
Track resistance: 8 0.5 at 20 C (tracks 1 and 5)

Sensor resistance: 4 1.6 k at 20 C (tracks 2
and 4)
F9Q ENGINE
Description
Turbocharger
Thermoplungers
Engine coolant temperature
sensor
DIESEL EQUIPMENT
Specifications
Make/Type
13
Special notes
ALLIED SIGNAL
Wastegate setting:
(fixed geometry turbo)
120 mbar for rod travel between 1 and 4 mm
400 mbar for rod travel between 10 and 12 mm
> 450 mbar with rod at end of travel
Resistance: 0.45 0.05 at 20 C
ELTH
Resistance: 2252 112 at 25 C
13-3
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Special notes
13
The Common Rail high-pressure injection system is designed to deliver a certain quantity of diesel fuel to the
engine at a precisely determined moment.
DESCRIPTION
The system consists of:
a low-pressure pump (1) (located in the fuel tank),
a fuel filter (2),
a priming valve (3),
a high-pressure regulator (4) mounted on the pump (it is forbidden to separate the regulator from the pump. If there
is a fault in one component, both must be replaced),
a high-pressure pump (5),
an injection rail (6) fitted with a diesel fuel pressure sensor and a pressure limiter (7),
four solenoid injectors,
various sensors,
an injection computer.
Dismantling the interior of the high-pressure pump and the injectors is prohibited.
13-4
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Special notes
13
OPERATION
The Common Rail high-pressure direct injection system is a sequential diesel injection system (based on the
multipoint injection system for petrol engines).
This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and
produces high engine torque at low engine speeds thanks to a pre-injection procedure.
The low-pressure pump (also known as the booster pump) feeds the high-pressure pump via the fuel filter during
the starting phase only.
The high-pressure pump generates the high pressure sent to the injector rail. The high-pressure regulator located on
the pump modulates the value of the high pressure via the computer. The rail supplies each injector through a steel
pipe.
The computer:
determines the value of injection pressure necessary for the engine to operate correctly and then controls the
pressure regulator. It checks that the pressure value is correct by analysing the value transmitted by the pressure
sensor located on the rail,
determines the injection time necessary to deliver the right quantity of diesel and the moment when injection should
start,
controls each injector electrically and individually after determining these two values.
The injected flow to the engine is determined by:
the duration of injector control,
the injector opening and closing speed,
the needle travel (determined by the type of injector),
the normal hydraulic flow of the injector (determined by the type of injector),
the high-pressure rail pressure controlled by the computer.
THE CLEANLINESS AND SAFETY ADVICE SPECIFIED IN THIS DOCUMENT MUST BE FOLLOWED DURING
ANY WORK CARRIED OUT ON THE HIGH-PRESSURE INJECTION SYSTEM.
13-5
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Special notes
13
POST-REPAIR CHECK
Re-prime the circuit. To do this, turn the low-pressure pump over by switching on the ignition several times, or turn
the low-pressure pump over with the diagnostic tool using the Actuator Commands menu.
After any operation, check that there are no diesel fuel leaks. Run the engine at idle speed until the engine
cooling fan starts up, then accelerate several times with no load.
IMPORTANT: the engine must not be run with diesel fuel containing more than 10% diester.
The system injects the diesel fuel into the engine at a pressure of up to 1350 bar. Before carrying out any
work, check that the injector rail is depressurized.
It is absolutely vital that you observe the tightening torque:
of the high-pressure pipes,
of the cylinder head injector,
of the pressure sensor.
When the high-pressure pump, injectors and high pressure supply, output and return unions are removed
or repaired, all openings should be fitted with new blanking plugs of the correct size to prevent
contamination entering.
When replacing the high-pressure pipe, follow the method below:
remove the high-pressure pipe,
fit anti-contamination plugs,
loosen the high-pressure rail,
fit the high-pressure pipe,
torque-tighten the union at the injector side,
torque-tighten the union at the high-pressure rail side,
torque-tighten the high-pressure rail mountings,
torque-tighten the pump/rail pipe (pump side first).
13-6
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Special notes
Dismantling the interior components of the pump is prohibited.

The fuel return pipe fitted to the injectors must be replaced when it is removed.
The diesel temperature sensor cannot be removed. It is part of the fuel return rail.
Loosening a High-pressure pipe connection when the engine is running is prohibited.
It is forbidden to remove the pressure regulator from the pump (type CP3).
13-7
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Cleanliness
13
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 contamination are:
damage to or destruction of the high-pressure injection system,
a component seizing or leaking.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a
few microns in size) should get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter through to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
metal or plastic chips,
paint,
fibres:
boxes,
brushes,
paper,
clothing,
cloths,
foreign bodies such as hairs,
ambient air,
etc.
IMPORTANT: it is not possible to clean the engine using a high-pressure washer because of the risk of damaging
connections. Furthermore, moisture may collect in the connectors and cause electrical connection problems.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM
Ensure that you have the plugs for the unions to be opened (bag of plugs available from the Parts Stores). Plugs
are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not
sufficient to make them reusable). Unused plugs must be thrown away.
Ensure that you have the resealable plastic bags for storing removed parts. There is less risk of parts stored in this
way being exposed to contamination. The bags must be used only once, and after use they must be thrown away.
Make sure that lint-free towelettes are to hand. Towelette part number: 77 11 211 707. The use of conventional
cloth or paper wipes is prohibited. They are not lint-free and may contaminate the fuel circuit of the system. Each
lint-free cloth should only be used once.
13-8
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Cleanliness
13
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
Use new thinner for each operation, (used thinner contains impurities). Pour it into a clean receptacle.
For each operation, use a clean brush in good condition (the brush must not shed its bristles).
Use a brush and thinners to clean the connections to be opened.
Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection
system zone). Check that no bristles remain adhered.
Wash your hands before and during the operation if necessary.
When wearing leather protective gloves, cover them with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The
plugs to be used are available from the Parts Stores. They must not, under any circumstances, be reused.
Close the resealable bag, even if it has to be reopened shortly afterwards. Ambient air carries impurities.
All components removed from the injection system must be stored in a hermetically sealed plastic bag once the
plugs have been inserted.
The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened.
In fact, these elements are liable to cause the entry of impurities into the system.
A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle.
13-9
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Cleanliness
13-10
vnx.su
13
F9Q ENGINE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DIESEL EQUIPMENT
Location of components
Diesel fuel filter with heater

Camshaft sensor
Air flowmeter with air temperature sensor
Thermoplunger unit
Turbocharger regulation solenoid valve
Turbocharging pressure sensor
Injection computer
Impact sensor
Preheating unit
Coolant temperature sensor
Engine speed sensor
Solenoid injector
High-pressure pump
13-11
vnx.su
13
DIESEL EQUIPMENT
F9Q ENGINE
1
2
3
4
5
6
7
High-pressure pump
Common injection rail
Injector
Pressure regulator
Pressure sensor
Fuel temperature sensor
Pressure limiter
13-12
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Cylinder marking sensor
12 Exhaust gas recirculation system valve

13 Thermoplunger unit
9 Priming catalytic converter

10 Turbocharger
11 Airflow sensor with integrated temperature sensor
13-13
14 Turbocharger regulation solenoid valve

15 Turbocharger pressure sensor
16 Preheating unit
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
17 Fuel filter
19 Injection computer
18 Impact sensor
20 Accelerator potentiometer
13-14
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Injection warning light
13
Vehicles using the high-pressure diesel fuel system are fitted with two injection warning lights. These warning lights
are used during the preheating phase and when there is an injection fault.
PRINCIPLE FOR WARNING LIGHTS COMING ON
The preheating warning light comes on when the ignition is switched on, remains lit during the preheating phase
and then goes out (see section 13 Pre/post-heating control).
When there is an injection fault (severity level 1), the fault warning light which is also the preheating warning light
comes on permanently, indicating the need to consult a Renault Dealer. These faults are:
internal computer fault,
engine immobiliser fault,
engine speed fault (vehicle does not start),
accelerator potentiometer fault,
air flowmeter fault,
vehicle speed sensor fault,
exhaust gas recirculation valve fault,
turbocharger regulation solenoid valve fault,
turbocharging pressure sensor fault,
Top Dead Centre sensor and camshaft sensor synchronisation fault.
When there is a serious injection fault (level 2), the warning light with the symbol of an engine and the word STOP
flashes to indicate that the vehicle must be stopped immediately. These faults are:
internal computer fault,
injector fault,
computer supply voltage fault,
rail pressure sensor fault,
rail pressure regulator fault,
Top Dead Centre sensor and camshaft sensor synchronisation fault.
If the engine overheats, the warning light with the engine symbol and the word STOP remains lit.
13-15
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Immobiliser function
13
This vehicle is fitted with an engine immobiliser system which is controlled by a key recognition system.
REPLACING AN INJECTION COMPUTER
Injection computers are supplied without a code, but they can all be programmed with one.
If a computer is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine
immobiliser function must be ensured.
To do this, switch on the ignition for a few seconds without starting the engine, then switch it off. With the ignition off,
the engine immobiliser function comes into operation after approximately 10 seconds (the red engine immobiliser
warning light flashes).
SPECIAL NOTES ON TESTING THE INJECTION COMPUTER
WARNING:
These vehicles have a special injection computer which does not operate unless it is coded.
Consequently, it is strongly recommended not to carry out tests using computers borrowed from the stores or from
another vehicle, to prevent coding and uncoding problems which could render the computers useless.
13-16
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Injection/air conditioning programming
13
THIS VEHICLE IS FITTED WITH A VARIABLE DISPLACEMENT COMPRESSOR

There is no air conditioning computer on this type of engine. The injection computer controls the compressor clutch
according to the request for the compressor to operate (Air conditioning function requested by the driver), which
can be interrupted at any moment by the coolant pressure sensor.
The tracks used for the air conditioning function are:
one wire on track A F4 of the computer which controls the air conditioning compressor clutch,
one wire on track A G4 of the injection computer. This wire carries the request for the compressor to start operating.
When the air conditioning function is selected, the idle speed does not change; it is
800 rpm.
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the injection computer prevents the compressor from operating.
Engine starting program
The compressor is prevented from operating for 2 seconds after the engine has started.
Recovery of output when the vehicle starts moving
If the potentiometer position is greater than 45%, and the vehicle speed is below 15 mph (25 km/h), the compressor
is cut off.
Anti-stall protection
During vthrottle-off, if the engine speed is below 675 rpm, the compressor clutch is disengaged. It is re-engaged
when the engine speed exceeds this figure.
Thermal protection program
The compressor does not come into operation when the coolant temperature is greater than + 102 C.
13-17
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Idle speed correction
13
IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
X: Engine speed in rpm.

Y: Coolant temperature in C
CORRECTION ACCORDING TO ELECTRICAL LOAD
The purpose of this adjustment is to compensate for the drop in voltage due to a power consumer being switched on
when the battery is not charged sufficiently. To achieve this, the idle speed is increased, which increases the speed
of rotation of the alternator, and this increases the battery voltage.
The lower the voltage, the more significant the correction. Correction of the engine speed is therefore variable. It
begins when the voltage drops to below approximately 12 V. Idle speed may reach a maximum speed of 900 rpm.
IDLE SPEED CORRECTION WHEN THE POTENTIOMETER IS FAULTY
If the idle speed is held at 1250 rpm. if the accelerator pedal potentiometer is faulty.
If the signal from the accelerator pedal position potentiometer and the brake switch signal are inconsistent, the
speed is changed to 1250 rpm.
IDLE SPEED CORRECTION WHEN DRIVING
The travelling idle speed is modified according to the gear engaged in the gearbox:
in 1st and 2nd gear, the idle speed is 825 rpm,
for other gears the speed is 870 rpm.
IDLE SPEED LIMITATION WHEN STATIONARY
If the vehicle is stationary with a gear engaged (clutch pedal depressed), then the maximum engine speed is limited
to 3000 rpm.
13-18
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Pre/postheating control
The pre/postheating function is controlled by the

preheating unit.
13
2) Starting the engine

The plugs remain supplied while the starter is being
activated.
PRE/POSTHEATING OPERATING PRINCIPLE

1) Switching on the preheating
3) Engine running, postheating

a) Variable preheating
During this phase, the plugs are supplied
continuously according to the coolant temperature.
The length of time that the warning lights are on

and the heater plugs supply depends on the
coolant temperature and the battery voltage.
For idle speed without pressing the accelerator pedal.
X
Y
Time in seconds
Coolant temperature in C
X
Y
In all cases the preheating warning light cannot

light up for more than 10 seconds.
b) Fixed preheating
After the warning light goes out the plugs remain
supplied for a fixed period of 10 seconds.
13-19
vnx.su
Time in seconds
F9Q ENGINE
DIESEL EQUIPMENT
Preheater plugs
13
The preheating plug resistance is 0.6 (connector

disconnected).
Pre-heater plugs
1.5
Plugs may be removed without having to open the

high-pressure circuit.
REMOVAL
Unclip the plug connector.
Clean the outside of the plug to avoid any impurities
entering the cylinder.
Loosen and remove the plugs.
REFITTING
Ensure that no contamination enters the cylinder
during this operation.
13-20
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Thermoplunger
The four thermoplungers are located on a water unit

mounted on the engine lifting bracket.
13
Control strategy
The purpose of the system is to reheat the coolant.
When the thermoplungers are operating the idle speed

is brought to 825 rpm.
The thermoplungers are supplied with 12 V by three

relays. One relay controls two thermoplungers, the two
other relays control one thermoplunger each. This
enables control of one, two, three or four
thermoplungers as required.
Thermoplungers cannot operate:

preheating,
post-heating,
if the engine speed is below 700 rpm,
heated windscreen on.
The resistance of the thermoplungers is:

0.45 0.05 at 20 C.
If the conditions mentioned above apply, the

thermoplungers are controlled according to a mapping
related to the air and coolant temperature.
X
Y
Air temperature in C
Non-shaded area: thermoplunger not supplied

Shaded area: thermoplunger supplied
13-21
vnx.su
DIESEL EQUIPMENT
Thermoplunger
F9Q ENGINE
13
If the battery voltage is > 13.5 V
If not
Then
Thermoplungers not supplied
One thermoplunger is supplied
If after 20 seconds the battery

voltage is > 13.5 V
If not
Then
Two thermoplungers supplied

voltage is > 13.5 V
If not
Then
Three thermoplungers supplied

voltage is > 13.5 V
If not
Then
Four thermoplungers are supplied if

the battery voltage is > 13.5 V and in
the conditions mentioned above
13-22
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Low pressure pump (booster pump)
13

Mot. 1397
Fuel pump securing nut
IMPORTANT:
During all operations on the fuel tank or fuel supply
circuit, it is vital to:
refrain from smoking or bringing incandescent
objects close to the work area,
protect yourself against diesel fuel splashes when
the pipes are removed (due to residual pressure).
Disconnect:
anti-splashback pipe (1),
fuel tank filler neck (2).
REMOVAL
WARNING: before removing any components, take
precautions to trap fuel running out of the pipes (do not
clamp pipes, this could damage them).
Remove the fuel tank filler pipe access flap.
Place a component jack under the tank to hold it.
13-23
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
13
Remove the fuel tank mounting bolts (3).
Remove the pump mounting nut (7) using tool

Mot.1397.
Lower the tank slightly to be able to gain access to the
fuel pipes and the electrical wiring.
Allow any fuel in the sender unit to drain, then remove

the pump-sender assembly, taking care not to damage
the float.
Disconnect:
pump electrical connector (4),
fuel return pipe (5),
fuel outlet pipe (6).
NOTE: if it is anticipated that several hours will elapse

between removal and refitting of the pump-sender
assembly, screw the nut back on the fuel tank to
prevent any distortion.
Remove the fuel tank and drain it if necessary.
13-24
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
REFITTING
Replace the sealing gasket.
Refit the pump/sender assembly, positioning the mark
on the sender unit (8) opposite the three raised lines
(9) on the tank.
Refit the nut and tighten to a torque of 6 daNm.
After tightening, check that the mark (8) on the pump/
sender assembly does in fact line up with the marks
(9) on the tank.
For the other refitting operations, proceed in the

reverse order to removal.
Re-prime the circuit. To do that, turn the low-pressure
pump over by switching on the ignition several times,
or turn the low-pressure pump over with the diagnostic
tool using the Actuator Commands menu.
13-25
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Fuel filter
The fuel filter is located in the engine compartment. It

is contained in a removable cartridge. This cartridge
contains a diesel fuel heater.
13
Unscrew the filter cover (4) and remove the filter

cartridge.
To replace the filter it is therefore necessary to remove

the whole unit.
REMOVAL
FOLLOW THE CLEANLINESS INSTRUCTIONS
CLOSELY
WARNING: watch out for the residual pressure and
the quantity of diesel fuel remaining in the pipes.
Disconnect from the filter:
the diesel fuel heater connector (1),
the fuel supply pipe to the engine (2),
the pipes (3) coming from the tank,
REFITTING
Remove the filter by unclipping it from its support.
Take care to line up the mark on the cover and the

mark on the bowl correctly.
It is vital to respect the position of the connections to
the filter.
Be careful not to squeeze or damage the pipes.
IMPORTANT: re-prime the system by switching on the
ignition several times, or turn the low-pressure pump
over with the diagnostic tool using the Actuator
Commands menu.
From time to time it is necessary to bleed the water
trapped in the diesel fuel filter via the bleed plug (5).
13-26
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Checking diesel pressure and flow
13
It is possible to check the pressure and flow in the low-pressure fuel circuit.
The low pressure is provided by the booster pump (electric pump fitted in the fuel tank which feeds the high-pressure
pump during starting phases).

Mot. 1311-01
or
Mot. 1328
Fuel pressure test kit
Mot. 1311-03
I adapter for fuel pressure test

kit
EQUIPMENT REQUIRED
2000 ml graduated cylinder
LOW PRESSURE CHECK (BOOSTER PUMP)
FLOW TEST (BOOSTER PUMP)
Fit an I adapter, Mot. 1311-03, to be able to connect

the fuel pressure test kit Mot. 1311-01 to the outlet (2)
of the fuel filter.
Make the pump flow into a 2000 ml graduated cylinder.

Turn on the ignition to run the pump. The pump is
supplied for 10 seconds if the engine is not started.
Turn over the fuel pump with the diagnostic tool or by

direct feed to the pump or by switching on the ignition.
The flow read should be 80 to 100 l/h minimum.

WARNING: it is forbidden to measure the pressure
and flow of the high-pressure pump.
Read the pressure, which should be 2.5 bar

maximum.
13-27
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
DISMANTLING THE PUMP INTERNALS IS
PROHIBITED
Mot. 1054
TDC setting pin
Mot. 1383
Tool for removing and refitting

the high-pressure pipes
Mot. 1200-02
Pump pulley retaining tool
Mot. 1525
Pulley extractor
Mot. 1525-01
Extractor claws for F9Q
Mot. 1367
Engine support bar
Mot. 1367-02
Engine support tool

EQUIPMENT REQUIRED
Low torque wrench
TIGHTENING TORQUE (in daNm and/or )

High-pressure pipe
2.5 0.2
High-pressure pump mounting
3 0.3
Rear pump support mounting
3 0.3
High-pressure pump pulley nut 1.5 then 60 10

Injection rail mounting bolt
2.2 0.2
WARNING: before carrying out any work, connect

the diagnostic tool to the injection computer and check
that the injection rail is not pressurized.
Make a note of the fuel temperature.
13-28
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
radiator grille mounting screws (6),
radiator grille.

CLOSELY
REMOVAL
Disconnect:
the battery,
heater unit connector (1).
Remove:
heater unit bolt and three nuts (2),
heater unit.
Disconnect the headlight units.

Remove:
both headlight unit mounting bolts (7),
the headlight units.
Disconnect:
Remove:
air filter unit mounting bolts (5),
13-29
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
Remove:
bonnet catch (8),
upper bumper mounting bolts (9),
air/air heat exchanger air inlet and outlet pipes,
13
bolt through the bumper (11),

front upper cross member central mounting bolts
(12), then the reinforcing strut,
cooling radiator mounting bolts (13),
computer shield mounting bolt (14),
front upper cross member mounting bolts (15),
upper cross member by pivoting it round the bumper.
air/air heat exchanger air inlet and outlet pipes (10),
13-30
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
Disconnect:
pressure regulator (1),
pressure sensor (2),
fuel temperature sensor (3).
13
High-pressure pipes using tool Mot. 1383, then fit

plugs,
Move the electrical wiring loom aside.
Remove:
diesel fuel supply and return pipes, then fit plugs,
13-31
vnx.su
rail mounting bolts (4),

the rail,
rear pump support mounting bolts (5),
the rear pump support.
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
13
Set the engine to Top Dead Centre using pin

Mot. 1054.
Place the pulley retaining tool Mot. 1200-02 in position

on the pulley.
Put the engine support tools Mot. 1367 and

Mot. 1367-02 in position.
Remove:
High-pressure pump gear nut (2).
Remove the suspended engine mounting.
High-pressure pump mounting nuts (3).

Remove:
timing cover screws (1),
the timing cover.
13-32
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
Position the F9Q extractor claws for Mot. 1525-01,
then the pulley extractor Mot. 1525.
Extract the pump by tightening the thrust bolt (4) of the
pulley extractor.
13-33
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
13
REFITTING
Refitting the rail and the High-pressure pipes
Leave removal of the protection plugs from any

component until last.
Refit the rail and hand-tighten the mounting bolts

without tightening them (the rail must be loose).
For refitting operations, proceed in the reverse order to

removal.
Refit the High-pressure pipes by hand-tightening the

nuts at the pump and injectors end, then the rail end.
NOTE: be careful not to put the High-pressure pipes or

the rear pump support under any strain.
Tighten the rail mounting bolts (3) to a torque of

2.2 daNm.
To do this:
Torque-tighten the High-pressure pipes to 2.5 daNm,

tightening the nuts at the pump and injectors end first,
then the rail end.
Refitting the rear pump support

Refit the rear pump mounting and hand-tighten the
mounting bolts so as to bring the mounting into contact
with the cylinder head and the pump.
Torque-tighten the rear pump support mounting bolts
to 3 daNm, tightening bolt (1) on the pump first, then
bolts (2) on the cylinder head.
13-34
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
High-pressure pump
The diesel fuel return pipe (4) must be replaced every
time it is removed.
Refit the suspended engine mounting (refer to the

procedure in Section 19).
The remaining refitting operations are performed in the
Commands menu.
13-35
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Injector rail
13

Mot. 1383

EQUIPMENT REQUIRED
Low torque wrench

High-pressure pipe
2.5 0.2
2.2 0.2
Pressure sensor
3.5 0.2
IMPORTANT: before carrying out any work, connect

the diagnostic tool, establish dialogue with the injection
computer and check that the injection rail is no longer
pressurized.
13-36
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Injector rail

CLOSELY
REMOVAL
Disconnect:
heat exchanger air intake pipe (2),
Disconnect:
pressure regulator (6),
pressure sensor (7),
fuel temperature sensor (8).
Move the electrical wiring loom aside.

Remove:
the air filter unit.
13-37
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Injector rail
Remove:
diesel fuel supply and return pipes, then fit plugs,
13
REFITTING
Refit the rail and hand-tighten the mounting bolts
without tightening them (the rail must be loose).
Refit the High-pressure pipes by hand-tightening the
nuts at the pump and injectors end, then the rail end.
Tighten the rail mounting bolts (3) to a torque of
2.2 daNm.
Torque-tighten the High-pressure pipes to 2.5 daNm,
tightening the nuts at the pump and injectors end first,
then the rail end.
High-pressure pipes using tool Mot. 1383, then fit

plugs,
rail mounting bolts (9),

the rail.
13-38
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Injector rail
time it is removed.

Commands menu.
13-39
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Injectors
13
IT IS FORBIDDEN TO DISMANTLE THE INSIDE OF

AN INJECTOR OR TO SEPARATE THE INJECTOR
HOLDER FROM THE NOZZLE.
Mot. 1383

EQUIPMENT REQUIRED
Low torque wrench

High-pressure pipe
2.5 0.2
2.2 0.2
Injector clamp mounting bolt
2.5 0.5

computer and check that the injection rail is not
pressurized.
13-40
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Injectors

CLOSELY
NOTE: injectors may be replaced individually.
REMOVAL
Disconnect:
diesel fuel return pipe, then fit plugs,

Remove:
13-41
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Injectors
13
Remove the high-pressure pipe using tool Mot. 1383.
REFITTING
Fit anti-pollution plugs.

Disconnect the injector connector.

Change the washer beneath the injector.
Remove:
the injector mounting clamp,
the injector,
the flame shield washer.
Refit the injector.

Torque-tighten the injector flange bolts to 2.5 daNm.
CLEANING
NOTE: be careful not to place the High-pressure pipes

under any strain.
It is absolutely forbidden to use the following when

cleaning the injector:
a wire brush,
an emery cloth,
an ultrasonic cleaner.
To do this:
undo the injection rail (the rail should be loose),
refit the High-pressure pipes by hand-tightening the
nuts at the injectors end first,
tighten the rail mounting bolts to a torque setting of
2.2 daNm,
torque-tighten the High-pressure pipes to 2.5 daNm,
tightening the nuts at the injectors end first.
To clean the nose of the injector, let it soak in

degreaser, then wipe it with a lint-free cloth.
13-42
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Injectors
time it is removed.

Commands menu.
13-43
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Pressure sensor

Pressure sensor
3.5 0.2

computer and check that the injection rail is not under
pressure.
Remove:

REMOVAL
Disconnect:
13-44
vnx.su
13
F9Q ENGINE
DIESEL EQUIPMENT
Pressure sensor
Disconnect the pressure sensor (6).
13
REFITTING
Replace the seal.
Screw in the sensor and torque-tighten it to 3.5 daNm.
Connect the sensor.
Commands menu.
Remove the pressure sensor (7).
13-45
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Accelerator potentiometer
GENERAL INFORMATION
13
Track allocation:
The accelerator pedal potentiometer is incorporated in

the accelerator pedal. Its replacement therefore
requires replacement of the accelerator pedal.
Track
REMOVAL
Disconnect:
the battery,
the accelerator pedal connector (1).
Remove:
the three pedal mounting bolts (2),
the pedal.
Description
Track 2 earth
Track 1 earth
Track 1 signal
Track 1 feed
Track 2 feed
Track 2 signal
NOTE: a fault on the accelerator position

potentiometer causes variations in the idle speed or
engine operation (see Section 13 Idle speed
correction).
REFITTING
13-46
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Central coolant temperature management
13
OPERATION
The injection computer uses the coolant temperature
to control:
the injection system,
the fan relay:
the cooling fan is activated at low speed then at
high speed if the coolant temperature exceeds
90 C and stops when the temperature falls below
95 C,
the fan unit can be controlled by the air
conditioning.
COOLANT TEMPERATURE WARNING LIGHT
The warning light is controlled by the computer via the
multiplex network.
It lights up when the coolant temperature exceeds
115 C and goes out when the temperature falls below
110 C.
The coolant temperature sensor (1) (injection and
coolant temperature indicator on the instrument panel)
is a three-track sensor.
Two tracks for the coolant temperature signal to the
computer (tracks B E1 and B K3).
This system allows the engine cooling fan to be
controlled by the injection computer. It consists of a
single temperature sensor used for the injection, the
engine cooling fan, the temperature indicator and the
temperature warning light on the instrument panel.
13-47
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Computer
13
GENERAL INFORMATION
The injection computer is located behind a sheet metal
shield under the expansion bottle.
REMOVAL
Remove the expansion bottle mounting screw (1) and
move it out of the way.
Disconnect:
the turbocharger regulation solenoid valve (2),
the turbocharging pressure sensor (3) and unclip it,
the preheating unit.
computer mounting bolts (5) and remove it, having

disconnected it beforehand.
Remove:
metal shield mounting bolts (4) and remove it from
above,
REFITTING
Proceed with refitting in the reverse order to removal.
If the computer has been replaced, carry out
programming of the immobiliser code by following the
procedure described in the Section Immobiliser.
13-48
vnx.su
F9Q ENGINE
DIESEL EQUIPMENT
Computer
13
TRACK ALLOCATION
CONNECTOR A
A3
A4
B1
B3
B4
--
--
C1
C3
E1
E2
E4
F1
F3
F4
G4
H2
--
---
Load potentiometer earth (track 2)

CAN L MULTIPLEX LINK (Passenger compartment)
Heated windscreen input
Load potentiometer earth (track 1)
CAN H MULTIPLEX LINK (Passenger
compartment)
Load potentiometer signal input (track 1)
Fault finding
Load potentiometer feed (track 1)
Clutch switch input
Vehicle speed input
Load potentiometer signal input (track 2)
Brake switch input
Air conditioning compressor control output
Air conditioning request input
Load potentiometer feed (track 2)
CONNECTOR B
B2
---
B3
C1
C2
C3
D1
D3
D4
E1
E3
F2
-------
F3
G1
G2
G3
H2
H3
H4
J2
J3
K3
L1
L2
L3
L4
M1
----
--
--
----
M2
M3
M4
-------
13-49
vnx.su
Exhaust gas recirculation system position

potentiometer earth
Plugs fault-finding input
Turbocharger pressure sensor signal input
potentiometer signal output
Preheating control relay
Diesel fuel pressure sensor input
Air temperature sensor input
Feed control relay output
Coolant temperature sensor earth
+ After ignition
potentiometer supply
Thermoplunger control relay 2 output
(2 thermoplungers)
Fuel temperature sensor earth
Air flowmeter feed
Engine speed sensor signal
Diesel pressure sensor supply
Engine speed sensor signal
Air flowmeter sensor signal input
Turbocharging pressure sensor feed
Fuel temperature input
Coolant temperature sensor input
High-pressure regulation valve output
Turbo regulation solenoid valve output
Power earth
Power earth
Exhaust gas recirculation system solenoid valve
control output
+ After relay
+ After relay
Power earth
F9Q ENGINE
DIESEL EQUIPMENT
Computer
13
CONNECTOR C
A1
A2
A3
A4
B3
B4
C1
E4
------
--
J4
K4
L1
L2
L3
L4
M1
M2
M3
M4
----
-----
13-50
vnx.su
Booster pump control output

Low speed fan assembly relay control outlet
Air flowmeter earth
Turbocharger pressure sensor earth
Diesel pressure sensor earth
High speed fan assembly relay control outlet
Camshaft sensor earth
(1 thermoplunger)
(1 thermoplunger)
Camshaft position sensor signal
Injector 4 control
Injector 3 feed
Injector 2 feed
Injector 2 control
Injector 1 control
Injector 3 control
Injector 1 feed
Injector 4 feed
113
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
Fault finding - Introduction
13
This document presents the fault finding procedure applicable to computers with part number 82 00 051 603
for F9Q 762 engines, and part number 82 00 051 600 for F9Q 760 engines.
EDC15C3C, Program No. CB, Vdiag No. 0C equipping: Primastar vehicle
To run diagnostics on this system, it is essential to have the following items:
the wiring diagram of the function for the vehicle concerned,
The Workshop Repair Manual for the vehicle in question,
the tools listed under the Special Tooling Required section.
DIAGNOSTIC PROCEDURE:
Use one of the diagnostic tools for identifying the system fitted on the vehicle (reading the computer type, program
number, Vdiag number, etc.).
Locate the Fault finding documents corresponding to the system identified.
Read the information provided in the Introductory section.
Read the faults in the computer memory and use the Interpretation of faults section of the documentation.
REMINDER: each fault is interpreted for a given type of storage (fault present, fault stored, fault present or stored).
The checks defined for handling each fault are therefore only to be performed if the fault stated by the diagnostic tool
is described for its type of storage. The type should be considered when the diagnostic tool is switched on after the
ignition has been turned off then back on.
If a fault is interpreted when it is declared stored, the conditions for applying fault finding procedures are shown in
the NOTES box. When these conditions are not satisfied, use the fault finding procedure to check the circuit of the
faulty part, since the fault is no longer present on the vehicle. Follow the same procedure when a fault is declared as
stored by the diagnostic tool but is only interpreted in the documentation for a present fault.
Carry out the conformity check (appearance of possible faults not yet identified by the system's self-diagnostic
procedure) and implement the associated fault finding procedure according to the results.
Confirm the repair (customer complaint disappears).
Implement the diagnostic procedure for each "Customer complaint" according to the "fault finding charts", if the
problem persists.
TOOLING REQUIRED:
Diagnostic tool: Consult II
Bornier part number: El. 1613 (necessary to avoid damaging the injection computer connector terminals).
IMPORTANT:
Any fault finding which requires an operation on the direct high pressure injection system
requires a comprehensive knowledge of the cleanliness and safety instructions as set out
in this Workshop Repair Manual, section 13.
13-1
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF001
PRESENT
OR
STORED
1.DEF
DIESEL INJECTION
Fault finding - Fault Interpretation
13
COMPUTER
1.DEF : Internal electronic fault.
NOTES
None.
If the fault is stored, clear the fault from the computer memory.
Switch off the ignition, then switch it on again to initialise the computer.
If the fault reappears, replace the engine management computer.
If necessary, modify the configuration of the new computer to match the equipment options present on the
vehicle.
If the fault is present, replace the engine management computer.
vehicle.
AFTER REPAIR
Deal with any other possible faults. Clear the faults from the computer memory.
Switch the ignition off and carry out a road test followed by a check with the diagnostic
tool.
13-2
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF002
PRESENT
OR
STORED
NOTES
CC.0
DIESEL INJECTION
13
COOLANT TEMPERATURE SENSOR CIRCUIT

CC.0 : Short circuit to earth
CO.1 : Short circuit or open circuit to + 12 V
1.DEF : Coolant operating temperature not attained
Conditions for applying the fault finding procedure to stored faults:
If the fault is declared present after:
the fault has been cleared
and the engine has been running for 1 minute.
Special notes
Use bornier El. 1613 for all operations on the engine management computer
connectors.
Use a workshop temperature sensor to compare the temperatures.
NOTES
None.
Check the coolant temperature sensor connectors.

Check the connectors on the engine management computer.
Repair if necessary.
Measure the resistance of the coolant temperature sensor between terminals 2 and 3 of its connector.
Replace the sensor if the Negative Temperature Coefficient is not approximately:
2252 112 at 25C.
811 39 at 50C.
283 8 at 80C.
Ensure insulation against earth of the connection between:
Engine management computer, connector B track2
Ensure continuity of the connection between:
Engine management computer, connector B track3
CO.1
NOTES
K3 track 3 coolant-temperaturesensor connector.

E1 track 2 coolant-temperaturesensor connector,
None.

Measure the resistance of the coolant temperature sensor between terminals 2 and 3 of the connector.
2252 112 at 25C.
811 39 at 50C.
283 8 at 80C.
Check the continuity and insulation relative to + 12 V on the connections between:
Engine computer, connector B track E1
Track 2 coolant temperature sensor
connector
Engine management computer, connector B track K3
connector
AFTER REPAIR
Switch off the ignition and carry out a road test followed by a check with the diagnostic
tool.
13-3
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF002
CONTINUED
1.DEF
NOTES
Conditions for applying the fault finding procedure to

stored faults:
The fault is declared present after:
a delay of 3.3 minutes with the engine running.
Special notes:
Use a workshop temperature sensor to compare the values.

Compare the engine temperatures indicated on the instrument panel and by the diagnostic tool "parameter"
screen with those indicated by the "workshop" temperature sensor.
If there is a significant difference, replace the engine temperature sensor.
or
Measure the resistance of the coolant temperature sensor between terminals 2 and 3 of its connector.
2252 112 at 25C.
811 39 at 50C.
283 8 at 80C.
Check the continuity and insulation against earth of the connection between: (connectors disconnected)
Engine management computer, connector B track K3
connector
Check the continuity and insulation relative to + 12 V on the connection between (connectors disconnected):
Engine management computer, connector B track E1
connector
Measure the line resistance of the following connections:
Track E1, connector B computer
Track 2 coolant temperature sensor connector
Track K3, connector B computer
Track 3 coolant temperature sensor connector
Carry out the necessary operations if the resistance is abnormally high.
With the engine cold, check the closed position of the thermostat.
Start of opening: 83C.
Check the level and leaktightness of the coolant circuit, see section 19 of the Workshop Repair Manual.
Carry out the necessary repairs.
AFTER REPAIR
tool.
13-4
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF012
PRESENT
OR
STORED
DIESEL INJECTION
13
BATTERY VOLTAGE
1.DEF : Voltage too low
2.DEF : Voltage too high

starting and a delay of 30 seconds with the engine running.
NOTES
Special notes:
If necessary, perform a complete check of the charge circuit using the Consult II
diagnostic tool.
1.DEF
NOTES
None.
Carry out the operations necessary to obtain the correct computer supply:
9 V < operating voltage < 14.5 V.
Using a multimeter, check the battery voltage directly at the terminals, then compare with the value displayed
by the diagnostic tool in Parameters menu PR004.
If there is no difference:
Recharge and test the battery and replace it if it is faulty.
Next check the charge circuit.
If there is a difference:
Check the condition of engine fuse F2 (corrosion, poor contact at terminals, etc.).
Check the tightness and the condition of the battery terminals.
Make sure there is no interference resistance on the power supply to the engine management computer:
Engine fuseholder (F2)
tracks M2 and M3 of connector A of the engine management computer
Earths
tracks L3, L4, M4 of connector A of the engine management computer
2.DEF
NOTES
None.
Carry out the operations necessary to obtain the correct computer supply:
9 V < operating voltage < 14.5 V.
Check the charging circuit.
AFTER REPAIR
tool.
13-5
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF015
PRESENT
OR
STORED
NOTES
1.DEF
DIESEL INJECTION
13
IMMOBILISER

Apply the fault finding strategy if the fault is either present or stored.
NOTES
None.
If the fault is stored, clear the fault from the computer memory.
vehicle.
vehicle.
AFTER REPAIR
tool.
13-6
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF019
PRESENT
OR
STORED
NOTES
CO.0
DIESEL INJECTION
13
AIR FLOW SENSOR CIRCUIT

CO.0
CC.1
1.DEF
2.DEF
:
:
:
:
Open circuit or short circuit to earth, engine running

Short circuit to + 12 V, engine running
Sensor supply fault
Signal inconsistency

If the fault reappears as stored after:
the engine has been running at varying speeds for 5 minutes.
Special notes:
connectors.
NOTES
Priority in the event of a combination of faults:

In the event of the simultaneous presence of fault DF022:
Air temperature sensor circuit CO.1, check the connection
of the air flowmeter connector.
Check the air flowmeter connectors.

Check the connectors on the engine management computer. Repair if necessary.
Ensure continuity and insulation against earth of the connection between:
Engine management computer, connector B track H4
Track 5 of the air flowmeter connector.
Check the presence of + 5 V on track 3 of the air flowmeter connector.
Ensure insulation as follows:
between tracks 5 and 6 of the air flowmeter connector,
between tracks 2 and 5 of the air flowmeter connector.
If the fault persists after these checks, replace the air flowmeter.
CC.1
NOTES
None.

Check insulation against + 12 V on the connection between:
Check the continuity of the following connections:
Engine management computer, connector B track L3
Engine management computer, connector B tracks L3, L4 and M4
Engine management computer, connector C track A3
Engine management computer, connector B tracks M2 and M3
Track 5 air flowmeter connector

Track 6 of the air flowmeter
connector
Battery earth
connector
connector
If the fault persists after these checks, replace the air flowmeter.
AFTER REPAIR
tool.
13-7
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF019
CONTINUED 1
1.DEF
NOTES

Deal with the DF091: Sensor feed voltage no. 1 fault as a
priority if it is present or stored.

Check the continuity and insulation relative to + 12 V on the connection between:
Engine management computer, connector B track G2
Check the insulation between tracks 3 and 4 of the air flowmeter connector.
Check the following insulations:
between tracks 3 and 6 of the air flowmeter connector,
between tracks 3 and 2 of the air flowmeter connector.
Check the presence of + 12 V after relay on track 4 of the air flowmeter connector.
Check for the presence of earth on tracks 2 and 6 of the air flowmeter connector.
AFTER REPAIR
tool.
13-8
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF019
CONTINUED 2
2.DEF
NOTES

stored faults:
starting and a rise in temperature at idle speed exceeding
60C followed by a delay of 40 seconds
or
if it reappears as stored after the fault has been cleared,
the engine started, the ignition switched off, followed by
the completion of power-latch and the ignition being
switched off.
Deal with the DF077 EGR valve 1.DEF or 2.DEF fault as a
prioriaty if it is declared present.

Check the continuity and insulation relative to + 12 V and earth on the connection between:
Ensure the continuity and insulation relative to + 12 volts of the connection between:
Check the presence of + 12 V after relay on track 4 of the air flowmeter connector.
Check continuity of the connection between earth and track 6 of the air-flowmeter connector.
Make sure there are no foreign bodies on the flowmeter grille.
Ensure that the air inlet circuit is tight.
Check the oil-vapour recycling circuit (excess oil).
Carry out the required operations.
AFTER REPAIR
tool.
13-9
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF022
PRESENT
OR
STORED
DIESEL INJECTION
13
AIR TEMPERATURE SENSOR CIRCUIT

CO.1 : Open circuit or short circuit to + 12 V

the engine has been running for 2 minutes.
NOTES
Special notes:
connectors.
CC.0
NOTES
None.
Check the air temperature sensor connections (flowmeter).

Ensure insulation against earth of the connection between:
Engine management computer, connector B track D3
Check the presence of:
Track 1 of air temperature sensor

connector, (flowmeter)
+ 5 V on track 3 of the air flowmeter connector.
Measure the Negative Temperature Coefficient air temperature sensor resistance between tracks 1 and 2 of
the air flowmeter:
Replace the air flowmeter if the Negative Temperature Coefficient is not approximately:
3714 161 at 10C.
2448 90 at 20C.
1671 59 at 30C.
CO.1
NOTES
Priorit dans le traitement en cas de cumul de dfaut:

In the event of simultaneous presence of fault "DF019: air
flowmeter 2.DEF", check that the flowmeter connector is
properly mated.
Check the air temperature sensor connections (flowmeter).

Check the continuity and insulation relative to + 12 V on the following connections:
Engine management computer, connector B tracks D3
Track 1 air temperature sensor
connector
Engine management computer, connector C tracks A3
Track 2 air temperature sensor
connector
Measure the Negative Temperature Coefficient between tracks 1 and 2 of the air flowmeter:
Replace the air flowmeter if the Negative Temperature Coefficient is not approximately:
3714 161 at 10C.
2448 90 at 20C.
1671 59 at 30C.
AFTER REPAIR
tool.
13-10
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF040
PRESENT
OR
STORED
1.DEF
DIESEL INJECTION
13
AFTER IGNITION FEED

1.DEF : Inconsistency after initialisation
NOTES
None.
Check after ignition power supply to the engine management computer on connector B in track E3.
If necessary, check:
the condition of the engine fuseholders F2 and F4 (oxidation, crimping of wires at the terminals and
condition of terminals on the fuse side),
the integrity of the ignition switch,
the engine management computer connectors.
If the fault persists:
Clear the fault from the computer memory.
vehicle.
AFTER REPAIR
tool.
13-11
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF048
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
LOW SPEED FAN ASSEMBLY CIRCUIT

CC.1 : Short circuit to + 12 V
CO.0 : Open circuit or short circuit to earth

the fault memory has been cleared and
actuator command AC011: Low speed fan assembly relay
Special notes:
connectors.
CC.1
NOTES
None.
Perform a check on the connectors of low speed fan relay socket "R10" in the engine fuse and relay box.
Measure the resistance of the low-speed fan relay coil:
Replace the relay if the resistance is not approximately 65 5 at + 20C
Remove the low speed relay and check the insulation relative to + 12 V on the connection between:
Track 2 low speed fan relay socket
CO.0
NOTES
None.
Perform a check on the connectors of low speed fan relay socket "R10" in the engine fuse and relay box.
Measure the resistance of the low-speed fan relay coil:
Replace the relay if the resistance is not approximately 65 5 at + 20C
Ensure the continuity and insulation against earth of the connection between:
Track 2 of the low speed fan
assembly relay socket
Check the presence of 12 V after relay on track 1 of the low speed fan assembly relay socket.
AFTER REPAIR
tool.
13-12
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF049
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
HIGH SPEED FAN ASSEMBLY CIRCUIT


actuator command "AC012: High speed fan assembly relay".
Special notes
connectors.
CC.1
NOTES
None.
Perform a check on the connectors of high-speed fan relay socket R9 in the engine fuse and relay box.
Measure the resistance of the high-speed fan relay coil:
Replace the relay if the resistance is not approximately 60 5 at + 20C.
Remove the high speed relay and check the insulation relative to + 12 V on the connection between:
Engine management computer, connector C track B4
Track 2 of the high speed fan
CO.0
NOTES
None.
Perform a check on the connectors of high-speed fan relay socket R9 in the engine fuse and relay box.
Measure the resistance of the high-speed fan relay coil:
Replace the relay if the resistance is not approximately 60 5 at +20C.
Track 2 of the high speed fan
Check the presence of 12 V after relay on track 1 of the high speed fan assembly relay socket.
AFTER REPAIR
tool.
13-13
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF061
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
HEATER PLUG CIRCUIT

1.DEF : Heater plug(s) faulty or in open circuit

actuator command AC010: Preheating relay.
Special notes:
connectors.
1.DEF
NOTES
None.
Check the preheating unit connectors.

Check the connections on all the heater plugs.
Ensure that the engine is earthed.
Check the resistance of heater plugs: replace any plug in which the resistance is not 0.6 0.1 at 20C.
Ensure the continuity of the following connections:
Preheating unit track 1
Cylinder 3 heater plug,
Cylinder 2 heater plug.
Check that fuse no. 1 (70A) on the engine fuse and relay box is intact.
Check the presence of + 12 V battery on track 3 of the heater plug relay.
Check the continuity of the connection between:
Engine management computer, connector B track B3
Track 9 preheating unit connector.
If the fault persists, replace the preheating unit.
AFTER REPAIR
tool.
13-14
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF067
PRESENT
OR
STORED
DIESEL INJECTION
13
FUEL PRESSURE SENSOR CIRCUIT

CC.0
CO.1
1.DEF
: Short circuit to earth

: Open circuit or short circuit to + 12 V
: Sensor supply fault

NOTES
Special notes:
connectors.
IMPORTANT: It is forbidden to carry out an ohmmeter check on the pressure sensor.
CC.0
NOTES
None.
Check the fuel pressure sensor connectors.

Check the insulation against earth on the connection between:
Check continuity of the connection between:
Track 2 fuel pressure sensor connector

If the problem persists, replace the rail pressure sensor.
CO.1
NOTES
None.

Check the fuel pressure sensor connectors. Repair if necessary.
Check the continuity and insulation relative to + 12 V on the connection between:
Engine management computer, connector B track B3
If the problem persists, replace the rail pressure sensor.
AFTER REPAIR
tool.
13-15
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF067
CONTINUED
1.DEF
NOTES

priority if it is present.

Check the continuity and the absence of interference resistance on the following connections:
Track 2 fuel pressure sensor
connector
connector
connector
If all these connections are correct, check presence of a power supply to the fuel pressure sensor:
+5V
Track 3 of rail pressure sensor connector
Earth
Track 1 of rail pressure sensor connector
If the feeds are correct, replace the fuel pressure sensor.
AFTER REPAIR
tool.
13-16
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF070
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
CAMSHAFT SENSOR / ENGINE SPEED CONSISTENCY

1.DEF :
2.DEF :
3.DEF :
4.DEF :
Frequency of camshaft sensor signal too high

Engine speed inconsistency
Tooth-to-tooth dynamic consistency of engine speed sensor
Inconsistent camshaft signal
Conditions for applying the fault finding strategy to the stored fault.
starter action for 10 seconds, or
the engine has been running for one minute.
Special notes:
connectors.
1.DEF
NOTES

Deal with fault DF012: Battery voltage as a priority if it is
declared present.
Check presence of power supply between tracks 1 and 3 of camshaft sensor connector:
12 V after relay
Track 3
Earth
Track 1
Ensure earthing of the engine block.
Check the state of the sensor (temperature rise). Replace it if necessary.
2.DEF
NOTES
None.
Check the engine speed sensor connectors.

Check the resistance of the engine speed sensor between sensor tracks A and B.
Replace the sensor if the resistance is not approximately: 800 80 .
Track A of the engine management

computer
Track B of the engine speed sensor
Check fastening, air gap and condition (overheating) of the sensor. Replace if necessary.
AFTER REPAIR
tool.
13-17
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF070
CONTINUED
3.DEF
NOTES
Conditions for applying the fault finding strategy to the

stored fault.
The fault reappears after:
it is cleared and the engine is started followed by the
engine running for one minute.

Ensure that the engine block is earthed.
track A of the engine management

computer
track B of the engine speed sensor
Check the resistance of the engine speed sensor between sensor tracks A and B.
Replace the sensor if the resistance is not approximately: 800 80 at 20C.
Carry out a conformance check on the flywheel (where applicable check the form of the engine speed signal
using an oscilloscope, broken tooth, etc.). Carry out the necessary repairs.
4.DEF
NOTES
None.
Check the camshaft sensor connections.

Engine management computer, connector C track K4
Engine management computer, connector C track C1
Track 2 of the camshaft sensor

connector
Track 1 of the camshaft sensor
connector
Check the presence of 12 V after relay on track 3 of the camshaft sensor connector.
Check the tension of the timing belt.
Check pinion/key assembly on the camshaft.
Check the timing adjustment.
AFTER REPAIR
tool.
13-18
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF071
PRESENT
OR
STORED
NOTES
CO.0
DIESEL INJECTION
13
PEDAL SENSOR CIRCUIT TRACK 1

1.DEF : Sensor supply fault
Special notes:
connectors.
NOTES

In the event of the simultaneous presence of the DF073:
Pedal sensor circuit track 2 CO.0 fault, check that the
pedal sensor connector is fully plugged in.
Check the pedal sensor connections.

Check the continuity and insulation against earth on the connection between:
Engine management computer, connector A track C1
Track 3 pedal sensor connector
Also ensure the insulation of this connection against the following connections:
Engine management computer, connector A track B3
Engine management computer, connector A track A3
Engine management computer, connector A track E1
Measure the resistance of the pedal sensor track 1 between tracks 2 and 4.
Replace the sensor if the resistance is not approximately: 1.2 0.48 k at + 20C.
CC.1
NOTES
None.

Check insulation relative to + 12 V on the connection between:

Track 2 pedal sensor connector.
Measure the resistance of the pedal sensor track 1 between tracks 2 and 4.
Replace the sensor if the resistance is not approximately: 1.2 0.48 k at + 20C.
AFTER REPAIR
tool.
13-19
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF071
CONTINUED
1.DEF
NOTES

As a priority, deal with fault DF091: Sensor supply voltage
No. 1 if the fault is present or stored.

Check the continuity and absence of interference resistance on the following connections:
Check the insulation between the following two connections:
Also check the insulation against + 12 V.

If the fault persists, go to the accelerator pedal sensor conformity check.
AFTER REPAIR
tool.
13-20
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
FUEL PRESSURE SIGNAL

DF072
PRESENT
OR
STORED
1.DEF :
2.DEF :
3.DEF :
4.DEF :
5.DEF :
Measured pressure too high

Measured pressure too low
OCR of rail pressure regulating solenoid valve too high
Regulating solenoid valve jammed closed
Regulating solenoid valve jammed open
Conditions for applying the fault finding procedure to the stored fault.
the engine has been running at idle speed for 2 minutes.
NOTES
Special notes:
connectors.
IMPORTANT: It is forbidden to carry out an ohmmeter check on the pressure
sensor.
1.DEF
5.DEF
NOTES

As a priority, deal in priority with the DF091: Sensor power
supply No. 1 or DF012: Battery voltage faults if one of
these two faults is present or stored.

Check the fuel pressure solenoid valve connectors.
Check the insulation against earth of the connection between:
Track 2 fuel pressure solenoid valve

connector
With the connector disconnected, check the insulation against 5 V on the connection between:
Track 2 rail pressure sensor
connector
Perform an AC006: Fuel pressure solenoid valve actuator command. A light whistling sound should be
heard from the fuel pressure regulator. If it cannot be heard, check the presence of + 12 V after relay on
track 1 of the fuel pressure sensor solenoid valve connector.
If the problem persists, go to the fault finding procedure for the interpretation of parameter: PR083.
AFTER REPAIR
tool.
13-21
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF072
CONTINUED
2.DEF
3.DEF
4.DEF
NOTES
None.

Check the fuel pressure solenoid valve connectors.
Check the presence of 12 V after relay on track 1 of the rail pressure regulating solenoid valve.
Check the continuity and absence of interference resistance on the following connections:
connector
At idling speed, warm engine (coolant temperature > 75C), view parameter PR083: Pressure in rail.
If the value displayed is not 275 30 bar, go on to perform the fault finding procedure for the interpretation of
parameters "PR083".
AFTER REPAIR
tool.
13-22
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF073
PRESENT
OR
STORED
DIESEL INJECTION
13
PEDAL SENSOR CIRCUIT TRACK 2

CO.0
CC.1
1.DEF
2.DEF
:
:
:
:
Open circuit or short circuit to earth

Short circuit or + 12 V
Sensor supply fault
Consistency between track 1 and track 2
successive cycles of full load and no load on the accelerator pedal.
NOTES
Special notes:
connectors.
CO.0
NOTES

In the event of the simultaneous presence of the DF071:
Pedal sensor circuit track 1 CO.0 fault, check that the
pedal sensor connector is fully plugged in
Check the connectors on the pedal sensor.

Engine management computer, connector A track F1
Also check the insulation of this connection against earth and against the following connections:
Measure the resistance of the pedal sensor - track 2, between tracks:
1 and 5
1.7 0.68 k at + 20C
Replace the sensor if the resistance is outside permitted tolerance values.
CC.1
NOTES
None.

track 6 pedal sensor connector
Ensure the presence of earth on track 1 of the pedal sensor connector.
If the fault persists, replace the pedal sensor.
AFTER REPAIR
tool.
13-23
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF073
CONTINUED
1.DEF
NOTES

As a priority, deal with the DF092: Sensor supply voltage
No.2 fault if it is present or stored.

Check the continuity and insulation against + 12 V on the connections between:
Engine management computer, connector A track H2
Ensure the insulation against earth of the connections between:
If the fault persists, replace the pedal sensor.
2.DEF
NOTES
None.

Measure the resistance of pedal sensor track 1, across tracks 2 and 4 of the pedal sensor connector.
Replace the sensor if the resistance is not approximately: 1.2 0.48 K.
Measure the resistance of pedal sensor track 2, between tracks 1 and 5 of the pedal sensor connector.
Replace the sensor if the resistance is not approximately: 1.7 0.68 K.
If the fault persists, go on to perform the accelerator-pedal sensor correctness check.
AFTER REPAIR
tool.
13-24
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF074
PRESENT
OR
STORED
DIESEL INJECTION
13
TURBOCHARGER PRESSURE SENSOR

OC.0 :
CC.1 :
1.DEF :
2.DEF :

Short circuit to + 12 V
Sensor supply fault
Inconsistency with atmospheric pressure
Special notes:
connectors.
NOTES
the engine has been started or after a road test.
CO.0
NOTES
None.
Check the turbocharger pressure sensor connectors.

Check the continuity and insulation against earth of the connection between:
Engine management computer, connector B track C1
Track B turbocharger pressure sensor
connector.
Also check the continuity of the connection between:
Engine management computer, connector B track J2
Track C turbocharger pressure sensor
connector
If the fault remains present, replace the turbocharger pressure sensor.
CC.1
NOTES
None.

Check the continuity and insulation against + 12 V on the connection between:
connector.
Also check the continuity of the connection between:
Engine management computer, connector B track A4
Track A turbocharger pressure sensor
connector
If the fault remains present, replace the turbocharger pressure sensor.
AFTER REPAIR
tool.
13-25
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF074
CONTINUED
1.DEF
NOTES


Engine management computer, connector B track J2
Track C turbocharger pressure sensor

connector
Also check the insulation on this connection against the earth and + 12 V and against the following
connections:
connector
connector
connector
Also check the insulation of this connection against + 12 V and against the connection between:
connector
2.DEF
NOTES
None.

Check the continuity and absence of interference resistance on the connections between:
connector
Check fitting of the sensor and the condition of its seal.
Check that there are no leaks in the induction circuit: unions, hoses, sleeves, exchanger, turbocharger.
Ensure there is no oil in the air inlet circuit.
Check the efficiency of the turbocharger.
If the problem persists, carry out the interpretation of commands diagnostic procedure AC004. If the wastegate
is not faulty, replace the turbocharger pressure sensor.
AFTER REPAIR
tool.
13-26
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF075
PRESENT
OR
STORED
NOTES
1.DEF
2.DEF
DIESEL INJECTION
13
ATMOSPHERIC PRESSURE SENSOR

1.DEF : Supply voltage too low
2.DEF : Supply voltage too high

Deal with the DF091: Sensor feed voltage no. 1 fault as a priority if it is present or
stored.
NOTES

If the fault is stored, clear the fault from the engine management computer memory.
vehicle.
vehicle.
AFTER REPAIR
tool.
13-27
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF077
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
EGR VALVE
CC.1 :
OC.0 :
1.DEF :
2.DEF :
Negative loop deviation
Positive loop deviation

the fault has been cleared from the memory and
actuator command AC007: EGR valve.
Special notes:
connectors.
CC.1
NOTES
None.
Check the connections of the exhaust gas recirculation valve.

Measure the resistance of the exhaust gas recirculation valve between tracks 1 and 5.
If the resistance is not approximately 8 0.5 at + 20C, replace the exhaust gas recirculation valve.
Engine management computer, connector B track M1
CO.0
NOTES
Track 5 exhaust gas recirculation valve

connector
None.

Engine management computer, connector B track M1
Track 5 of the exhaust gas recirculation
valve connector
Check the presence of + 12 V after relay on track 1 of the exhaust gas recirculation valve connector.
AFTER REPAIR
tool.
13-28
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF077
CONTINUED
1.DEF
2.DEF
NOTES
None.

Check leaktightness of the air intake circuit and the exhaust gas recirculation circuit.
If the problem persists, carry out the interpretation of commands diagnostic procedure: AC007.
AFTER REPAIR
tool.
13-29
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF078
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
WASTEGATE
CC.1 :
OC.0 :
1.DEF :
2.DEF :
Positive deviation in turbocharging regulation
Negative deviation in turbocharging regulation

The fault reappears as stored after:
the fault memory has been cleared and actuator command AC004: Wastegate, or
if the fault becomes present during a road test.
Special notes:
connectors.
CC.1
NOTES
None.
Check the wastegate connectors.

Track 1 wastegate connector.
Check the resistance of the wastegate (turbocharger pressure limitation valve) between tracks 1 and 2.
Replace the wastegate if the resistance is not approximately: 16.5 1.6 at + 25C / (22.1 2.2 at + 110C).
CO.0
NOTES
None.

Check the insulation against earth of the connection between:
Track 1 wastegate connector
Check the presence of + 12 V after relay on track 2 of the wastegate connector.

Replace the wastegate if the resistance is not approximately: 16.5 1.6 at + 25C / (22.1 2.2 at + 110C).
AFTER REPAIR
tool.
13-30
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF078
CONTINUED 1
1.DEF
NOTES

Deal with the DF074: turbocharger pressure sensor fault
as a priority if it is declared present.

Check the presence of 12 V after relay on track 2 of the wastegate connector.
Replace the wastegate if the resistance is not approximately: 16.5 1.6 at + 25C / 22.1 2.2 at + 110C
If the fault persists, this indicates that the pressure measured by the computer exceeds that set by the
wastegate management system.
Check integrity of the wastegate (jamming/seizing: open).
Check wastegate movement (jamming/seizing: closed).
Check the setting of the wastegate control rod (Workshop Repair Manual section 12: Pressure regulator
valve).
AFTER REPAIR
tool.
13-31
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF078
CONTINUED 2
2.DEF
NOTES

Deal with the DF074: turbocharger pressure sensor fault

Replace the wastegate if the resistance is not approximately: 16.5 1.6 at + 25C / 22.1 2.2 at + 110C.
If the fault persists, this indicates that the pressure measured by the computer is lower than that set by the
wastegate management system.:
Check integrity of wastegate valve (jamming/seizing: closed)
Check the condition and sealing of the air inlet circuit.
Check the leaktightness of the vacuum system, from the vacuum pump up to the wastegate control LDA
via the solenoid valve (or flap valve).
Check the efficiency of the vacuum pump.
Check the setting of the wastegate control rod (Workshop Repair Manual section 12: Pressure
regulator valve ).
Check wastegate movement (jamming/seizing: open).
Check the turbocharger.
AFTER REPAIR
tool.
13-32
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF079
PRESENT
OR
STORED
DIESEL INJECTION
13
THERMOPLUNGER RELAY No. 3

OC.0 : Open circuit or short circuit to earth
Special notes:
connectors.
NOTES
CC.1

the engine has been started, after the engine has been running for 30 seconds at
idle speed, with heated windscreen not selected and the engine temperature at
starting less than 70C, or
if it reappears after being cleared followed by actuator command: AC002.
NOTES
None.
Check the connectors on the additional heater 3 relay socket in the engine fuse and relay box.
Check the integrity of the additional heater 3 relay socket in the engine fuse and relay box:
Insulation between tracks 3 and 5 of the relay.
Measure the resistance of the relay coil, between tracks 1 and 2.
replace the relay if the resistance is not approximately 65 5 at + 20C.
Engine management computer, connector C track E4
Track 2 of the additional heater
no. 3 relay socket in the engine fuse
and relay box
Also check the insulation of this connection against the following connections:
Additional heater no. 3 in the engine fuse and relay box track 1
+ 12 V after relay
Additional heater no. 3 in the engine fuse and relay box track 3
+ 12 V battery
CO.0
NOTES
None.
Check the connectors on the "additional heater 3" relay socket in the engine fuse and relay box.
Measure the resistance of the "additional heater 3" relay coil, between its tracks 1 and 2:
replace the relay if the resistance is not approximately 65 5 at + 20C.
Engine management computer, connector C track E4
Track 2 of the additional heater no. 3
relay socket in the engine fuse and
relay box
Check the presence of + 12 V after igntion on track 1 of the additional heater no. 3 relay socket.
AFTER REPAIR
tool.
13-33
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF081
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
PREHEATING RELAY CIRCUIT

CC.1 : Short circuit to +12 V

actuator command AC010: Preheating relay.
Special notes
connectors.
CC.1
NOTES
None.

Track 8 preheating unit connector
CO.0
NOTES
None.

Track 8 preheating unit connector
Check the presence of 12 V battery on track 3 of the preheating unit connector (via F01; 70A)
AFTER REPAIR
tool.
13-34
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF082
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
LOW PRESSURE PUMP RELAY CIRCUIT


actuator command AC005: Low pressure pump relay control.
Special notes:
connectors.
CC.1
NOTES
None.
Check the low pressure pump relay socket connections R3 in the engine fuse and relay box.
Remove the low pressure pump relay and check the insulation against + 12 V on the connection between:
Track 2 low pressure pump relay socket
High pressure pump relay socket in the engine fuse and relay box track 1
+12 V after ignition
Low pressure pump relay socket on the engine fuse and relay box track 3
+12 V battery
Check the integrity of the "low-pressure pump" relay in the engine fuse and relay box:
Measure the resistance of the relay coil, between tracks 1 and 2.
CO.0
NOTES
None.
Perform a check on the connectors of low-pressure pump relay socket R3 in the engine fuse and relay box.
Track 2 low pressure pump relay
socket
Check the presence of + 12 V after relay on track 1 of the low pressure pump relay.
Measure the resistance of the low pressure pump relay coil between its tracks 1 and 2.
AFTER REPAIR
tool.
13-35
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF083
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
FUEL PRESSURE SOLENOID VALVE CIRCUIT

1.DEF : Consistency after switching off the ignition

actuator command AC006: Fuel pressure solenoid valve control.
Special notes:
Use bornier El. 1613 for all operations on the computer connector.
CC.1
NOTES
None.
Check the fuel pressure solenoid valve connections.

With the fuel pressure solenoid valve connector disconnected, check the insulation against + 12 V on the
connection between:
Engine management computer B track L1
Track 2 fuel pressure solenoid valve connector
Measure the resistance of the fuel-pressure solenoid valve across tracks 1 and 2:
Replace the solenoid valve if the value is not approximately: 5 05 at 20C.
CO.0
NOTES
None.

Measure the resistance of the fuel-pressure solenoid valve across tracks 1 and 2:
Replace the solenoid valve if the value is not approximately: 5 0.5 at 20C.
connector
Check the presence of + 12 V after relay on track 1 of the fuel pressure solenoid valve.
AFTER REPAIR
tool.
13-36
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF083
CONTINUED
1.DEF
NOTES

Deal with the DF088 Consistency of flywheel signal fault

Track B engine speed sensor
Track A engine speed sensor
Measure the line resistance of the connection between:
Track 2 of the fuel pressure solenoid

valve
Measure the resistance of the fuel pressure solenoid valve between tracks 1 and 2:
Replace the solenoid valve if the value is not approximately: 5 0.5 at 20C.
If the problem persists, carry out the interpretation of commands correctness check: AC006.
AFTER REPAIR
tool.
13-37
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF088
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
FLYWHEEL SIGNAL INCONSISTENCY

1.DEF : Overspeed detected

the fault has been cleared,
the engine has been started followed by acceleration to over 2500 rpm.
Special notes:
connectors.
1.DEF
NOTES
This fault appears following an engine overspeed of

> 5000 rpm

Check the insulation against + 12 V and the earth on the following connections:
Track B engine speed sensor
Track A engine speed sensor
Measure the resistance of the engine speed sensor between tracks A and B of the sensor.
Replace the sensor if the resistance value is not approximately 800 80 at 20C.
AFTER REPAIR
tool.
13-38
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF089
PRESENT
OR
STORED
1.DEF
2.DEF
DIESEL INJECTION
13
INJECTION CONTROL CAPACITOR VOLTAGE

NOTES

stored faults:
the engine has been running for one minute.
vehicle.
vehicle.
AFTER REPAIR
tool.
13-39
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF090
PRESENT
OR
STORED
1.DEF
DIESEL INJECTION
13
ANALOGUE TO DIGITAL CONVERTER

NOTES
None.
vehicle.
vehicle.
AFTER REPAIR
tool.
13-40
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF091
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
SENSOR SUPPLY VOLTAGE No. 1


The fault reappears as stored after:
The fault has been cleared and
the engine has been running for 1 minute.
Special notes:
connectors.
1.DEF
NOTES
None.
Check the connectors of the following sensors:

pedal sensor,
fuel pressure sensor,
air flowmeter,
exhaust gas recirculation valve position sensor,
turbocharger pressure sensor.
Display parameter PR090: Sensors no.1 supply voltage. If this voltage is below 4.9 V, disconnect the
connectors on all the sensors referred to above one by one.
If the voltage returns to normal (wait a few seconds between each disconnection so that the computer can
take the measurement), replace the faulty sensor (or repair the faulty connection).
Clear the faults created by the multiple disconnections.
If the voltage is still below 4.9 V when all these sensors are disconnected, check that there is no short circuit
in these sensor supply lines:
Disconnect all the sensors referred to above and the computer-side connectors and check the insulation
between:
tracks 2 and 4 of the pedal sensor connector;
tracks 1 and 3 of the fuel pressure sensor connector;
tracks 2 and 3 of the air-flowmeter connector.
tracks 2 and 4 of the exhaust gas recirculation valve position sensor connector,
tracks A and C of the turbocharger pressure sensor connector.
If all the insulation is correct, replace the engine management computer.
vehicle.
AFTER REPAIR
tool.
13-41
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF091
CONTINUED
2.DEF
NOTES
None.

pedal sensor,
fuel pressure sensor,
air flowmeter,
exhaust gas recirculation valve position sensor,
turbocharger pressure sensor.
Display parameter PR090: Sensors no.1 supply voltage. If this voltage is above 5.1 V, disconnect all the
sensor connectors referred to above one by one:
If the voltage returns to normal, replace the faulty sensor (or repair the faulty connection) (wait a few seconds
between each disconnection so that the computer can take the measurement).
Clear the faults created by the multiple disconnections.
If the voltage is still above 5.1 V with all these sensors disconnected, check that there is no short circuit to
+ 12 V on these sensor supply lines (+ 5 V):
Disconnect all the sensors referred to above and the connectors on the computer side and check the
insulation against + 12 V on tracks:
4 of the pedal sensor connector;
3 of the fuel pressure sensor connector;
3 of the air flowmeter connector;
2 of the exhaust gas recirculation valve position sensor connector,
C of the turbocharger pressure sensor connector.
If all these tracks are insulated against + 12 V, replace the engine management computer. If necessary, modify
the configuration of the new computer to match the equipment options present on the vehicle.
AFTER REPAIR
tool.
13-42
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF092
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13


The fault reappears after:
The fault has been cleared and
Special notes:
connectors.
1.DEF
NOTES
None.

pedal sensor,
Refrigerant pressure sensor.
Display parameter PR091: Sensor no.2 supply voltage. If the value of this voltage is below 4.9 V, disconnect
the sensor connectors referred to above one by one and display PR091 again.
If the voltage returns to normal (wait a few seconds after each disconnection so the computer can take the
measurement), replace the faulty sensor (or repair the faulty connection).
If the voltage is still below 4.9 V, with all these sensors disconnected, check that there is no short circuit on
these sensor supply lines.
Disconnect all the sensors referred to above and the computer-side connectors and check the insulation
between:
tracks 1 and 5 of the pedal sensor connector;
tracks A and B of the refrigerant pressure sensor connector.
If these checks reveal a short circuit, perform the necessary repairs.
If these checks do not reveal a short circuit, replace the engine management computer.
vehicle.
AFTER REPAIR
tool.
13-43
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF092
CONTINUED
2.DEF
NOTES
None.

pedal sensor,
refrigerant pressure sensor.
Display parameter PR091: Sensor no.2 supply voltage. If the value of this voltage is above 5.1 V, disconnect
the sensor connectors referred to above one by one and display PR091 again;
If the voltage returns to normal (wait a few seconds after each disconnection so the computer can take the
measurement), replace the faulty sensor (or repair the faulty connection).
If the voltage is still above 5.1 V with all these sensors disconnected, check that there is no short circuit to
+ 12 V on these sensor supply lines (+ 5 V):
Disconnect all the sensors referred to above and the connectors on the computer side and check the
insulation against + 12 V on tracks:
5 of the pedal sensor connector.
B of the refrigerant pressure sensor connector.
If these checks reveal a short circuit to + 12 V, perform the necessary repairs.
If these checks do not reveal a short circuit, replace the engine management computer.
vehicle.
AFTER REPAIR
tool.
13-44
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF093
PRESENT
OR
STORED
1.DEF
2.DEF
DIESEL INJECTION
13
MICROCONTROLLER
1.DEF
2.DEF
: Internal electronic fault.

: Inconsistency
NOTES
None.
If the fault is present or stored, clear the fault from the engine management computer memory.
Switch off the ignition, then switch it on again to initialise the computer. Carry out a road test.
vehicle.
AFTER REPAIR
tool.
13-45
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF094
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13


the engine has been started, after the engine has been running at idle speed for
30 seconds, with heated windscreen not selected and the engine temperature at
if it reappears after being cleared followed by actuator command: AC301.
Special notes:
connectors.
CC.1
NOTES
None.
Check the connectors on the "additional heater 1" relay in the engine fuse and relay box.
Check the integrity of the "additional heater 1" relay in the engine fuse and relay box:
Insulation between tracks 3 and 5 of the relay (at rest position).
Measure the resistance of the relay coil, between tracks 1 and 2:
replace the relay if its resistance is not approximately: 64 5 at +20C.
Engine management computer, connector C track J4
Track 2 additional heater 1 relay socket in
the engine fuse and relay box.
Also check the insulation of this connection against following connections:
Additional heater no. 1 relay socket in the engine fuse and relay box, track 1
+ 12 V after relay
Additional heater no. 1 relay socket in the engine fuse and relay box, track 3
+ 12 V battery
CO.0
NOTES
None.
Check the connectors on the "additional heater 1" relay in the engine fuse and relay box.
Check the presence of + 12 V after ignition on track 1 of additional heater 1 relay socket. Measure the
resistance of the relay coil, between tracks 1 and 2:
replace the relay if its resistance is not approximately: 64 5 at + 20C.
Engine management computer, connector C track J4
Track 2 additional heater 1 relay socket
in the engine fuse and relay box.
AFTER REPAIR
tool.
13-46
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF095
PRESENT
OR
STORED
DIESEL INJECTION
13

1.DEF : Vehicle speed too high
2.DEF : Vehicle speed signal frequency too high
3.DEF : Inconsistency between engine speed and air flow

If the fault becomes present:
during a road test at a speed above 2000 rpm.
NOTES
Special notes:
connectors.
1.DEF
NOTES
Condition for appearance of fault 1.DEF: if speed is

> 200 km/h for 10 seconds .
Check the condition of the sensor, if the body shows any deformation due to overheating, replace the sensor.
Perform a road test and compare the speed indicated by the diagnostic tool (Parameters menu) with that
shown on the instrument panel:
If these two values do not coincide,
Check the following continuity (obtain the appropriate wiring diagram):
Engine management computer connector A track E4 / speed sensor track B1 / track 13 black connector
on instrument panel.
If continuity is ensured between these three points, replace the engine management computer.
vehicle.
If these two values coincide, perform the following checks:
Check the insulation against the earth and against + 12 V on the following connection:
Track B1 vehicle speed sensor
connector
Ensure the presence of earth on track B2 of the vehicle speed sensor.
Check the presence of + 12 V on track A of the vehicle speed sensor.
If the fault persists, remove the speed sensor and check the condition of the sensor drive pinion. If necessary
replace the sensor.
AFTER REPAIR
tool.
13-47
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF095
CONTINUED
Condition for appearance of 3.DEF:

If the computer detects a speed signal lower than 10 km/h
but the fuel flow and engine speed show a higher speed.
2.DEF
3.DEF
NOTES
Special notes:
If the road test highlights a clutch problem (slipping), consult
Workshop Repair Manual Section 2 and correct the
problem. After the repair, follow the general notes for DF095
before applying the fault-finding procedure.
Check the vehicle speed sensor connectors.

Check the condition of the sensor, if the body shows any deformation due to overheating, replace the sensor.
Check the integrity of fuse F4 in the engine fuse and relay box.
Check the presence of 12 V after ignition on track A of the vehicle speed sensor.
Ensure the presence of earth on track B2 of the vehicle speed sensor.
Check the continuity of the following connection:
Track B1 vehicle speed sensor
connector
Also check the insulation against the earth and against + 12 V on the same connection.
The speed sensor supplies a signal which is shared by four control units: The injection control unit, the radio,
the video display and the instrument panel.
To eliminate a possible fault caused by one of these elements, disconnect them one by one (except the
injection control unit) and perform a road test between each disconnection.
If the fault is not present during the road test after one of the disconnections, this means that the control unit
in question was causing an electrical fault.
If this is the case, clear the fault, carry out a final road test to confirm the source of the fault and if the
fault does not reappear, replace the unit found to be faulty
If the fault persists, remove the vehicle speed sensor and check condition of the pinion, its rod and the
connection to the sensor itself.
Replace the pinion or sensor if necessary.
AFTER REPAIR
tool.
13-48
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF097
PRESENT
OR
STORED
DIESEL INJECTION
13
CLUTCH CONTACT INFORMATION

1.DEF: Inconsistent vehicle speed

If the fault becomes present:
during a road test exceeding 60 mph (100 km/h).
NOTES

Deal with the DF095: Vehicle speed signal fault as a priority if it is declared present
or stored.
Special notes:
connector.
1 - Perform a check on the connectors of the clutch switch.

Display state ET012: Clutch switch signal. Press the clutch pedal and note whether this state becomes
active:
If it becomes active,
Reset the engine management computer. Switch the ignition back on, road test the vehicle and then take a
fault reading. If the fault reappears, go to step 2.
If it does not become active,
Ensure that the switch is correctly adjusted.
Ensure the presence of earth on track B3 of the clutch switch.
Track A1 clutch switch
Check the operation of the clutch switch:

Closing of the contact between tracks A1 and B3 when the clutch pedal is depressed.
Opening of the contact between tracks A1 and B3 when the clutch pedal is released.
Replace the switch if necessary.
2 - If the fault persists:

Clear the fault from the computer memory.
Carry out a road test.
vehicle.
AFTER REPAIR
tool.
13-49
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF098
STORED
NOTES
1.DEF
DIESEL INJECTION
13
MAIN RELAY
1.DEF : Relay cut-out too soon
2.DEF : Relay cut-off too late
Conditions for applying the fault finding procedure:

the fault has been cleared and
the ignition is switched off with loss of dialogue and
the ignition is switched on again and dialogue is re-established.
NOTES
None.
Check the connectors on R2 main relay socket in the engine fuse and relay box.
Check that the battery terminals (+ and -) are tight and in good condition.
Main relay R2 track 5
tracks M2 and M3, connector B of the engine management computer
Track D4, connector B of the engine management computer
Check the condition of the F2 fuse connections on the engine fuse and relay box (crimping of the wires on the
terminals and condition of the terminals).
Check the condition of the engine management computer earth connections: tracks L3, L4, M4, connector B
of the engine management computer.
Check the conformity of the impact sensor.
If the fault persists after these checks, replace main relay R2.
2.DEF
NOTES
None.
Check the connectors on main relay R2 in the engine fuse and relay box.
Check the insulation against earth for the following connection:
Track D4, computer connector B
Check the conformity of the main relay (relay removed).
Insulation of contacts across tracks 3 and 5.
Measure the resistance of the coil across tracks 1 and 2:
Check the integrity of the impact sensor.
If the fault persists after these checks, replace the main relay R2.
AFTER REPAIR
tool.
13-50
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF099
PRESENT
OR
STORED
DIESEL INJECTION
13
CYLINDER INJECTOR CIRCUIT 1

1.DEF : Overcurrent on injector energising current
2.DEF : Undercurrent on the injector energising current

If the fault reappears as present following:
starting the engine.
NOTES
Special notes:
connectors.
1.DEF
NOTES
None.
Check the connections for injector no. 1.

Measure the resistance of injector no. 1:
Replace the injector if the resistance between tracks 1 and 2 is not: 0.33 at + 20C / 2 max.
Engine management computer, connector C track M1
Track 2 injector no. 1 connector
Check insulation against earth on the following connection:
Track 1 of the connector to the no. 1

injector
If the fault persists, replace the injector.
2.DEF
NOTES
None.


Measure the resistance of injector no. 1:

AFTER REPAIR
tool.
13-51
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF100
PRESENT
OR
STORED
DIESEL INJECTION
13


If the fault reappears as present following:
starting the engine.
NOTES
Special notes:
connectors.
1.DEF
NOTES
None.

Measure the resistance of injector no. 2.
Engine management, computer C track L4
Engine management, computer C track L3
Check insulation against earth on the following connection:
Engine management computer, connector C track L3
Track 1 of injector no. 2 connector
2.DEF
NOTES
None.



AFTER REPAIR
tool.
13-52
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF101
PRESENT
OR
STORED
DIESEL INJECTION
13

1.DEF :Overcurrent on injector energising current
2.DEF :Undercurrent on the injector energising current

If the fault becomes present after:
the engine is started.
NOTES
Special notes:
connectors.
1.DEF
NOTES
None.

Check the insulation against earth on the following connection:
2.DEF
NOTES
None.



AFTER REPAIR
tool.
13-53
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF102
PRESENT
OR
STORED
DIESEL INJECTION
13


If the fault reappears as present after:
NOTES
Special notes:
connectors.
1.DEF
NOTES
None.

Ensure insulation against earth for the following connection:
Track 1 of the injector no. 4 connector
2.DEF
NOTES
None.



AFTER REPAIR
tool.
13-54
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF104
PRESENT
OR
STORED
NOTES
DIESEL INJECTION
13
THERMOPLUNGER No. 2 RELAY


the engine has been started, after the engine has been running at idle speed for
30 seconds, with heated windscreen not selected and the engine temperature at
if it reappears after being cleared followed by actuator command: AC302
Special notes:
connectors.
The no. 2 thermoplunger relay powers thermoplungers 2 and 3 in parallel.
CC.1
NOTES
None.
Check the connectors on additional heater2 relay in the engine fuse and relay box.
Engine management computer, connector B track F3
track 2 additional heater 2 relay socket
Additional heater 2 relay socket, track 1
+ 12 V after relay
Additional heater 2 relay socket, track 3
+ 12 V battery
Check the integrity of the additional heater 2 relay:
Measure the resistance of the relay coil, between tracks 1 and 2:
Replace the relay if the resistance is not approximately: 82 5 at + 20C.
CO.0
NOTES
None.
Check the connectors on the additional heater 2 relay in the engine fuse and relay box.
Check continuity and insulation against earth of the connection between:
Track 2 additional heater 2 relay socket
Check the presence of + 12 V after relay on track 1 on additional heater 2 relay socket
Measure the resistance of the additional heater 2 relay coil, between its tracks 1 and 2:
Replace the relay if the resistance is not approximately: 82 5 at + 20C.
AFTER REPAIR
tool.
13-55
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DF105
PRESENT
OR
STORED
DIESEL INJECTION
13
STABILISED VOLTAGE REGULATOR

vehicle.
vehicle.
AFTER REPAIR
tool.
13-56
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
A.C. RELAY CONTROL CIRCUIT, COLD LOOP

DF111
PRESENT
OR
STORED
NOTES
1.CC.1
1.CO.0
1.DEF
2.DEF
3.DEF
: Short circuit to + 12 V on the compressor relay control line

: Open circuit or short circuit to earth of the compressor relay control line.
: Refrigerant pressure sensor voltage too low
: Refrigerant pressure sensor voltage too high
: Refrigerant pressure sensor supply fault

the fault has been cleared and actuator command AC003: Air conditioning
suppression command is issued or
the engine is started followed by a request for air conditioning.
Special notes:
connectors.
CC.1
NOTES
None.
Check the connections on the compressor control relay socket.

Remove the compressor relay and check the insulation against + 12 V on the connection between:
Track A2 compressor control relay
socket
Check the resistance of the air conditioning compressor control relay coil:
Replace the relay if the resistance is not 88 10 .
CO.0
NOTES
None.
Check the connections on the compressor control relay socket.

Track A2 compressor control relay
socket
Check the presence of 12 V after relay on track 1 of the compressor control relay socket.
Check the resistance of the air conditioning compressor control relay coil:
Replace the relay if the resistance is not 88 10 .
AFTER REPAIR
tool.
13-57
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
DF111
CONTINUED
1.DEF
2.DEF
NOTES
None.
Check the refrigerant pressure sensor connections.

Check the continuity (and absence of interference resistance) on the following connections:
Track A refrigerant pressure sensor
connector
Track B refrigerant pressure sensor
connector
Track C refrigerant pressure sensor
connector
If the fault persists, check conformance of the air conditioning circuit.
1.DEF: Underpressure in the refrigerant fluid circuit;
2.DEF: Overpressure in the refrigerant fluid circuit.
3.DEF
NOTES

priority if it is present.
Check the refrigerant pressure sensor connections.

Check the continuity (and absence of interference resistance) on the following connections:
Track A refrigerant pressure sensor
connector
Track B refrigerant pressure sensor
connector
Track C refrigerant pressure sensor
connector
With the connectors disconnected, check insulation values between these same connections.
AFTER REPAIR
tool.
13-58
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
FLOW AT SELF-TEST AFTER IGNITION SWITCHED OFF

DF141
STORED
1.DEF : Inconsistency with engine speed

Deal with any other fault that is present or stored as a
priority.
1.DEF
NOTES
Conditions for application of the fault finding

procedure:
the fault has been cleared,
followed by several power latch* phase ends, each
preceded by an engine start and acceleration to
> 2000 rpm cycle.
* Information regarding the notes: This fault is detected
when the ignition is switched off, during the power latch
phase. Moreover, this detection is based on a "counting"
strategy and is therefore not performed at each ignition
switch-off. If it is detected during a power latch, it will not
necessarily be detected during the next. After a fault is
cleared, then, several power latches should be performed,
each preceded by one cycle with the engine running (see
above), to attempt to make the fault reappear.
Conditions for appearance of the fault: this fault appears if the engine speed does not drop below a certain
value ( 300 rpm) in a very short time (t < 1.5 seconds) after the ignition is switched off. It is therefore necessary
to eliminate all mechanical, hydraulic or other causes which keep the engine running after it has been switched
off.
It is therefore necessary to eliminate all causes which could keep the engine running after the ignition is
switched off.
Check that there is not an excess of engine oil, and correct the oil level if required.
Check that there are no leaks in the injector pipes (see injector fault finding in the Help section).
Perform the necessary operations, clear the fault and then carry out the instructions again.
If the fault persists, replace the engine management computer. If necessary, modify the configuration of the
new computer to match the equipment options present on the vehicle.
AFTER REPAIR
tool.
13-59
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
Order
DIESEL INJECTION
Fault finding - Conformity check
Do not refer to this conformity check until you have checked that there is no fault with
Test conditions: engine stopped, ignition on.
Function
Battery voltage
Parameter or state
Check or action
Symbol on display and

notes
ET001: Computer +after

ignition
state: ACTIVE
PR004: Computer supply

voltage
12.4 < X < 12.8 V
ET003: Engine
immobiliser
2
Immobiliser
Synchronisation
(between
camshaft sensor
and engine speed
sensor)
Fault finding
In the event of a problem,

refer to fault finding
procedure PR004
status: INACTIVE
The computer is locked!
ET133: Code
programmed
state: YES
The computer has a code stored
in memory!
state: STANDBY, then

becomes "Complete"
once the engine is
started.
ET157: synchronisation
E027T: Pre/postheating
relay command
status: ACTIVE as soon

as the ignition is switched
on and until the end of
pre-postheating
ET011: pre-postheating
signal
status: ACTIVE as soon

as pre-postheating is
completed
Pre/postheating
Boosting pump
13
ET105: Low-pressure
pump relay control
status: ACTIVE, as soon

as the ignition is switched
on.
Becomes: INACTIVE, as
soon as the engine is
running, or after 10
seconds if the engine
does not start.
13-60
vnx.su
In the event of problems,

refer to the engine
immobiliser diagnostic
Any phase difference
between the camshaft
sensor and the TDC
sensor causes clearing of
DF070.
If starting is impossible:
the status becomes
"UNDERWAY" while the
starter motor is running,
and will only become
"performed" if the engine
starts.
If ET011 is "ACTIVE" at
the same time as ET027,
a plug has failed or the
diagnostic connection of
the pre-postheating unit is
in open circuit.
+ appearance of DF061.
This function ensures

priming of the lowpressure circuit
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
Order
Function
Switches
DIESEL INJECTION
Test conditions:engine stopped, ignition on.
Parameter or state
Check or action

notes
ET012: Clutch switch

signal
state: DEPRESSED or
RELEASED, depending
on actions on the pedals
ET154: Brake pedal

Engine overheating
warning light:
Instrument panel
warning lights
Supply voltage
Preheating + electronic
failure warning light
Temperature
sensors
4.9 V < X < 5.1 V
PR091: Sensor supply

voltage No. 2
4.9 V < X < 5.1 V
Inlet pressures
Fault finding
None
The coolant temperature
warning is lit when the
coolant temperature is
> 110C, and turns off
when the temperature
drops below 105C again.
perform the fault finding
procedure for the
instrument panel
None
X = Engine temperature
5 C

strategy PR002
X = vehicle external
temperature 5 C

strategy PR003
X = Engine temperature
10 C

strategy PR001
PR016: Atmospheric
pressure
X = Atmospheric pressure

refer to diagnostic PR016
PR082: Turbocharger
pressure
X Atmospheric pressure

refer to diagnostic PR082
PR003: Air temperature
PR001: Fuel temperature
10
Indicator lights controlled

by the engine computer
via the multiplexed
network: as soon as the
ignition is switched on
and for a few seconds
PR090: Sensor supply

voltage No. 1
PR002: Coolant
temperature
13
13-61
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
Order
DIESEL INJECTION
Test conditions:engine stopped, ignition on.
Function
RCO signal:
Exhaust gas
recirculation
valve
11
Parameter or state
Check or action
PR095: Exhaust gas
recirculation valve opening
cyclic ratio
PR088: Copy exhaust gas
recirculation valve position
Symbol on display
and notes
PR094: Turbocharger
wastegate opening cyclic ratio
Diesel pressure
In the event of a
problem, go to fault
finding procedure
AC007.
X = 5%
In the event of a
problem, go to fault
finding procedure
AC004.
PR083: Manifold pressure
0 < X < 4 bars
PR202: Regulated fuel flow

rate
X 25000 mm3/s
PR033: Fuel flow
10 < X < 80 mm3/

stroke
Fuel flow
Fault finding
X = 5%
X1V
Wastegate
12
13
If the engine has just

been stopped, wait a
few seconds to obtain
this value. In the event
of a problem, consult the
fault finding procedure
for PR083
ACCELERATOR PEDAL NO
LOAD
PR008: Pedal potentiometer
voltage track 1
PR005: Pedal load
X = 0%
PR092: Pedal load

(circuit No. 1)
X = 0%
PR093: Pedal load

(circuit No. 2)
X = 0%

voltage track 2
13
X = 0.71 V
X = 0.35 V
Accelerator pedal
sensor
ACCELERATOR PEDAL
FULL LOAD
voltage track 1
X = 4.1 V
PR005: Pedal load
X = 100%
PR092: Pedal load

(circuit No. 1)
X = 100%
PR093: Pedal load

(circuit No. 2)
X = 100%

voltage track 2
X = 2.1 V
13-62
vnx.su
Important:
approximately every
5 seconds the computer
performs a test to set
PR009 at 0 V.
This corresponds to
normal operation.
If only one track

responds after the pedal
is depressed, change
the pedal sensor.
If the voltages shown
does not correspond to
+ or - 0.3 V, replace the
pedal sensor.
In the event of pedal
sensor failure, the
engine speed is frozen
at 1200 rpm (for return
to workshop).
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
Order
Function
DIESEL INJECTION
Only perform this conformity check if a full check using the diagnostic tool revealed no
faults.
Test conditions: warm idling engine, without electric consumer.
Parameter or state
Check or action

notes
PR002: Coolant
temperature
15
Engine speed
Diesel pressure
Fault finding
800 rpm 50
PR 006: Engine speed
14
13
higher than 80C
PR062: Engine speed

reference
800 rpm 50.
PR035: Idling-speed
correction
X = 0 rpm 50
(Depending on increase
or decrease in the tool
configuration menu)
PR083: Manifold pressure
X = 275 bar 30
(approximately 1350 bar
at most when at full load)
PR086: Manifold-loop
deviation
X 0 bar
ET105: Low-pressure pump

relay control
None
In the event of a problem

consult the fault finding
procedure PR083.
state: INACTIVE
FLOW RATES:
Fuel
16
Air
X 1210 mm3/s
PR202: Regulated fuel flow

rate
PR033: Fuel flow
X 5 mm3/ stroke
PR075: Idling speed fuel

flow reference
X 5 mm3/ stroke
X 34 kg/h at 800 rpm,
(approx. 390 kg/h under
load in the case of a full
load)
PR050: Air flow

measurement
None
None
RCO signal:
17
Exhaust gas
recirculation
valve
PR095: Exhaust gas

recirculation valve opening
cyclic ratio
X 33%

go to fault finding
procedure AC007.
Wastegate
PR094: Wastegate opening

cyclic ratio
X 85%

go to fault finding
procedure AC004.
13-63
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
Order
Function
DIESEL INJECTION
13
Test conditions: warm idling engine, without electric consumer.
Parameter or state
Check or action

notes
Fault finding
If necessary consult the Workshop Repair Manual, Section 13: Injection/air conditioning strategy.
If the injection computer allows compressor operation
ET102: Air conditioning
requested
ET037: Low-speed fan unit

relay control
18
Air conditioning
(selected)
state: ACTIVE
status: ACTIVE
Becomes inactive if the
refrigerant pressure
> 22 bar
ET038: High-speed fan unit

relay control
compressor relay control.
PR006: Engine speed
status: ACTIVE
only if the refrigerant
pressure > 22 bar
state: ACTIVE
800 rpm
If the injection computer does not allow compressor

operation
requested
state: ACTIVE
ET037: Low-speed fan unit

relay control
state: INACTIVE

compressor relay control.
state: INACTIVE
PR006: Engine speed
X = 800 rpm
13-64
vnx.su
In the event of
anomalies, refer to the
heating/ventilation
diagnostics
If the refrigerant
pressure is > 22 bars,
the fan assembly is
triggered at high speed
until the pressure falls
below 20 bars again.
In the event of a fan unit
problem, go to command
AC011 or AC012
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
NOTES
Order
13
Function
Engine cooling
19
Parameter or state
Check or action

notes
PR002: Coolant
temperature
ET038: High speed fan
assembly relay control
(with air conditioning)
or
ET037: Low speed fan
assembly (without air
conditioning)
If PR002 at 93C
then
=
state: ACTIVE
The fan must run at high
speed
Fault finding
on the fan, go to
command AC012
When the temperature
drops to 88C again, the
fan assembly cuts out
(the command state
becomes: INACTIVE).
If necessary, refer to Workshop Repair Manual section 13: Centrally managed

coolant temperature
20
21
Electrically heated
windscreen
(selected)
Thermoplungers
ET186: Heated
windscreen
state: ACTIVE
None
PR006: Engine speed
1,000 rpm
ET106: Thermoplunger
relay control No. 1
relay no. 2 control
Command statuses:
ACTIVE or INACTIVE,
depending on
authorisation of the
injection computer
relay no. 3 control
825 rpm
PR006: Engine speed
13-65
vnx.su
If necessary, refer to
Workshop Repair Manual
section 13:
Thermoplungers.
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
Order
DIESEL INJECTION
Test conditions: engine stopped, ignition on. ET003 Inactive.
Function

notes
Description
Thermoplungers
You should hear the relay

activate (two sequences of
~ 1 second )
AC302: No.2
thermoplunger relay
24
Air conditioning
compressor
control
Turbocharging
solenoid valve
In the event of a problem:

consult fault finding
procedure AC302.
procedure AC002.
AC303: No.3
thermoplunger relay
23
Fault finding
procedure AC301.
AC301: No.1
thermoplunger relay
22
13
AC003: Air conditioning

inhibition
One should hear the relays

and compressor being
actuated (ten sequences)

procedure AC003.
AC004: Wastegate
During entry of the

command, maintain a
vacuum pressure of
approx. 600 mbar at the
valve inlet to hear it
operating and check
operation of the wastegate
diaphragm.

procedure AC004.

procedure AC005.

procedure AC006.
25
Boosting pump
AC005: Low pressure

pump relay command
One should hear the relay

being actuated and the
pump running (one
sequence of approx.
15 seconds)
26
Fuel pressure
regulator
AC006: Solenoid valve

control of fuel pressure
(or flow regulation
solenoid valve)
Place your hand on the

valve to feel it operating
13-66
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
DIESEL INJECTION
Test conditions: engine stopped, ignition on. ET003 Inactive.
Order
Function
27
Exhaust gas
recirculation valve
28
29
13
Preheating relay
Parameter or state
Check or action

notes
Fault finding
AC007: Exhaust gear

recirculation valve
command
Place your hand on the

valve to feel it operating

procedure AC007.
Place a clamp-on
ammeter on track 3 (on
the red 5 mm2 wire) of the
preheating relay and
check that the current
consumption is approx.
80 A.
AC010: Preheating
relay
Any plug fault should

clear fault DF061.
Locate the faulty plug by
placing the clamp-on
ammeter directly on the
power supply wires of
each plug: approx.
20A/ plug
AC011: Low speed fan

unit relay

activating and observe
that the fan unit is running
at low speed (only if the
vehicle is equipped with air
conditioning)

procedure AC011.
AC012: High speed fan

unit relay

activating and observe
that the fan unit is running
at high speed (only if the
vehicle is equipped with air
conditioning)

procedure AC012.
(For vehicles without air conditioning, only the AC011 command is operational. It causes the fan to run at high
speed)
13-67
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
Fault finding - Parameter interpretation
13
FUEL TEMPERATURE
PR001:
NOTES
IMPORTANT: In the event of a relatively low outside temperature, the difference

between the fuel temperature and the engine temperature after cold starting may be
greater than 30C.
No faults should be present or stored.
Perform this fault finding procedure after an inconsistency is displayed in the
Parameter menu.
Special note:
Use a temperature sensor to compare the values displayed on the diagnostic tool.
connector.
Check for the absence of interference resistance on the following lines:

between track J3, connector B of the computer and track 1 of the temperature sensor connector,
between track G1, connector B of the computer and track 2 of the temperature sensor connector.
Repair.
Check that the sensor follows the "resistance as a function of temperature" (NTC) calibration curve correctly.
3820 282 at 10C
2050 100 at 25C
810 47 at 50C.
Compare the value displayed by the diagnostic tool with the value shown by a temperature sensor (placed on
the return circuit).
Replace the sensor if it deviates (if a sensor deviates, it is often due to an electric shock).
AFTER REPAIR
Repeat the conformity check.
13-68
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
COOLANT TEMPERATURE
PR002:
NOTES

Parameter menu.
Special note:
Use a temperature sensor to compare the values displayed on the diagnostic tool.
connector.
Check that the cooling circuit is topped up and properly bled. Carry out the required operations.
between track E1, connector B of the computer and track 2 of the temperature sensor connector.
between track K3, connector B of the computer and track 3 of the temperature sensor connector.
Repair.
2252 112 at 25C / 811 39 at 50C / 283 8 at 80C.
Compare the value displayed on the instrument panel with that shown by the diagnostic tool, and if they do not
correspond, compare with the value shown by a temperature sensor (placed in the expansion bottle). Replace
the sensor if there is a significant difference.
Replace the sensor if it deviates (if a sensor deviates, it is often due to an electric shock).
AFTER REPAIR
13-69
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
AIR TEMPERATURE
PR003:

Perform this fault finding procedure after noting an inconsistency in the parameter
menu.
NOTES
Special note:
Use a temperature sensor to compare the values displayed on the tool.
connector.
Check that there are no foreign bodies on the air flowmeter grille. Clean if necessary.
between tracks D3, connector B of the computer and track 1 of the temperature sensor connector,
between tracks A3, connector C of the ECU and track 2 of the temperature-sensor connector
Repair.
3714 161 at 10C / 2448 90 at 20C / 1671 59 at 30C.
Compare the value displayed by the diagnostic tool with the value shown by a temperature sensor (placed on
the flowmeter grille via the air filter outlet).
Replace the sensor (integrated into the air flowmeter) if it deviates (a sensor which deviates is often the result
of an electric shock).
AFTER REPAIR
13-70
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
COMPUTER SUPPLY VOLTAGE

PR004
NOTES

menu.
Ignition on
If the voltage is lower than the minimum recommended, the battery is discharged or unserviceable:
Recharge and teste the battery, check the charge circuit to detect the source of the problem, if necessary
replace the battery.
If the voltage is above the recommended level, the battery is overcharged:
Check that the charging voltage is correct with and without electrical consumers.
At idle speed
If the voltage is lower than the minimum recommended, the charging voltage is too low, or the battery is
unserviceable:
Check the electrolyte level, recharge the battery and perform a test.
If the battery is not faulty, check the charging circuit to find the source of this problem.
If the voltage is above the maximum recommended level, the charging voltage is too high:
The alternator regulator is faulty. Rectify this fault.
AFTER REPAIR
13-71
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
ATMOSPHERIC PRESSURE SENSOR

PR016
NOTES
menu.
The atmospheric pressure sensor is inside the engine management computer, and no repairs are possible.
Simply check that the computer's air vent is not clogged.
If the parameter is not correct, reset the computer. Check parameter PR016 with the engine running and with
the engine stopped but the ignition on.
If the value read is not correct, replace the computer.
vehicle.
AFTER REPAIR
13-72
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
TURBOCHARGER PRESSURE
PR082
NOTES

Parameter menu or after a customer complaint (lack of performance, fumes, etc.).
Check the turbocharger pressure.:

While stationary, with the engine idling + full load for 3 seconds (up to 4170 rpm) the tool should indicate a
turbocharger pressure of:
~ 1850 hPa for F9Q 760 / F9Q 762 engines
During a road test, with the engine idling + full load for 3500 rpm, the tool should indicate a turbocharger
pressure of:
~ 1995 hPa for F9Q 760 engines
~ 1850 hPa for F9Q 762 engines
If the turbocharger pressures are not in conformance, check that the sensor is operating correctly by
proceeding as follows:
Remove the hose from the turbocharger pressure sensor at the inlet manifold end and connect it to a vacuum
pump. Then check the values displayed by the diagnostic tool, in the "parameters" screen, against the pressure
and vacuum values given by your vacuum pump.
Maximum pressure to apply: 2200 hPa or 2.2 bar.
Minimum pressure to apply: 400 hPa or 0.4 bar.
In the event of a deviation > 100 hPa or 0.1 bar (depending on precision of the pump pressure
gauge). Check that there is no interference resistance on the signal line and on the sensor supply
lines. Replace the sensor if the electric connections are not faulty.
If there is no deviation, check:
the leaktightness of the hose connecting the sensor to the inlet nozzle, and the tightness of its
collars,
the leaktightness of the admission circuit: unions, hose, sleeves, exchanger, turbocharger.
Perform the interpretation of commands fault finding procedure: AC004: Wastegate.
Ensure there is no oil in the air inlet circuit.
Check the efficiency of the turbocharger.
Ensure there is no back-pressure at the exhaust.
AFTER REPAIR
13-73
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
RAIL PRESSURE
PR083
NOTES

Perform this diagnostic after detecting an inconsistency in the parameters menu or
following a customer complaint (starting problem, lack of power, injection noise, etc.).
It is strictly forbidden to carry out an ohmmeter check on the rail pressure sensor.
Normal rail pressure value according to operating conditions:
Idling
- 275 bars 30 for F9Q 760 and F9Q 762 engines
During full load (3 seconds)
- 1480 bar max. for F9Q 760 engines
- 1100 bar max. for F9Q 762 engine
If the pressures do not conform and there is an engine operating fault (starting fault, injection noise, inadequate
performance, irregular engine operation), perform the following checks:
1 Make sure there is no interference resistance on the connections between:
2 Make sure the low-pressure diesel circuit is primed (max. 2.5 bar) at the outlet of pump EKP13
(submerged in the tank), regulated by the anti-return valve between 0.2 and 0.5 bar at the high pressure
pump inlet).
3 Check filter condition: pressure difference of at most 0.3 bar between the diesel fuel filter inlet and
outlet.
4 Check that there are no leaks on the high pressure circuit (visual checks, odours, etc.): pump, regulation
solenoid valve, pipes, rail unions, injectors, etc.
5 Check the operation of the pressure regulator (AC006 fault finding procedure).
6 Ensure correct operation of the injectors (return leakage too high, clogging, sticking: see injector fault
finding procedure).
AFTER REPAIR
13-74
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
REFRIGERANT FLUID PRESSURE

PR192

Parameter menu or after a customer complaint (no air conditioning, etc.).
NOTES
Display PR192 from the Parameter or Function menu of your diagnostic tool:
Start the engine, maintain a speed of 1500 rpm and turn on the air conditioning:
if the pressure is above normal, continue to stage no. 2.
if the pressure does not increase or remains lower than normal, go to the command menu on your diagnostic
tool and check the operation of the compressor and its relay by running command AC003. In the event of a
problem, apply the relevant fault finding procedure.
If the compressor and relay are not faulty: Check the conformity of the refrigerant pressure sensor by
comparing* the value shown on the diagnostic tool (PR192) with the value given by the pressure gauges
on an air conditioning station.
* IMPORTANT: the tool displays the absolute pressure, if the high pressure gauge on your charge station
displays the relative pressure, there will be a normal deviation between the two values, approximately equal to
atmospheric pressure.
If the values do not match, (gap > 1.5 bar), ensure the continuity and absence of interference resistance
on the connections between:
Track 1 refrigerant pressure sensor

Track 2 refrigerant fluid pressure
sensor
Track 3 refrigerant fluid pressure
sensor
If the computer/refrigerant pressure sensor connections are not faulty, replace the refrigerant
pressure sensor (see section 62 of the Workshop Repair Manual).
If the values coincide, the sensor is not faulty, continue to stage no. 2
Stage no. 2Perform a complete fault finding check on the air conditioning.
AFTER REPAIR
13-75
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
Fault finding - Interpretation of commands
13
AIR CONDITIONING INHIBITION

AC003
NOTES

Perform this diagnostic after detecting an anomaly in the command menu or following
a problem with the air conditioning compressor.
If the compressor does not engage when command AC003 is issued, carry out the following checks:
If the compressor
relay does not
operate
Check the continuity of the following connection:
Engine management computer, connector A, track F4
Track 2 Compressor relay socket R6
Check fuse F2 and the power supplies of the compressor relay socket:
Compressor relay socket R6 track 1
12 V after relay
Compressor relay socket R6 track 3
12 V battery.
Check the resistance of the compressor clutch coil: 3.5 0.5.
If all these checks are OK, check operation of the compressor relay by the engine management computer in
the following way:
Remove the compressor relay, put a 50 to 100 resistor on the mounting in place of the relay coil (tracks 1
and 2), reconnect the voltmeter terminal (-) on track 2 of the relay socket and the (+) voltmeter terminal on
track 1 of the relay socket:
Clear the fault and run command AC006;
If the voltmeter does not display the battery voltage (ten sequences), replace the engine management
computer. If necessary, modify the configuration of the new computer to match the equipment options
present on the vehicle.
If the voltmeter displays the battery voltage (ten sequences), replace the compressor relay.
If the compressor
relay operates
Check the air conditioning compressor clutch resistance: 3.5 0.5.
Check the continuity and insulation relative to earth of the following connection:
Compressor relay socket "R6", track 5
Track A compressor connector
Check the presence of earth on track B of the compressor connector.
Check fuse F3 (15A) and its holder and terminals.
Check power supply of the compressor relay socket: track 3
12 V battery
Check the conformance of compressor diode No. 10 in the engine fuse/relay box.
AFTER REPAIR
13-76
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
TURBOCHARGING LIMITATION VALVE

AC004
NOTES
Carry out this fault finding procedure following interpretation of an unresolved fault, or
following handling of the interpretation of PR082 and/or following a customer complaint
(lack of power, smoke, etc.).
In the event of a problem on the braking assistance (SERVOFREIN), first check that the vacuum pump
operates correctly and check the conformity of its unions and wastegate.
IMPORTANT: When performing this command, a vacuum pressure (600 mbar) must be maintained at the inlet
of the solenoid valve, in order to hear it operate and verify the simultaneous operation of the wastegate flap.
If, when this command is executed, no flap movement is observed:
Check the resistance of the wastegate (turbocharger pressure limitation valve) between its tracks1 and 2.
Replace the wastegate if the resistance is not approximately: 16.5 1.6 at + 25C / 22.1 2.2 at
+ 110C.
Make sure there is no interference resistance on the connections between:
Track 1 of the turbocharger pressure
regulator
12 V after relay
Track 2 of the turbocharger pressure
regulator
Check the leaktightness of the vacuum circuit, from the vacuum pump to the wastegate control diaphragm
(to check the operation of the wastegate diaphragm and its flap, operate it directly with a vacuum pump).
Check the setting of the wastegate rod (Workshop Repair Manual section 12: Wastegate).
Check the upper and lower stops of the wastegate flap.
AFTER REPAIR
13-77
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
LOW PRESSURE PUMP RELAY

AC005
NOTES
No faults should be present or stored

Perform this diagnostic after detecting a malfunction in the command menu or following
a customer complaint (starting problem).
Reminder: the low-pressure pump is used for priming the high-pressure pump. As soon as the engine speed
exceeds 300 rpm or the high pressure reaches approx. 250 bar, the relay command is deactivated.
If relay "R3" is not actuated, (by command AC005): Carry out a check of the connectors of relay socket "R3".
If the problem persists, check that relay R3 is operated by the engine management computer as follows:
Disconnect relay R3, put a 50 to 100 resistor on the relay socket in place of the coil and connect the
voltmeter as follows:
Positive terminal on + 12 V battery
Negative terminal on track 2 of relay socket "R3".
Delete the fault.
Run command AC005,
If the voltmeter does not display the battery voltage (a sequence of approximately 10 seconds), replace the
computer. If necessary, modify the configuration of the new computer to match the equipment options
present on the vehicle.
If the voltmeter indicates the battery voltage correctly, replace relay "R3".
If the relay is actuated, but the low-pressure pump does not work, check with the help of the wiring diagram:
the battery + power supply for track 3 of relay socket "R3";
the continuity of the connection between track 5 of relay socket "R3" and track 1 of the low-pressure pump
motor connector;
the conformity of low-pressure pump relay "R3" (and its mounting);
the conformity of the low pressure pump (insulation, etc.),
the continuity of the connection between track 2 of the low-pressure pump motor connector and earth.
AFTER REPAIR
13-78
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
AC006
NOTES
DIESEL INJECTION
13
FUEL PRESSURE SOLENOID VALVE

(pressure regulator)
Perform this diagnostic after detecting an anomaly in the command menu, or following
interpretation of an unresolved fault, or following a customer complaint.
Special note: a suspected problem with the pressure regulator (or flow regulator)
requires the pump/regulator unit to be replaced.
Check the resistance of the pressure regulator between tracks 1 and 2.

If the resistance is not approximately: 5 0.5 at 20C. Replace the pump/pressure regulator unit.
Make sure there is no interference resistance between:
Track 2 of the pressure regulator connector.
12 V after relay
Track 1 of the pressure regulator connector.
Check the operation of the computer output stage by measuring the solenoid valve Opening Cyclic Ratio while
executing its command. During the 24 seconds of this command, the valve receives ten cycles from two successive
Opening Cyclic Ratios which can be measured in the following ways:
By voltmeter: With the solenoid valve connected, link the voltmeter's earth lead to track 2 of the fuel pressure
solenoid and the positive lead to track 1, clear any fault from the fuel pressure solenoid valve, then execute
command AC006:
The voltmeter should display two successive voltages approximately equal to the battery voltage and
the current Opening Cyclic Ratio, i.e. successively: ~ 3.15 V for an Opening Cyclic Ratio of 25% then
~ 9.45 V for an Opening Cyclic Ratio of 75% (ten cycles).
By oscilloscope on 5 V/div calibre and a base time of 1 ms/div: with the solenoid valve connected, connect the
oscilloscope to the battery earth and the positive touchpoint on track 2 on the fuel pressure solenoid valve, clear
a possible fault on the fuel pressure solenoid valve, then initiate command AC006:
The oscilloscope should display a square signal of 12.5 V amplitude at a frequency of 185 Hz (with an Opening
Cyclic Ratio which switches from 25 to 75% successively).
If the measurement does not indicate any control, or a fixed direct current, replace the engine management
computer, if necessary modify the configuration of the new computer against the options presented on the vehicle.
If the solenoid valve, its connection and its management are in conformance, go on to the next stage:
With the engine running at a different speed, display PR202: Regulated fuel flow:
If this value falls without a noticeable decrease in the rail pressure, this may indicate seizure or jamming of the
flow solenoid valve (jammed open).
In this case, and in the case of overpressure in the rail:
Check operation of the injectors: see Help section
on the pressure sensor: Interpretation of PR083 fault finding procedure,
If these two checks do not indicate any fault, replace the pump/regulator assembly.
If this value increases without a noticeable increase in the rail pressure, this may indicate sticking or jamming of
the pressure solenoid valve (jammed shut).
In this case, and in the case of underpressure in the rail:
Ensure correct operation of the "parameter interpretation diagnostic PR083 pressure sensor, check 1".
Make sure that the low-pressure diesel circuit is primed (max. 2.5 bar) at the outlet of pump EKP13 (submerged
in the tank), regulated by the anti-return valve between 0.2 and 0.5 bar at the high pressure pump inlet).
Check the leaktightness of the low pressure and high pressure diesel circuit (visual checks, odours, etc.): pump
body, pressure regulator, pipes, rail unions and injectors, etc. Perform the necessary repairs.
Check tension of the high pressure pump drive belt.
Check the operation of the injectors: Injector fault finding, see Help section.
If the checks are correct, replace the pump/regulator unit.
AFTER REPAIR
13-79
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
AC007
NOTES
DIESEL INJECTION
13
EGR VALVE
Perform this fault finding procedure following unresolved fault DF077 (1.DEF or 2.DEF)
or following a customer complaint (poor performance, smoke, etc.).
Stage no. 1:
If its resistance is not approximately 8 0.5 at + 20C, replace the exhaust gas recirculation valve.
Make sure there is no interference resistance on the connections between:
Engine ECU, connector B track M1
Track 5 exhaust gas recirculation valve connector
12 V after relay
Track 1 exhaust gas recirculation valve connector
Check the operation of the computer output stage by measuring the exhaust gas recirculation valve Opening
Cyclic Ratio while executing the command. During the 24 seconds of this command, the valve receives ten
cycles of two successive Opening Cyclic Ratios, which can be measured in the following ways:
By oscilloscope on 5 V/div calibre and a base time of 2 ms/div: with the exhaust gas recirculation valve
connected, connect the oscilloscope earth to the battery earth and the positive touchpoint on track 5 of the
exhaust gas recirculation valve, clear any possible exhaust gas recirculation valve fault, then initiate
command AC007.
The oscilloscope should display a square signal of 12.5 V amplitude at a frquency of 140 Hz, (with an
Opening Cyclic Ratio ranging from 25 to 75%).
Or with a voltmeter: with the exhaust gas recirculation valve connected, connect the voltmeter earth
braiding on track 2 of the exhaust gas recirculation valve and the positive braid to
track 1, clear any possible exhaust gas recirculation valve fault, then initiate command AC007; the voltmeter
should display two successive voltages approximately equal to the product of the battery voltage and the
current Opening Cyclic Ratio, i.e. successively: 3.15 V for an Opening Cyclic Ratio of 25% then 9.45 V for
an Opening Cyclic Ratio of 75% (10 cycles).
If the oscilloscope (or the voltmeter) does not indicate any control, or a fixed direct current, replace the engine
management computer. If necessary, modify the configuration of the new computer to match the equipment
options present on the vehicle.
If the exhaust gas recirculation valve, its connection and its automation are not faulty, continue to the next
stage:
Stage no. 2
Disconnect the connector and remove the exhaust gas recirculation valve:
If removal reveals that the valve is blocked (e.g.: valve in open position), replace the exhaust gas
recirculation valve.
Otherwise, reconnect the connector, clear the fault and run command AC007:
The valve receives two successive Opening Cyclic Ratio cycles: 25% and 75%.
Then check:
The movement of the valve when the command is executed, (2.25 mm 0.1 for an Opening Cyclic Ratio of
25% and 6.75 mm 0.3 for an Opening Cyclic Ratio of 75%).
There is no clearance between the exhaust gas recirculation valve and its control stalk as well as the general
condition (clogging, hard point, etc.).
Valve closing when the command is completed.
If during command AC007, no movement of the exhaust gas recirculation valve is noticed, or if these checks
reveal an irreparable blockage or seizing, replace the exhaust gas recirculation valve.
AFTER REPAIR
13-80
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
LOW SPEED FAN ASSEMBLY RELAY

AC011
NOTES

Perform this fault finding procedure after detecting an anomaly in the commands menu
or following an engine cooling or air conditioning fault.
REMINDER: if the vehicle is not fitted with air conditioning, there is no low speed fan assembly relay; in that
case it is replaced by the fan assembly relay "R9". In this case, command AC011 triggers fan operation at high
speed and the procedure to be complied with in case of problems is the procedure for command AC012.
If relay "R10" is not actuated (when command AC011 is run):

Check the "R10" relay socket connections.
If the problem persists, check that relay "R10" is controlled by the engine management computer as follows:
Disconnect relay "R10", put a 50 to 100 resistance on relay socket "R10", in place of the coil and connect
a voltmeter as follows:
Negative terminal on track 2 of the "R10" relay socket.
Clear the fault and initiate the "AC011" command.
If the voltmeter does not display the battery voltage (ten sequences of 1 second), replace the computer.
vehicle.
If the voltmeter displays the battery voltage (ten sequences of 1 second), replace relay "R10".
If relay "R10" activates, but there is still a coolant temperature or air conditioning warning fault, use the wiring
diagram to check:
the conformance of fan fuse "F03";
presence of + battery supply on track 3 of the low speed fan unit relay socket, "R10",
the conformity of relay "R10",
the continuity of the connection between track 5 of relay socket "R10" and track 1 of the low-speed resistor;
the conformity of the low-speed resistor (resistance and connections);
the continuity of the connection between track 2 of the low speed resistor connector and track 1 of the fan
connector;
the condition of the fan;
the continuity of the connection between track 2 of the fan connector and earth.
AFTER REPAIR
13-81
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
HIGH-SPEED FAN ASSEMBLY

AC012
NOTES

Perform this fault finding procedure after detecting a fault in the commands menu or
following a problem of engine cooling.
REMINDER: if the vehicle is not fitted with air conditioning, this command is not operational. Fan operation at
high speed is in that case triggered by command AC011 and the procedure to be complied with in case of
problems is as follows:
If relay "R9" is not activated (when command AC012 is executed):

Check the "R9" relay socket connections.
If the problem persists, check that relay "R9" is operated by the engine management computer as follows:
Disconnect relay "R9", fit a 50 to 100 resistor on the "R9" relay socket in place of the coil and attach a
Negative terminal on track 2 of "R9" relay socket
Clear the fault and initiate the "AC012" command.
If the voltmeter does not display the battery voltage (ten sequences of 1 second), replace the computer.
vehicle.
If the voltmeter displays the battery voltage (ten sequences of 1 second), replace relay. "R9".
If relay "R9" activates, but there is still a coolant temperature warning fault, use the wiring diagram to check:
the conformance of fan fuse "F03";
presence of + battery supply on track 3 of the high speed fan unit relay socket, "R9",
the conformity of relay "R9",
the continuity of the connection between track 5 of relay socket "R9" and track 1 of the fan connector,
the conformity of the fan assembly,
the continuity of the connection between track 2 of the fan connector and earth.
AFTER REPAIR
13-82
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13

AC301
NOTES

Perform this fault finding procedure in the event of the function not working properly,
indicated in the command menu or in the event of a passenger compartment heating
or demisting fault.
If relay "R7" is not actuated when command AC301 is run:

Check the connectors of additional heater No. 1 relay socket "R7".
Disconnect relay "R7", put a 50 to 100 resistor on the relay socket in place of the coil and connect the
Negative terminal on track 2 of relay socket "R7"
Clear the fault.
Run command AC301.
If the voltmeter does not display the battery voltage (two sequences of 1 second), replace the computer.
vehicle.
If the voltmeter does display the battery voltage (two sequences of 1 second), replace relay "R7".
If relay "R7" activates, but there is still a passenger compartment heating or demisting fault, use the wiring
diagram to check:
the conformance of fuse "F01" (70A);
the presence of + 12 V battery on track 3 of relay socket "R7",
the conformance of relay "R7";
the continuity between track 5 of relay socket "R7" and the supply lug of thermoplunger 1;
the conformity of the thermoplunger resistance: 0.45 0.05 at 20C,
the presence of earth at the plenum chamber (thermoplunger mounting).
Also check the level of the cooling circuit and that there are no leaks.
AFTER REPAIR
13-83
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13

AC302
NOTES

or demisting fault.
Special note:
The "No. 2 thermoplunger relay", supplies thermoplungers 2 and 3 in parallel.
If relay "R8" is not activated when command AC302 is executed:

Battery negative terminal on track 2 of relay socket "R8".
Delete the fault.
Begin command AC302.
vehicle.
diagram to check:
the continuity between track 5 of relay socket "R8" and the supply terminals of thermoplungers 2 and 3,
the conformity of the thermoplunger resistors: 0.45 0.05 at 20C,
AFTER REPAIR
13-84
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13

AC002
NOTES

or demisting fault.
If relay "R1" is not activated when command AC002 is executed:

Negative terminal on track 2 of relay socket "R1"
Clear the fault.
Run command AC002.
vehicle.
diagram to check:
the continuity between track 5 of relay socket "R1" and the supply lug of thermoplunger 4;
the conformity of the thermoplunger resistance: 0.45 0.05 at 20C.
AFTER REPAIR
13-85
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
NOTES
DIESEL INJECTION
Fault finding - Customer complaints
13
Before carrying out the steps associated with customer complaints, check for the
absence of faults and the conformity (or otherwise) of the parameters and states, using
If the customer complaint is not eliminated, then proceed according to the
corresponding fault finding chart.
NO COMMUNICATION WITH THE COMPUTER
CHART 1
STARTING DIFFICULT OR IMPOSSIBLE
CHART 2
INJECTION NOISE
CHART 3
POOR PERFORMANCE
CHART 4
IRREGULAR ENGINE OPERATION
CHART 5
13-86
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
CHART 1
DIESEL INJECTION
Fault finding - Fault finding chart
13
No communication with the engine management computer
Check the conformity of the vehicle type and the domain selected on your tool.
Make sure that the tool is not faulty by trying to establish dialogue with a computer on another vehicle.
In the engine fuse and relay box, check the correctness of:
fuses F2 and F4,
the injection computer supply relay, marked "R2":
65 5
between tracks 1 and 2
infinite resistance
between tracks 3 and 5 (contact open)
resistance < 0.3
between tracks 3 and 5 (contact closed)
Check the conformity of the impact sensor (inertia sensor) at rest (before impact): continuity between tracks 1
and 3.
Place bornier Ele 1613 on the engine harness on the computer side, and verify conformance of the power
supplies:
Engine management computer, connector B track E3
+ After ignition
Engine management computer, connector B tracks L3, L4 and M4
Earth
by shunting tracks 3 and 5 of relay socket "R2":
Engine management computer, connector B tracks M3 and M2
+ Battery (after relay)
Ensure continuity of the connection between:
Track 2 relay socket "R2"
Check the supply to the diagnostic socket:

+ before ignition on track 16 / + after ignition on track 1 / earth on tracks 4 and 5
Ensure the continuity of the following connection:
Diagnostic socket track 7 (line K)
If the tool is not faulty, try to communicate with another computer on the same vehicle.
If you cannot communicate with another computer on the same vehicle, it may be that a faulty computer is
causing interference on line K. To locate it, proceed by elimination by successively disconnecting the following
computers (depending on the equipment): air conditioning, air bag, ESP and ABS, UCH, instrument panel,
central communication unit, proximity sensor. Try to make communication between each disconnection.
If you still can't enter into communication, disconnect all the above-mentioned computers, as well
as the engine management computer, and check insulation against + 12 V and against earth of
track 7 of the diagnostic socket.
If you can enter into communication with another computer on the same vehicle: replace the engine
management computer. If necessary, modify the configuration of the new computer to match the equipment
options present on the vehicle.
AFTER REPAIR
Perform a road test followed by a check with the diagnostic tool.
13-87
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
CHART 2
Starting problems
(no starting or difficulty starting the engine)
NOTES
Before analysing this customer complaint, check for absence of faults, and conformity
(or otherwise) of parameters and statuses, using the diagnostic tool.
If the customer complaint is not resolved, perform the following checks:
See next
page
impossible
Is starting difficult or impossible?

difficult
Check the engine earths.

Make sure the engine speed reaches 250 rpm when the starter motor is operated, displayed in the parameter
screen.
Ensure that the correct fuel is being used.
Check that the low pressure diesel circuit is primed (presence of air bubbles upstream of the pump; if there are
numerous such bubbles, look for the air leak).
Check the supercharging pressure at the high-pressure pump inlet, namely: 0.2 to 0.5 bar.
Check operation of pre-heater plugs (absence of DF061 fault).
Check condition of diesel fuel filter (measurement of the pump pressure upstream and downstream of the
filter).
Ensure the tightness of the high-pressure circuit - pump, pipes, unions (visual check + odours).
Check the condition of the air filter (clogging).
Check the position of the exhaust gas recirculation valve (blockage, mechanical seizing, see interpretation of
commands: AC007).
Check the consistency of the coolant temperature sensor signal (compare the value given by the tool with that
given by a thermometer).
Ensure correct operation of the injectors (return leakage too high, clogging, sticking: see injector fault finding
procedure).
Check compression values:
1: according to current consumption in the starting phase (Compression test menu on the
CONSULT II tool).
2: in the event of unbalanced fuel consumption, use a compression meter to complete the
measurements.
AFTER REPAIR
13-88
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
CHART 2
Starting impossible
(or vehicle starts and stalls immediately)
NOTES
From the "STATUS" menu on your diagnostic tool, verify the

conformance of the immobiliser system: "ET003" should be "inactive",
"ET110" should be "YES".
Correct
Incorrect
Check the position and conformance of the impact switch.
Check the presence of 12 Volts after relay on tracks M2 and M3 of
connector B on the engine management computer.
Check the battery charge as well as the condition and tightness of the
terminals and the engine earth connections.
Check the engine fuses (+ mountings, wires and terminals).
Check the conformance of the main relay (+ mountings, wires and
terminals).
Check the engine speed sensor mounting.
Check the absence of fault: DF070; camshaft sensor/engine speed
consistency.
Make sure the engine speed reaches 250 rpm when the starter motor
is operated, displayed in the parameter screen.
Ensure the presence and conformity of fuel in the tank.
Refer to the immobiliser

fault finding procedure.
test
YES
Activate the starter motor:

Does the pressure rise normally in the rail?
high pressure 170 bar at approx. 250rpm
NO
Make sure of correct

operation of the injectors
(no internal leaks,
gumming or jamming)
Check the engine
compression.
AFTER REPAIR
Make sure the low-pressure diesel circuit is primed.

Check the condition of the fuel filter (measurement of the LP pump
pressure upstream and downstream of the filter).
Check the leaktightness of the high-pressure circuit - pump, pipes,
unions (visual checks + smells).
Ensure correct operation of the pressure sensor (interpretation of
parameters: PR083)
Make sure that the pressure regulator is not jammed/seized.
Check the injectors (refer to the injector fault finding procedure in the
Help section).
13-89
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
CHART 3
Injection noise
NOTES
REMINDER: A just-audible knocking noise under low load conditions between 1800 and 2500 rpm is a
characteristic of the normal operating noise for this engine. No intervention is therefore recommended. This
noise should disappear as the engine is revved up.
If occurring following cold-starting:
Ensure correct operation of the preheating function.
Check the consistency:
of the fuel and engine temperatures; fault finding procedure PR002 and PR001
of the rail pressure signal; diagnostic PR083
If the fault persists, carry out an injector fault finding procedure.
If you hear the noises at idling speed:

Check the condition of the injector connectors and contact, and the pressure regulator.
Ensure the correct fuel is being used.
Check that there is no air in the low pressure fuel circuit.
Ensure supply to the fuel heater.
Check the condition of the air filter.
Check the position of the exhaust gas recirculation valve (interpretation of commands: AC007).
Check the consistency of the airflow signal.
If the fault persists, perform the fault finding procedure on the injectors, then the high pressure pump.
If occurring at all engine speeds,
Check the condition of the injector connectors and contacts, and the pressure regulator.
Ensure the correct fuel is being used.
Check the consistency and stability of the rail pressure signal (PR083 fault finding procedure).
If occurring at transient engine speeds:

In road testing, when changing gear, view the PR202 parameter; if the value varies, without having any major
influence on the rail pressure, this may indicate seizure of the flow controller. In this case, refer to diagnostic
AC006.
AFTER REPAIR
13-90
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
CHART 4
Poor performance
NOTES
Is the poor performance accompanied by smoke?
NO
If yes: check whether the wastegate or its solenoid valve are jammed in open
position (use fault finding procedure AC004).
NO
Is the poor performance il accompanied by smoke at full load?

If yes: check whether the exhaust gas recirculation valve is jammed in open
position. Use fault finding procedure AC007.
Does the engine rotate on all cylinders?

If no: check the operation of the injectors (injector fault finding procedure Help
section).
Check the conformity of the pedal sensor, atmospheric pressure sensor and exhaust gas recirculation valve.
Check the level of clogging of the air filter.
Make sure there are no foreign bodies on the grille of the flowmeter and in the air inlet section (e.g., detachment
of the internal lining of a hose).
Check:
the condition of the intercooler (clogging),
the leaktightness of the admission circuit between flowmeter and turbocharger,
the tightness of the oil vapour rebreathing circuit,
the flow regulator (jamming or seizing; use fault finding procedure AC006),
the wastegate and its solenoid valve (jamming or seizing),
the absence of leaks in the low pressure and high pressure diesel circuit,
the turbocharger efficiency.
Check consistency of the following signals: flowmeter, coolant temperature sensor, turbocharger pressure
sensor, fuel-temperature sensor.
Check the engine compression.
Make sure there is no back-pressure at the exhaust.
AFTER REPAIR
13-91
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
13
CHART 5
Irregular engine operation
NOTES
If, when changing gears, the vehicle jerks or builds up engine speed (with loss of engine braking), check
conformance of the clutch sensor and if need be carry out the DF097 procedure: Step 1.
Ensure that the correct fuel is being used.
Make sure the low-pressure circuit is primed (no air in the circuit).
Check conformance of rail pressures: 250 bar at idling speed and 1350 bar under load with foot hard down
on the accelerator.
Check conformity of the air flow:
30 to 36 kg/h air flow at 800 rpm,
390 kg/h under load at full load.
If this is not the case, check the leaktightness of the inlet circuit and ensure that there are no foreign bodies on
the flowmeter grille.
Check the operation of the turbocharging function (refer to AC004).
Check the injectors: with engine running at idling speed, disconnect the injectors one after the other:
If disconnecting one of the injectors does not cause a change in operation, it indicates a fault (electrical or
mechanical). After eliminating the connections as the possible cause of the fault, replace the faulty injector.
Clear the faults caused by the multiple disconnections, then perform a conformity check.
Check the engine compression values.
AFTER REPAIR
13-92
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
Fault finding - Help
13
INJECTOR FAULT FINDING PROCEDURE

STAGE no. 1: check for electrical conformity
If you perform this fault finding procedure following an unresolved fault (DF099 to DF102), go directly to step 2.
Otherwise, carry out the following checks:
Resistance between tracks 1 and 2 of each injector: 0.33 at 20C /2 max.
Continuity, absence of interference resistance and insulation on the following connections:
Track 2 of of injector no. 1 connector
Track 2 of the connector for injector no. 3
Track 1 of the connector for injector no. 3
Track 2 of the injector no. 4 connector,
Track 1 of the injector no. 4 connector
STAGE no. 2: check the balance of the injector return flow

From the "parameters" menu of your diagnostic tool, check conformance of the fuel pressure at 800 rpm, at approx.
2000 rpm, then after switching off the engine. Failure of one or more injectors can result in either an overpressure
or an underpressure in the rail:
Fit tappings on the injector returns towards the measuring cylinders, start the engine and check the flow balance,
first at 800 rpm then at 2000 rpm:
In the event of overpressure in the rail:
Replace the injector for which the return indicates no leak or a smaller leak than for the other returns,
In the event of under-pressure in the rail:
Replace the injector whose return shows a stronger leak than the others.
The gradual fall in pressure in the rail, when the engine is switched off, is obtained by discharge of the high
pressure towards the injector return circuits (about 2 minutes to fall below 2 bar). It is therefore possible to carry
out the same procedure for checking flow balance after the engine has been switched off, or, better still, after timing
(obtaining a high rail pressure, with the engine stopped, due to a sudden engine switch-off).
STAGE 2: check on leaktightness of the injector nozzle

If the engine starts:
With the engine running, disconnect the injectors one after the other.
Replace the injector which causes no variation in operation when it is disconnected. (this also applies to
blocked closed injectors). Clear the faults that are caused by these multiple disconnections, and then road
test the vehicle to confirm repair.
If the engine does not start:
Check the level and condition of the engine oil (contamination by diesel oil).
If the preceding check indicates pollution, remove the injectors to pinpoint which one is leaking. (If one of
the four nozzles is wet and the other three are dry, the injector with the wet nozzle is leaking). Replace
the faulty injector.
For removal of injectors, refer to the method defined in the Workshop Repair Manual, Section 13.
13-93
vnx.su
EDC15C3C - Bosch
Program No.: CB
Vdiag No.: 0C
F9Q 760 / 762
DIESEL INJECTION
Fault finding - Glossary
13
F9Q 760 and 762 engine speed (60 and 74 kW):

Idling, warm engine
800 rpm
Idling + heated windscreen
1000 rpm
Idling + thermoplungers
825 rpm
Fast idling in the event of accelerator pedal sensor failure:
1200 rpm
Maximum engine speed, no load
3000 rpm
High pressure pump
CP3
from 275 to 1350 bar
Boosting pump
2.5 bar max. / flow rate 80 to 100 litres/h. minimum
Anti-return valve and low pressure controller
Calibration: from 0.2 to 0.5 bar
Pressure sensor
screwed on rail
Injector
0.33 at 20C / 2 max
Flow regulator (on high-pressure pump)
R = 5 at 20C (not removable)
Injection computer
128 tracks
Accelerator pedal sensor
R track 1 = 1200 480

R track 2 = 1700 680
Heater plug
R = 0.6 (consumption at start of preheating 20A)
Air temperature sensor
R = 3714 161 at 10C / 2448 90 at 20C / 1671 59 at 30C
Diesel oil temperature sensor
R = 3820 282 at 10C / 2050 100 at 25C / 810 47 at 50C
Engine coolant temperature sensor
R = 2252 112 at 25C / 811 39 at 50C / 283 8 at 80C
Engine speed sensor
R = 800 80 at 20C
Camshaft sensor
Hall-effect sensor
Turbocharger pressure sensor
Power supply 5 0.25 V / pressure from 0 to 2.5 bar.
Wastegate control solenoid valve
R = 16.5 1 to 25C
Air flowmeter
Track 1: air temperature signal
Track 4: + 12 V battery
Track 2: - flowmeter
Track 5: air flow signal
Track 3: + 5 V flowmeter
Track 6: Earth
R between tracks 1 and 5 (coil): = 8 0.5 at 20C
Thermoplungers
R = 0.45 0.05 at 20C
(R = resistance)
13-94
vnx.su
F9Q ENGINE
ANTI-POLLUTION
114
Oil vapour rebreathing
14
CIRCUIT DIAGRAM
A Oil vapour rebreathing pipe for the bottom of engine

1
2
3
4
B Oil vapour rebreathing pipe for the top of engine.
Engine
Oil decanter
Air filter unit
Inlet manifold
C Oil decanter.
D Oil vapour rebreathing pipe linked to the inlet pipes.
INSPECTION
To ensure the correct operation of the anti-pollution
system, the oil vapour rebreathing circuit must be kept
clean and in good condition.
14-1
vnx.su
ANTI-POLLUTION
F9Q ENGINE
CIRCUIT DIAGRAM
1
2
3
4
5
6
Engine
Injection computer
Inlet manifold
Exhaust manifold
Exhaust gas recirculation solenoid valve
REMOVING THE VALVE

The exhaust gas recirculation valve is an interference fit with the inlet
manifold.
To make it easier to replace, it is preferable to remove the manifolds.
AIM OF THE EXHAUST GAS RECIRCULATION CIRCUIT
Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content
of the exhaust gases.
The injection computer allows gas to pass by controlling a solenoid valve.
14-2
vnx.su
14
F9Q ENGINE
ANTI-POLLUTION
14
OPERATING PRINCIPLE
The valve is controlled by an Opening Cyclic Ratio
(OCR) signal emitted by the injection computer. The
Opening Cyclic Ratio signal adjusts the opening of
the valve and consequently the quantity of exhaust
gas directed back to the inlet manifold.
OPERATING CONDITIONS
The parameters controlling activation of the exhaust
gas recirculation solenoid valve are the following:
coolant temperature,
air temperature,
atmospheric pressure,
accelerator pedal position,
engine speed,
air flow,
injection flow rate,
turbocharging pressure.
If there is a fault in:

the coolant temperature sensor,
the air temperature sensor,
the atmospheric pressure sensor,
the exhaust gas recirculation solenoid valve is fed for
40 seconds on each return to idle speed if the air
temperature is greater than 15 C.
Exhaust gas recirculation is cut off if:

the battery voltage is below 9 V,
engine speed is below 600 rpm.
engine speed is greater than 3000 rpm.
mapping (engine speed/load) exceeds a given
threshold,
vehicle speed is less than 7.5 mph (12 kph), and
engine speed is less than 1000 rpm
after running for 18 minutes if the air temperature
stays between 10 C and 30 C.
The exhaust gas recirculation valve is not controlled
after engine start-up depending on coolant
temperature mapping.
X
Y
Time
Coolant temperature (C)
1
2
4
5
6
14-3
vnx.su
Solenoid feed
Sensor feed
Sensor earth
Solenoid earth
Sensor output
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
117
17
GENERAL APPROACH TO FAULT FINDING

To carry out a fault finding test on the SAGEM 2000 Vdiag 08 injection system, the
following elements are required:
The wiring diagram of the function on the vehicle concerned.
Consult II diagnostic tools.
Multimeter.
Test bornier El. 1590.
Use one of the diagnostic tools to identify the system fitted on the vehicle (reading the computer family
- SAGEM 2000 Vdiag 08).
NOTE:
If dialogue cannot be established with the computer, go straight to the Customer complaints section and refer to
FAULT FINDING CHART 1 No dialogue with the computer.
Read the faults stored in the computer memory and use the Fault interpretation section of the
documents.
Reminder:
the interpretation of a fault should be considered when using the diagnostic tool after the engine
has been switched off and on again.
There are two types of fault interpretation, faults present and faults stored in memory.
If the fault is declared "Present":
run the diagnostic directly.
If the fault is declared "Stored":
follow the notes for application to a stored fault.
If the fault is not returned as "present", run the diagnostic but do not replace components.
In both cases, complete the fault finding procedure by performing the "After repair" section.
17-1
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
Performance of the conformance check (appearance of possible malfunctions not yet declared by the
system's self diagnosis procedure) and application of the relevant fault finding techniques according to
results.
Validation of the repair (elimination of the sections on "Customer complaints" and "Fault finding chart").
Use of the sections on "Customer complaints" and "Fault finding chart", if the problem persists.
IMPORTANT
Do not drive the vehicle until you have checked that the computer is clear of any fault relating to the throttle
unit.
CHARACTERISTICS OF THE BORNIER

The El. 1590 bornier comprises a 112-track base fixed to a printed circuit carrying 112 coppered areas
numbered from 1 to 112.
Using the wiring diagrams, it is easy to identify connections or other parts needing to be checked.
IMPORTANT
Any checks using bornier El. 1590 should only be performed with the battery disconnected.
The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 V be
applied to the test points.
17-2
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF002
PRESENT
OR
STORED
INJECTION
Fault finding - Interpretation of faults
17
THROTTLE POTENTIOMETER CIRCUIT

DEF : Unidentified electrical fault
IMPORTANT:
Do not drive the vehicle until you have checked that the computer is clear of any
fault relating to the throttle unit.
NOTES
If faults DF125 and DF126 are present, deal with these as a priority.
a change in engine speed.
Check the cleanliness, connection and condition of the connections on the throttle potentiometer.
Replace the connectors if necessary.
Disconnect the computer. Check the cleanliness and condition of the connectors.
Connect the bornier in place of the computer and check the insulation, continuity and absence of
interference resistance on the following connections:
Computer track G4, connector B
Computer track D3, connector B
Throttle position potentiometer

(See the connector track numbers in the corresponding wiring diagram)

Check the cleanliness of the throttle, and correct rotation of the throttle valve.
Check that tracks 1 and 2 of the throttle potentiometer correctly follow their curves of resistance (see
values in the Help section).
Repair or replace the throttle unit if necessary.
If the fault has still not disappeared, deal with the other faults and then proceed to the conformity
check.
AFTER REPAIR
If the throttle unit has been replaced, reinitialise the programming (RZ008).
Follow the instructions to confirm repair:
If the fault is present, continue to deal with the fault.
If the fault is stored in memory, ignore it.
Deal with any other possible faults.
Clear the fault memory.
17-3
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF003
PRESENT
OR
STORED
NOTES
DEF
INJECTION
17
AIR TEMPERATURE SENSOR CIRCUIT

OBD : OBD (On Board Diagnostic) fault

Tripping of the fan with the engine running
Check the cleanliness, connection and condition of the sensor and the
connector.
Connect the bornier in place of the computer and check the insulation, continuity
and absence of interference resistance on the following connections:
Computer track E3, connector B


Check the resistance of the air temperature sensor (see the values in the
Helpsection).
If necessary replace the sensor.
If the fault has still not disappeared, deal with the other faults and then
proceed to the conformity check.
If the fault had been characterised as "DEF", it may change characterisation and
become "OBD"; this is normal.
AFTER REPAIR

If the fault is present and characterised as "DEF", continue to process the fault.
If the fault is stored and characterised as "DEF", ignore it.
If the fault is present or stored and characterised as "OBD", ignore it.
17-4
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF003
CONTINUED
OBD
NOTES
Run the engine until the fan begins to run.
If the fault's characterisation has become DEF after the instructions have been
followed, the electrical fault has been detected. Accordingly, it should be dealt with
as a fault present and characterised as DEF.
If the fault is still characterised as "OBD" after the instructions have been followed,
the electrical fault has been present several times but is no longer detected.
Accordingly, the circuit must be checked without changing parts which are not clearly
identified as at fault.
This check should be based on the fault finding procedure for the "DEF"
characterisation.
AFTER REPAIR

17-5
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF004
PRESENT
OR
STORED
NOTES
DEF
INJECTION
17


Tripping of the fan with the engine running
connector.
Computer track F2, connector B


Check the resistance of the air temperature sensor (see the values in the
Helpsection).
AFTER REPAIR

17-6
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF004
CONTINUED
OBD
NOTES
characterisation.
AFTER REPAIR

17-7
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF005
PRESENT
OR
STORED
NOTES
DEF
INJECTION
17
PRESSURE SENSOR CIRCUIT


the ignition is switched off and dialogue is lost;
the ignition has been switched on again and dialogue re-established,
10 seconds at idle speed.
Check that the manifold pressure sensor is properly fitted

Check that the inlet line is tight, from the throttle to the cylinder.
Verify that no seals are defective.
Check that the fuel vapour absorber bleed is not disconnected or jammed open.
Verify that the manifold air temperature sensor is properly fitted.
Check that the resonator is not cracked.
Check the cleanliness, connection and condition of the sensor and its
connection.
Replace as necessary.
Using a vacuum pump, check the consistency of the manifold pressure.
Check consistency with parameter PR001 in the diagnostic tool.
Computer track H2, connector B
Pressure sensor
Pressure sensor
Pressure sensor

AFTER REPAIR

17-8
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF005
CONTINUED
OBD
NOTES
characterisation.
AFTER REPAIR

17-9
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF006
PRESENT
OR
STORED
NOTES
DEF
INJECTION
17
PINKING SENSOR CIRCUIT


a road test while the engine is warm and at a high engine speed.
Check the conformity of the fuel in the fuel tank.

Check the conformity of the spark plugs.
Check that the pinking sensor is tightened.
connector.
Computer track A2 connector B
Computer track B2 connector B
Computer track C2 connector B
Pinking sensor
Pinking sensor
Pinking sensor screening

AFTER REPAIR

17-10
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF006
CONTINUED
OBD
NOTES
characterisation.
AFTER REPAIR

17-11
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF008
PRESENT
OR
STORED
NOTES
CO.0
CC.1
DEF
INJECTION
17
FUEL PUMP CONTROL RELAY CIRCUIT

CO.0
CC.1
DEF
OBD
:
:
:
:

Short circuit to +12 V
Unidentified electrical fault
OBD (On Board Diagnostic) fault

the ignition is switched on.
Check the supply fuse of the fuel pump relay.

Replace the fuse if necessary.
Check the cleanliness, connection and condition of the petrol pump relay
connector.
Replace the connector if necessary.
Disconnect the relay. Check the condition and cleanliness of the contacts.
With the ignition on, check for the presence of +12 V on track 1 of the fuel pump
relay, connector side.
Check the resistance of the fuel pump relay on tracks 1 and 2 (see the value in the
Help section).
Replace the fuel pump relay if necessary.
and absence of interference resistance on the following connection:
Computer track D1 connector C
Fuel pump relay

If the fault had been characterised as "CO.0, CC.1 or DEF", the fault may change
characterisation and become "OBD"; this is normal.
AFTER REPAIR

If the fault is present and characterised as "CO.0, CC.1 or DEF", continue to deal
with the fault.
If the fault is stored and characterised as "CO.0, CC.1 or DEF", ignore it.
17-12
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF008
CONTINUED
OBD
NOTES
If, after following the instructions, the characterisation has become "CO.0, CC.1 or
DEF", the electrical fault is detected. Accordingly, it should be dealt with as a present
fault and characterised as "CO.0, CC.1 or DEF"
This check should be based on the fault finding of the characterisations "CO.0, CC.1
or DEF".
AFTER REPAIR

with the fault.
17-13
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF009
PRESENT
OR
STORED
NOTES
INJECTION
17
ACTUATOR RELAY CONTROL CIRCUIT


Check the condition and cleanliness of the vehicle's battery and earth leads.
Check the two supply fuses of the actuator relays.
Replace if necessary.
Check the cleanliness, connection and condition of the actuator relay connector.
Check the resistance of the actuator relay across tracks 1 and 2. (See the value in the Help section).
Replace the actuator relay, if necessary.
Check for the presence of 12 V on track 1 of the actuator relay, connector side.
interference resistance on the following connection:
Injection computer track D4, connector B
Actuator relay.

check.
AFTER REPAIR
Follow the instructions to confirm the repair.

17-14
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
LOW-SPEED FAN ASSEMBLY CIRCUIT

DF010
PRESENT
NOTES

Deal with fault DF004 first if it is present.
Check the cleanliness, connection and condition of the low-speed fan assembly relay connector.
With the ignition on, check for the presence of + 12 V on track 1 of the relay.
Check the resistance of the low-speed fan assembly relay on tracks 1 and 2 (see the value in the Help
section).
Replace the low-speed fan assembly relay if necessary.
Computer track F1, connector C
Low-speed fan relay

check.
AFTER REPAIR

17-15
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF011
PRESENT
OR
STORED
NOTES
INJECTION
17
FAULT WARNING LIGHT CIRCUIT

None.
Test the multiplex network.

Refer to the "Multiplex Network" and "Instrument Panel" sections of the Workshop Repair Manual.
Perform fault finding on the "Instrument panel" system if necessary.
AFTER REPAIR
None.
17-16
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF014
PRESENT
OR
STORED
INJECTION
17
CANISTER BLEED SOLENOID VALVE CIRCUIT

CO.0
CC.1
DEF
OBD
:
:
:
:

Deal with faults DF009 or DF019 first if they are present.

NOTES
CO.0
CC.1
DEF

Check the cleanliness, connection and condition of the fuel vapour absorber
bleed solenoid valve connector.
With the ignition on, check for the presence of + 12 V on the fuel vapour absorber
bleed solenoid valve.
Computer track E1, connector C
Fuel vapour absorber bleed

valve

Check the resistance of the fuel vapour absorber bleed solenoid valve (see value in
the Help section).
Replace the solenoid valve, if necessary.
AFTER REPAIR

with the fault.
17-17
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF014
CONTINUED
OBD
NOTES
fault and characterised as "CO.0, CC.1 or DEF"
or DEF".
AFTER REPAIR

with the fault.
17-18
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF017
PRESENT
OR
STORED
INJECTION
17
FLYWHEEL SIGNAL INFORMATION

1.DEF
2.DEF
1.OBD
2.OBD
:
:
:
:
Engine flywheel target fault

Absence of tooth signal
(On Board Diagnostic) OBD fault: engine flywheel target
OBD fault: absence of flywheel signal
The pressure sensor must not be faulty when performing this fault finding test.
NOTES
1.DEF
2.DEF

Check the positioning of the flywheel signal sensor.
Check the cleanliness, connection and condition of the sensor, the cable and its
connector.
Flywheel signal sensor

Flywheel signal sensor

Check the resistance of the flywheel signal sensor (see the value in the Help
section).
Check the cleanliness and condition of the engine flywheel.
NOTE:
If the target mounting has been altered, modify the programming.
If the fault had been characterised as "1.DEF or 2.DEF", the fault may change
characterisation and become "1.OBD or 2.OBD"; this is normal.
AFTER REPAIR

If the fault is present and characterised as "1.DEF or 2.DEF", continue to deal with
the fault.
If the fault is stored and characterised as "1.DEF or 2.DEF", ignore it.
If the fault is present or stored and characterised as "1.OBD or 2.OBD", ignore it.
17-19
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF017
CONTINUED
1.OBD
2.OBD
NOTES
If, after following the instructions, the characterisation has become "1.DEF or
2.DEF", the electrical fault is detected. Accordingly, it should be dealt with as a
present fault and characterised as "1.DEF or 2.DEF".
If the fault is still characterised as "1.OBD" or "2.OBD" after the instructions have
been followed, the electrical fault has been present several times but is no longer
detected.
This check should be based on the fault finding of the characterisations "1 DEF" or
"2.DEF".
If the fault had been characterised as "1.DEF or 2.DEF", the fault may change
characterisation and become "1.OBD or 2.OBD"; this is normal.
AFTER REPAIR

If the fault is present and characterised as "1.DEF or 2.DEF", continue to deal with
the fault.
If the fault is stored and characterised as "1.DEF or 2.DEF", ignore it.
17-20
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
UPSTREAM OXYGEN SENSOR HEATER CIRCUIT

DF018
PRESENT
OR
STORED
CO.0
CC.1
1.DEF
2.DEF
1.OBD
:
:
:
:
:

Heating output of oxygen sensor defective
(On Board Diagnostic) OBD fault: upstream oxygen sensor heating
output
2.OBD : OBD fault: upstream oxygen sensor heating output
If faults DF009 and DF019 are present, deal with them first.
NOTES
CO.0
CC.1
1.DEF
2.DEF

running the engine for 10 seconds.
Check the cleanliness, connection and condition of the upstream oxygen sensor
connector.
With the ignition on, check for the presence of + 12 V on track A of the upstream
oxygen sensor connector.
Computer track G1, connector C
Upstream oxygen sensor

Check the heating resistance of the upstream oxygen sensor (see the value in the
Help section).
Replace the upstream oxygen sensor if necessary.
If the fault had been characterised as "CO.0, CC.1, 1.DEF or 2.DEF", the fault may
change characterisation and become "1.OBD or 2.OBD"; this is normal.
AFTER REPAIR

If the fault is present and characterised as "CO.0, CC.1, 1.DEF or 2.DEF",
continue to deal with the fault.
If the fault is stored and characterised as "CO.0, CC.1, 1.DEF or 2.DEF", ignore it.
17-21
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF018
CONTINUED
1.OBD
2.OBD
NOTES
If, after following the instructions, the characterisation has become "CO.0, CC.1,
1.DEF or 2.DEF", the electrical fault is detected. It should therefore be dealt with as
a present fault and characterised as "CO.0, CC.1, 1.DEF or 2.DEF".
detected.
This check should be based on the fault finding of the characterisations "CO.0, CC.1,
1.DEF or 2.DEF".
AFTER REPAIR

17-22
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF019
PRESENT
OR
STORED
INJECTION
17
SUPPLY
1.DEF : + 12 V after actuator relay electrical fault

NOTES

the ignition is switched off and dialogue is lost;
the ignition is switched on and dialogue is established.
Disconnect the actuator relay.

Check the cleanliness, connection and condition of the actuator relay connections.
With the ignition on, check for 12 V on track 3 of the actuator relay.
If 12 V is not present, check the supply fuse (see the relevant section in the Workshop Repair Manual).
Check the insulation and continuity of the wire.
Check the resistance of the actuator relay across tracks 1 and 2. (See the value in the Help section).
Replace the relay if necessary.
Injection actuator relay

If that does not work, replace the actuator relay.
check.
AFTER REPAIR

17-23
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF021
PRESENT
OR
STORED
NOTES
INJECTION
IMMOBILISER
None.

Refer to the "Multiplex Network" and "Immobiliser" sections of the Workshop Repair Manual.
Perform fault finding on the "Immobiliser" system if necessary.
AFTER REPAIR
None.
17-24
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
COMPUTER
DF022
PRESENT
NOTES
1.DEF
2.DEF
3.DEF
4.DEF
:
:
:
:
Computer fault
Computer fault: motorised throttle control
Backup memory area fault
Immobiliser memory area fault
None.
1.DEF
2.DEF
Computer defective or not to specification.

Replace the injection computer.
3.DEF
4.DEF
Do not replace the injection computer immediately.
AFTER REPAIR
Carry out the following procedure:

Switch the ignition on and establish dialogue with the computer.
Clear the computer memory.
Switch the ignition off and wait for loss of dialogue with the computer.
Switch the ignition on and establish dialogue with the computer.
If the computer fault is still present, carry out this procedure again.
If the computer fault is still present after the fifth attempt at clearing, replace the
injection computer.
17-25
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
HIGH-SPEED FAN ASSEMBLY CIRCUIT

DF030
PRESENT
NOTES

Check the cleanliness, connection and condition of the high-speed fan assembly relay connector.
Check the resistance of the low-speed fan assembly relay tracks 1 and 2 (see the value in the Help section).
Replace the high-speed fan assembly relay if necessary.
High-speed fan assembly relay

check.
AFTER REPAIR

17-26
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF032
PRESENT
OR
STORED
NOTES
INJECTION
17
COOLANT TEMPERATURE OVERHEATING WARNING LIGHT

CIRCUIT
None.

AFTER REPAIR
None.
17-27
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DOWNSTREAM OXYGEN SENSOR HEATER CIRCUIT

DF038
PRESENT
OR
STORED
CO.0
CC.1
1.DEF
2.DEF
1.OBD
:
:
:
:
:

Heating output of oxygen sensor defective
(On Board Diagnostic) OBD fault: downstream oxygen sensor heating
output
2.OBD : OBD fault: downstream oxygen sensor heating output
NOTES
CO.0
CC.1
1.DEF
2.DEF

running the engine for 10seconds.
Check the cleanliness, connection and condition of the downstream oxygen
sensor connector.
With the ignition switched on, check the presence of + 12 V on track A of the
downstream oxygen sensor connector.
Downstream oxygen sensor

Check the heating resistance of the downstream oxygen sensor (see the value in
the Help section).
Replace the downstream oxygen sensor if necessary.
AFTER REPAIR

If the fault is present and characterised as "CO.0, CC.1, 1.DEF or 2.DEF", continue
to deal with the fault.
17-28
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF038
CONTINUED
1.OBD
2.OBD
NOTES
If, after following the instructions, the characterisation has become "CO.0, CC.1,
1.DEF or 2.DEF", the electrical fault is detected. It should therefore be dealt with as
a present fault and characterised as "CO.0, CC.1, 1.DEF or 2.DEF".
detected.
This check should be based on the fault finding of the characterisations "CO.0, CC.1,
1.DEF or 2.DEF".
AFTER REPAIR

17-29
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
CYLINDER 1 INJECTOR CIRCUIT

DF052
PRESENT
OR
STORED
CO
CC.0
CC.1
DEF
OBD
:
:
:
:
:
Open circuit
Short circuit to earth
NOTES
CO
CC.0
CC.1
DEF

The fault is declared present after
Check the cleanliness, condition and connection of cylinder injector 1 and its
connections.
Clean or replace as necessary.
With the ignition switched on, check for the presence of + 12 V on track 1 of the
injector 1 connector.
Injection computer track L4, connector B
Cylinder 1 injector

Check the resistance of cylinder injector 1 (see the value in the Help section).
Replace the injector if necessary.
If the fault had been characterised as "CO, CC.0, CC.1 or DEF", the fault may change
AFTER REPAIR

If the fault is present and characterised as "CO, CC.0, CC.1 or DEF", continue to
deal with the fault.
If the fault is stored and characterised as "CO, CC.0, CC.1 or DEF", ignore it.
17-30
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF052
CONTINUED
OBD
NOTES
If, after following the instructions, the characterisation has become "CO, CC.0, CC.1,
or DEF", the electrical fault is detected. It should therfore be dealt with as a present
fault characterised as "CO, CC.0, CC.1, or DEF".
This verification should be based on the fault finding of the characterisations "CO,
CC.0, CC.1, or DEF".
AFTER REPAIR

17-31
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17

DF053
PRESENT
OR
STORED
CO
CC.0
CC.1
DEF
OBD
:
:
:
:
:
Open circuit
NOTES
CO
CC.0
CC.1
DEF

connections.
With the ignition on, check for the presence of + 12 V on track 1 of the injector 2
connector.
Cylinder 2 injector

AFTER REPAIR

17-32
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF053
CONTINUED
OBD
NOTES
AFTER REPAIR

17-33
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17

DF054
PRESENT
OR
STORED
CO
CC.0
CC.1
DEF
OBD
:
:
:
:
:
Open circuit
NOTES
CO
CC.0
CC.1
DEF

connections.
connector.
Cylinder 3 injector

AFTER REPAIR

17-34
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF054
CONTINUED
OBD
NOTES
AFTER REPAIR

17-35
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17

DF055
PRESENT
OR
STORED
DEF
CO
CC.0
CC.1
OBD
:
:
:
:
:

Open circuit
NOTES
CO
CC.0
CC.1
DEF

connections.
connector.
Injection computer track M2, connector B
Cylinder 4 injector

AFTER REPAIR

17-36
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF055
CONTINUED
OBD
NOTES
AFTER REPAIR

17-37
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF057
PRESENT
OR
STORED
INJECTION
17
UPSTREAM OXYGEN SENSOR CIRCUIT

If other faults are present, deal with them first.

NOTES
DEF

a period of 5 minutes of richness regulation (engine running).
Check that the manifold pressure sensor is properly fitted.

Check that there are no leaks in the fuel vapour absorber bleed circuit.
Check that the throttle air temperature sensor is properly fitted.
Check the condition and fitting of the upstream sensor.
Replace the sensor if necessary.
Check for air leaks on the exhaust system.
If the vehicle is driven frequently in town, decoke the engine.
Check the cleanliness, connection and condition of the upstream oxygen sensor
connections.
With the ignition on, check the presence of + 12 Volts on the upstream oxygen
sensor.
AFTER REPAIR

17-38
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF057
CONTINUED

Computer track C1, connector C
Computer track B1, connector C
Oxygen sensor
Oxygen sensor

If the fault persists, replace the oxygen sensor.
OBD
NOTES
characterisation.
AFTER REPAIR

17-39
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF058
PRESENT
OR
STORED
INJECTION
17
DOWNSTREAM OXYGEN SENSOR CIRCUIT

NOTES
DEF
The fault is declared as present in one of the following cases:
A road test driving smoothly after the fan has come into operation and the double
richness ratio loop ET027 is active.
A road test driving smoothly after the fan has come into operation, followed
immediately by a road test on a slope in no load conditions (deceleration phase).
Verify the condition and fitting of the downstream sensor.

Check the cleanliness, connection and condition of the downstream oxygen
sensor connections.
With the ignition on, check the presence of + 12 V on the downstream oxygen
sensor.
Computer track A2, connector C
Oxygen sensor
Oxygen sensor
AFTER REPAIR

17-40
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF058
CONTINUED
OBD
NOTES
characterisation.
AFTER REPAIR

17-41
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF061
PRESENT
OR
STORED
INJECTION
17
IGNITION COIL 1 - 4 CIRCUIT

CO.0
CC.1
DEF
OBD
:
:
:
:

Deal with faults DF009, DF019 or DF008 first if they are present.
NOTES
CO.0
CC.1
DEF

Disconnect the connectors from the pencil coils of cylinders 1 and 4.

Check the cleanliness and condition of the connections and pencil coils.
Check the primary and secondary resistances of the pencil coils 1 and 4 (see the
Computer track H2, connector C
Coil 1
Coil 1
Coil 4

Check the continuity and insulation of the wiring between coil 4 and the fuel pump
relay (this relay supplies the ignition coils).
Check the electrical resistance of the fuel pump relay (see the value in the Help
section).
AFTER REPAIR

with the fault.
17-42
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF061
CONTINUED
Check the cleanliness and condition of the fuel pump relay connections.
Check the insulation and continuity of the line between track 3 of the relay and
supply fuse.
OBD
NOTES
fault characterised as "CO.0, CC.1 or DEF"
or DEF".
AFTER REPAIR

with the fault.
17-43
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF062
PRESENT
OR
STORED
INJECTION
17
IGNITION COIL 2-3 CIRCUIT

CO.0
CC.1
DEF
OBD
:
:
:
:

Deal with faults DF009, DF019 or DF008 first if they are present.
NOTES
CO.0
CC.1
DEF

Disconnect the connectors from pencil coils 2 and 3.

Check the cleanliness and condition of the connections and pencil coils.
Check the primary and secondary resistance of the ignition coils on cylinders 2
and 3 (see the values in the Help section).
Computer track H3, connector C
Coil 2
Coil 2
Coil 3

Check the continuity and insulation of the line between coil 3 and the fuel pump
relay (this relay supplies the ignition coils).
Check the electrical resistance of the fuel pump relay (see the value in the Help
section).
AFTER REPAIR

with the fault.
17-44
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF062
CONTINUED
Check the cleanliness and condition of the fuel pump relay connections.
Check the insulation and continuity of the line between track 3 of the relay and
supply fuse.
OBD
NOTES
fault characterised as "CO.0, CC.1 or DEF"
or DEF".
AFTER REPAIR

with the fault.
17-45
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF064
PRESENT
OR
STORED
NOTES
DEF
INJECTION
17
VEHICLE SPEED SIGNAL


Check the cleanliness and external condition of the vehicle speed sensor.
Check the cleanliness and condition of the target.
Check the cleanliness, condition and connection of the connections.
Check the electrical resistance of the vehicle speed sensor (see the value in
theHelp section).
Disconnect the computer. Check the cleanliness and condition of the
connectors.
Computer track C3, connector B
Vehicle speed sensor
(See the connector track numbers in the corresponding wiring diagram).

If that does not work, replace the sensor.
AFTER REPAIR

17-46
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF064
CONTINUED
OBD
NOTES
If, after following the instructions, the characterisation has become "DEF", the electrical fault is detected.
Accordingly, it should be dealt with as a fault present and characterised as DEF.
If, after following the instructions, the fault still has its "OBD" characterisation, the electrical fault has been
present several times but is no longer detected.
Accordingly, the circuit must be checked without changing parts which are not clearly identified as at fault.
This check should be based on the "DEF" fault finding of the characterisations.
AFTER REPAIR

17-47
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF082
PRESENT
OR
STORED
NOTES
INJECTION
PETROL/LPG CONNECTION
None.

Refer to the Multiplex network section in the Workshop Repair Manual.
AFTER REPAIR
None.
17-48
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF083
PRESENT
OR
STORED
NOTES
INJECTION
ABS/INJECTION CONNECTION
None.

Refer to the Multiplex network section in the Workshop Repair Manual.
AFTER REPAIR
None.
17-49
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
OXYGEN SENSOR OPERATING FAULT

DF102
PRESENT
NOTES
OBD
: OBD fault (On Board Diagnostic)
1.OBD : OBD fault detected when running
If faults DF009, DF019, DF018, DF038, DF057 or DF058 are present, deal with
them in priority.

Check the cleanliness, connection and condition of the upstream oxygen sensor connections.
With the ignition on, check the presence of + 12 V on the upstream oxygen sensor.
Oxygen sensor
Oxygen sensor

check.
AFTER REPAIR

17-50
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
CATALYTIC CONVERTER OPERATING FAULT

DF106
PRESENT
NOTES
OBD
1.OBD : OBD fault present
2.OBD : OBD fault detected when driving
Deal with the other faults first.
Check sealing of the complete exhaust system.

Check the condition and assembly of the downstream oxygen sensor.
Check the connection and condition. of the downstream oxygen sensor wires and connector.
Inspect the, condition of the catalytic converter Deformation may be the cause of the fault.
Visually check for signs of thermic shock. A warm catalytic converter may be damaged if it comes into
contact with cold water.
Make sure there has been no excessive oil or coolant consumption.
Ask the customer if they have used an additive or other products of this kind. Such products can contaminate
the catalytic converter and damage its performance sooner or later.
This could destroy the catalytic converter.
If the cause of the damage is identified, it is possible to change the catalytic converter.
If you replace the catalytic converter, make absolutely sure that the problem has been solved,
otherwise the new catalytic converter may be damaged.
check.
AFTER REPAIR

17-51
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF109
PRESENT
INJECTION
17
POLLUTANT MISFIRES
OBD
Deal with the other faults first.

NOTES
Misfiring on one
cylinder
Misfiring on all
cylinders
1 and 4
OR
2 and 3
Misfiring on all four

cylinders
Refer to states ET093, ET094, ET095 and ET096 to ascertain how many cylinders
are misfiring.
This means that the problem is probably due to a component which can only act on this
cylinder:
Injector fault
Spark plug fault (check conformance)
HV cable fault
Ignition coil fault
pair of cylinders:
Ignition coil fault
This means that the problem is probably due to a component which can only act on all
the cylinders:
Check that the correct petrol is used.
Check condition and conformity of spark plugs.
If the fault is still present, carry out the following checks:
Check the flywheel sensor.

Check the condition and cleanness of the flywheel.
Check the mounting of the flywheel sensor.
Check the sensor / flywheel air gap
Check the cylinder compression.
Check the whole petrol supply circuit.
Check the whole ignition system.
AFTER REPAIR
Ensure that all the faults have been processed.

Clear the stored faults. It is not necessary to clear the programming.
To check the correct state of repair of the system:
There should be no further electrical faults.
Programming should have been carried out.
The engine should be warm (minimum 75C).
Run at idling speed with all electrical users engaged for 15 minutes.
If the fault reappears, continue the fault finding procedure.
17-52
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DESTRUCTIVE MISFIRE
DF110
PRESENT
NOTES
Misfiring on one
cylinder
Misfiring on all
cylinders
1 and 4
OR
2 and 3
Misfiring on all four

cylinders
OBD
1.OBD : OBD fault present
2.OBD : OBD fault detected when driving
If faults relating to ignition or the petrol supply circuit are present, deal with them
first.
Refer to states ET093, ET094, ET095 and ET096 to ascertain how many cylinders
are misfiring.
cylinder:
Injector fault
Spark plug fault (check conformance)
HV cable fault
Ignition coil fault
pair of cylinders:
Ignition coil fault
This means that the problem is probably due to a component which can only act on all
the cylinders:
Check that the correct petrol is used.
Check condition and conformity of spark plugs.
If the fault is still present, carry out the following checks:
Check the flywheel sensor.

Check the condition and cleanness of the flywheel.
Check the mounting of the flywheel sensor.
Check the sensor / flywheel air gap
Check the cylinder compression.
Check the complete petrol supply circuit.
Check the complete ignition system.
AFTER REPAIR
Ensure that all the faults have been processed.

Clear the stored faults. It is not necessary to clear the programming.
To check the correct state of repair of the system:
There should be no further electrical faults.
Programming should have been carried out.
The engine should be warm (minimum 75C).
Run at idling speed with all electrical users engaged for 15 minutes.
If the fault reappears, continue the fault finding procedure.
17-53
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
FUEL SYSTEM OPERATING FAULT

DF116
PRESENT
NOTES
OBD
If faults relating to ignition or the petrol supply circuit are present, deal with them
first.
Carry out a complete check on the fuel supply system.
Check the cleanliness of the petrol fuel tank if necessary.

check.
AFTER REPAIR

17-54
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
IMMOBILISER CODE NOT PROGRAMMED
DF117
PRESENT
NOTES

Refer to the "Multiplex Network" and "Immobiliser" sections of the Workshop Repair Manual.
Perform fault finding on the "Immobiliser" system if necessary.
AFTER REPAIR
None.
17-55
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF118
PRESENT
OR
STORED
NOTES
INJECTION
17
REFRIGERANT PRESSURE SENSOR CIRCUIT


Check the cleanliness, connection and condition of the refrigerant pressure sensor.
Check the electrical resistance of the refrigerant sensor (see value in the Help section).
Computer track J3, connector B
Pressure sensor
Pressure sensor
Pressure sensor

check.
AFTER REPAIR

17-56
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
OBD WARNING LIGHT CIRCUIT

DF120
PRESENT
CO.0
CC.1
DEF
OBD
NOTES
None.
:
:
:
:


AFTER REPAIR
None.
17-57
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF123
PRESENT
OR
STORED
INJECTION
17
THROTTLE POSITION POTENTIOMETER CIRCUIT TRACK 1

IMPORTANT: Do not drive the vehicle until you have checked that the computer
is clear of any fault relating to the throttle unit.
NOTES
Throttle position potentiometer track 1


Check that track 1 of the throttle potentiometer correctly follows its resistive curve (see the values in the
Help section).
Repair or replace the throttle position potentiometer if necessary.
check.
AFTER REPAIR
17-58
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
THROTTLE POSITION POTENTIOMETER CIRCUIT TRACK 2

DF124
PRESENT

NOTES


Check that track 2 of the throttle potentiometer correctly follows its resistive curve (see the values in the
Help section).
check.
AFTER REPAIR
17-59
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF125
PRESENT
OR
STORED
NOTES
INJECTION
17
PEDAL POTENTIOMETER TRACK 1 CIRCUIT


switching the accelerator from no load to full load.
Check that the pedal is not mechanically seized.

Check the cleanliness, connection and condition of the pedal potentiometer connector.
Computer track H3, connector A
Computer track G2, connector A
Pedal potentiometer track 1


Check that track 1 of the pedal potentiometer correctly follows its curve of resistance (see the values in
the Help section).
Replace the pedal potentiometer if necessary.
check.
AFTER REPAIR

17-60
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
PEDAL POTENTIOMETER TRACK 2 CIRCUIT

DF126
PRESENT
NOTES


switching the accelerator from no load to full load.

Computer track F4, connector A


Check that track 2 of the pedal potentiometer correctly follows its curve of resistance (see the values in
the Help section).
check.
AFTER REPAIR

17-61
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF129
PRESENT
OR
STORED
INJECTION
17
PEDAL POTENTIOMETER CIRCUIT

DEF : Consistency of pedal potentiometer tracks
Deal with faults DF125 or DF126 first if they are present.
NOTES

The fault is declared as present in one of the following cases:
When the ignition is switched on without depressing the accelerator pedal for the first
10 seconds.
During gradual switching of the pedal potentiometer from no load to full load
condition.
During full load condition for 10 seconds.

Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer

Check that tracks 1 and 2 of the pedal potentiometer correctly follow their curves of resistance.
(See values in the "HELP" section).
check.
AFTER REPAIR

17-62
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF134
PRESENT
OR
STORED
NOTES
INJECTION
17
INSTRUMENT PANEL CONNECTION

None.

Refer, in the Workshop Repair Manual, to the "Multiplex Network" and "Instrument Panel" sections.
AFTER REPAIR
None.
17-63
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF135
PRESENT
OR
STORED
INJECTION
BRAKE PEDAL SENSOR CIRCUIT
1.DEF
2.DEF
: Fault on one of the two brake pedal contacts

: Fault on both brake pedal contacts
It is essential that the ABS is not defective when carrying out this test.
NOTES
Fault finding conditions for stored fault:

a long press on the brake pedal.
Check the cleanliness, connection and condition of the double-contact switch and its connections.
Computer track E4 or G3, connector A
Brake pedal switch

Brake pedal switch

If the fault does not disappear, deal with the other faults then go to the conformity check.
AFTER REPAIR

Process any other faults
17-64
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF136
PRESENT
OR
STORED
INJECTION
17
ACCELERATOR PEDAL / MOTORISED THROTTLE VALVE

CIRCUIT
DEF
: Consistency between the position of the pedal and the position of the
motorised throttle valve
1.DEF : Fault on + 5 V supply
2.DEF : Fault on potentiometer power supply No. 1
3.DEF : Fault on potentiometer power supply No. 2
NOTES
If faults DF137, DF123, DF124, DF125, DF126, DF129 or DF002 are present, deal
with them first.
Check the cleanliness, connection and condition of the pedal potentiometer and its connections.
Check the cleanliness, connection and condition of the motorised throttle and its connections.
Check that tracks 1 and 2 of the throttle potentiometer correctly follow their curves of resistance (see
Clean or replace the throttle unit if necessary.
Check the electrical resistance of the throttle motor (see the value in the Help section).
Check that the resistances of pedal potentiometer tracks 1 and 2 correctly follow their curves of resistance
(see the values in the Help section).
AFTER REPAIR
17-65
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DF136
CONTINUED

Computer track M3, connector B
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Motorised throttle valve
Motorised throttle valve potentiometer

check.
AFTER REPAIR
17-66
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF137
PRESENT
OR
STORED
INJECTION
17
MOTORISED THROTTLE
DEF :
1.DEF :
2.DEF :
3.DEF :

Motorised throttle valve servo control fault
Motorised throttle valve thrust stop search fault
General motorised throttle valve control fault
NOTES
Check the cleanliness, connection and condition of the connections.



Check the cleanliness of the throttle unit and that the throttle rotates correctly.
check.
AFTER REPAIR
17-67
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF168
PRESENT
OR
STORED
INJECTION
17
AIR INTAKE CIRCUIT

OBD
NOTES
If faults DF123, DF124, DF125, DF126, DF129, DF136, DF137 or DF002 are
present, deal with them first.

Check that the manifold air temperature sensor is correctly mounted.
AFTER REPAIR

17-68
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
DF233
PRESENT
OR
STORED
NOTES
INJECTION
DIRECTIONAL STABILITY CONTROL
None.

Refer to the ABS / ESP and Multiplex network sections in the Workshop Repair Manual.
Carry out fault finding on the ABS and ESP if necessary.
AFTER REPAIR
None.
17-69
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Only carry out this conformity check after a full check with the diagnostic tool
(the values shown in this conformity check are only given as a guide).
Conditions for the application of this check: engine stopped, ignition on.
Parameter or State
check or Action
Display and notes
Fault finding
procedure
SUPPLY FUNCTION
Battery voltage
ET001:
+ After ignition
computer
PR004:
Computer supply
voltage
ACTIVE
11.8 < X < 13.2 V
In the event of a fault:

procedure
PR004
SENSOR FUNCTION
Activate the starter motor:
2
Engine flywheel
signal
Coolant
temperature
sensor
ET060:
Flywheel signal with

engine running
ACTIVE

procedure
PR060
PR002:
Coolant
temperature
Engine temperature
5C

procedure
PR002
PR003:
Air temperature
Temperature under
bonnet 5C

procedure
PR003
PR016:
Atmospheric
pressure
1000 mbar 3%
(atmospheric
pressure)
Manifold pressure
1000 mbar 3%
(atmospheric
pressure)
Air temperature
sensor
Atmospheric
pressure sensor
PR001:
17-70
vnx.su

procedure
PR001
INJECTION
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
17
Function
Parameter or State
check or Action
Display and notes
Fault finding
procedure
PEDAL ASSEMBLY FUNCTION

Accelerator pedal released
ET129:
Accelerator pedal
position: no load
ACTIVE
ET128:
Accelerator pedal
position: full load
INACTIVE
PR112:
Measured pedal
position
15 1
PR120:
Pedal no load
programming
15 1

procedure
PR112
Accelerator pedal pressed

lightly
6
Accelerator pedal
ET129:
Accelerator pedal
position: no load
INACTIVE
ET128:
Accelerator pedal
position: full load
INACTIVE

procedure
PR112
Accelerator pedal under full

load
ET129:
Accelerator pedal
position: no load
INACTIVE
ET128:
Accelerator pedal
position: full load
ACTIVE
PR112:
Measured accelerator
pedal position
80 4
17-71
vnx.su

procedure
PR112
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Parameter or State
check or Action
Display and notes
Fault finding
procedure
Brake pedal released
ET110:
Brake pedal
INACTIVE
ET143:
Redundant brake
pedal
(Confirmation
signal)
INACTIVE

procedure
ET110
ET143
Brake pedal
Brake pedal depressed
ET110:
Brake pedal
ACTIVE
ET143:
Redundant brake
pedal
(Confirmation
signal)
ACTIVE
17-72
vnx.su

procedure
ET110
ET143
INJECTION
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
17
Function
Parameter or State
check or Action
Display and notes
Fault finding
procedure
MOTORISED THROTTLE VALVE FUNCTION

Accelerator pedal released
Motorised throttle
unit
ET111:
Throttle valve stops

programming
ACTIVE

switch off the ignition
and wait for the loss
of dialogue.
Switch on the ignition
again.
ET118:
Motorised throttle unit

in defect mode
INACTIVE

a fault is declared by
the diagnostic tool
ET130:
Motorised throttle
valve closed
ACTIVE
PR113:
Reference position of
the motorised throttle
valve
15 1

procedure
PR017
PR017:
Measured valve
position
15 1
PR110:
Measured valve
position track 1
15 1
PR111:
Measured valve
position track 2
15 1
PR119:
Motorised throttle
valve lower stop
10 1
17-73
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Parameter or State
check or Action
Display and notes
Fault finding
procedure
MOTORISED THROTTLE VALVE FUNCTION

Accelerator pedal under full
load
8
(continued)
Motorised
throttle unit
ET118:
Motorised throttle unit

in defect mode
INACTIVE

a fault is declared by
the diagnostic tool
ET131:
Motorised throttle
valve open
ACTIVE
PR113:
Reference position of
the motorised throttle
valve
90 3

procedure
PR017
PR017:
Measured valve
position
90 3
PR110:
Measured valve
position track 1
90 3
PR111:
Measured valve
position track 2
90 3
PR118:
Motorised throttle
valve upper stop
92 3
17-74
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Only carry out this conformity check after a full check with the diagnostic tool (the
values shown in this conformity check are only given as a guide).
Parameter or State
check or Action
Display and notes
Fault finding
procedure
ACTUATOR CONTROLS
10
AC010:
Fuel pump relay
The fuel pump should

be heard operating

procedure
AC010
AC271:
Low-speed fan
assembly relay
The fan should be

heard running at low
speed

procedure
AC271
AC272:
High-speed fan
assembly relay
The fan should be

heard running at high
speed

procedure
AC272
AC016:
Canister bleed
solenoid valve
The fuel vapour

absorber solenoid
valve should be heard
operating

procedure
AC016
AC612:
Motorised throttle
unit
The motorised throttle

valve should be heard
operating

procedure
AC612
Fuel supply
Fan assembly
11
Fuel vapour
absorber bleed
12
Motorised
throttle unit
17-75
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Conditions for application of the check: Engine warm at idle speed, without
electrical consumers.
Parameter or State
check or Action
Display and notes
Fault finding
procedure
ELECTRICAL SUPPLY FUNCTION
Battery voltage
ET001:
+ After ignition
PR004:
Computer supply
voltage
ACTIVE
13 < X < 14.5 V

procedure
PR004
SENSOR FUNCTION
Flywheel signal
Atmospheric
pressure sensor
Pinking sensors
ET060:
Flywheel signal with

engine running
PR016:
Atmospheric
pressure
PR001:
Manifold pressure
PR015:
Anti-pinking
correction
PR013:
Medium pinking
signal
17-76
vnx.su
ACTIVE

procedure
ET060
X = Atmospheric
pressure

procedure
PR001
280 < X < 360 mbar
X5
30 < X < 60

procedure
PR013
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Parameter or State
check or Action
Display and notes
Fault finding
procedure
FAN FUNCTION
PR002:
Coolant
temperature
ET035:
Low-speed fan
assembly
PR002:
Coolant
temperature
ET036:
High-speed fan
assembly
The fan should cut in when

the engine coolant
temperature exceeds
99 C
ACTIVE
In the event of a
fault:
procedure
ET035
Fan assembly
The fan should cut in when
the engine coolant
temperature exceeds
102 C
ACTIVE
In the event of a
fault:
procedure
ET036
IDLE SPEED REGULATION FUNCTION
Idle speed
regulation
ET039:
Idle speed
regulation
ACTIVE
PR006:
Engine speed
725 < X < 775 rpm
PR041:
Idle speed setpoint
725 < X < 775 rpm
PR055:
After-Sales idle
speed set point
-16 rpm < X < +16 rpm
(Possibility or reducing or
increasing the idling speed by
means of the commands
parameterised as VP004 and
VP003)
PR040:
Idle speed
divergence
-25 < X < +25 rpm
PR022:
Idling opening
cyclic ratio
20 % < X < 30 %
PR021:
Idling opening
cyclic ratio adaptive
17-77
vnx.su
-6 % < X < 6 %
In the event of a
fault:
procedure
ET039
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Parameter or State
check or Action
Display and notes
Fault finding
procedure
RICHNESS REGULATION FUNCTION
Richness
regulation
ACTIVE
ET037:
Richness regulation
PR009:
Upstream sensor
voltage
20 < X < 800 mV
PR035:
Richness ratio
correction value
0 < X < 255

procedure
ET037
OXYGEN SENSOR FUNCTION
Upstream
oxygen sensor
Downstream
oxygen sensor
ET030:
Upstream O2 sensor
heating
ACTIVE

procedure
ET030
ET157:
Upstream sensor
state
ACTIVE

procedure
ET157
ET158:
Downstream sensor
state
ACTIVE

procedure
ET158
ET031:
Downstream O2
sensor heating
ACTIVE

procedure
ET031
INFORMATION FUNCTION
10
Heated
windscreen
Switch on the windscreen

heating
ET013: Heated windscreen
17-78
vnx.su
ACTIVE

procedure
ET013
SAGEM2000
Program No.: A3
Vdiag No.: 0C
NOTES
Order
Function
INJECTION
17
Conditions for application of the check: Road test.
Parameter or State
check or Action
Display and notes
Fault finding
procedure
SENSOR FUNCTION
Vehicle under load
Pinking sensor
PR015:
Anti-pinking
correction
X5
PR016:
Atmospheric
pressure
1000 mbar 3%
(Atmospheric
pressure)
PR001:
Manifold pressure
Atmospheric
pressure sensor
280 < X < 360 mbar

procedure
PR013

procedure
PR001
POLLUTANT EMISSIONS
2500 rpm after driving.
CO < 0.3 %
CO2 > 13.5 %
O2 < 0.8 %
HC < 100 ppm
Pollutant
emissions
0.97 < < 1.03
With the engine at idling

speed, wait for stabilisation.
CO < 0.5 %
HC < 100 ppm
0.97 < < 1.03
17-79
vnx.su

refer to the emission
control technical note
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
Fault finding - Interpretation of states
HEATED WINDSCREEN
ET013
NOTES
There must be no faults present or stored.

"Air conditioning" computer.

If the fault is still present, perform fault finding on the Air Conditioning computer.
AFTER REPAIR
17-80
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
UPSTREAM O2 SENSOR HEATING

ET030
NOTES
Check the cleanliness, connection and condition of the upstream oxygen sensor connector.
Check the heating resistance of the upstream oxygen sensor (see the value in the Help section).
With the ignition on, check for the presence of + 12 V on track A of the upstream oxygen sensor connector.

AFTER REPAIR
17-81
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
DOWNSTREAM O2 SENSOR HEATING

ET031
NOTES
Check the cleanliness, connection and condition of the downstream oxygen sensor connector.
Check the heating resistance of the downstream oxygen sensor (see the value in the Help section).
With the ignition switched on, check the presence of + 12 V on track A of the downstream oxygen sensor
connector.

AFTER REPAIR
17-82
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
POWER ASSISTED STEERING PRESSURE SWITCH

ET034
NOTES
Check the power assisted steering fluid level.

Check that there are no leaks.
Check the cleanliness, connection and condition of the power steering pressure switch connector.
Replace the pressure switch if necessary.
Disconnect the connector and check for the presence of earth (check the track number on the relevant wiring
diagram).
Disconnect the computer. Check the cleanliness and condition of the connections.
Pressure switch
Power assisted steering pressure switch

Earth

Check that the pump is operating correctly.
If these points are correct, replace the power assisted steering pressure switch.
AFTER REPAIR
17-83
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
LOW-SPEED FAN ASSEMBLY

ET035
NOTES
Check the cleanliness and general condition of the fan unit (no point of resistance).
Check the cleanliness, connection and condition of the fan assembly relay connector.
Disconnect the low-speed fan relay.
Check for the presence of + 12 V on track 3 on the connector side of the relay.
With the ignition on, check for the presence of + 12 V on track 1 of the relay, connector side.
section).
Low-speed fan relay

Check the insulation, the continuity and the absence of interference resistance of the connection
between track 5 of the relay and the fan assembly.
Check the insulation, the continuity and the absence of interference resistance of the fan unit earth
connection.
If that still does not work, replace the fan assembly.
AFTER REPAIR
17-84
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
HIGH-SPEED FAN ASSEMBLY

ET036
NOTES
Check the cleanliness and general condition of the fan unit (no point of resistance).
Check the cleanliness, connection and condition of the fan assembly relay connector.
Disconnect the high-speed fan relay.
Check for the presence of + 12 V on track 3 on the relay, connector side.
With the ignition on, check for the presence of + 12 V on track 1 of the relay, connector side.
Check the resistance of the high-speed fan assembly relay on tracks 1 and 2 (see the value in the Help
section).
High-speed fan relay

connection.
If that still does not work, replace the fan assembly.
AFTER REPAIR
17-85
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
RICHNESS REGULATION
ET037
NOTES

Check the cleanliness, connection and condition of the connector for the upstream oxygen sensor.
Check the resistance of the upstream oxygen sensor signal circuit (check the value in the Help section).
With the ignition on, check for the presence of + 12 V on the upstream oxygen sensor connector (see the track
number of the connector on the corresponding wiring diagram).



Check the spark plugs and the entire ignition circuit.
Check that there are no leaks in the fuel vapour absorber bleed circuit,
Check that the inlet manifold and the exhaust system are completely sealed.
Check the petrol supply circuit and its filter.
Check fuel pressure.
If idling is irregular, check the valve clearances and the timing.
Replace the oxygen sensor if the fault persists.
AFTER REPAIR
17-86
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
IDLE SPEED REGULATION
ET039
NOTES
NOTES
Idle speed is too slow.
Clean the air supply circuit (throttle unit, idle speed regulation stepper motor), since it may be dirty.
Check the engine oil level (too high => splashing).
Check the engine compression
Check the valve clearances and timing.
Check ignition.
Check the injectors
NOTES
Idle speed is too high.
Check the engine oil level.

Check that the pressure sensor is operating correctly.
Check the cleanliness of the pipes on the manifold.
Check the pneumatically-controlled solenoid valves.
Check the manifold gaskets.
Check the throttle unit gaskets.
Check the brake servo sealing.
Check that the restrictions are present in the oil vapour rebreathing circuit.
Check the valve clearances and timing.
AFTER REPAIR
17-87
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
FLYWHEEL SIGNAL WITH ENGINE RUNNING
ET060
NOTES
Check the cleanliness, connection and condition of the target sensor, its connector and the cable.
Check that the engine flywheel is mounted correctly.
Check the sensor/flywheel air gap.
Target sensor
Target sensor

Check the resistance of the target sensor (see the value in the Help section).
If there is still a fault, check the cleanliness and condition of the flywheel.
AFTER REPAIR
17-88
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
BRAKE PEDAL
ET110
NOTES
Check that the pedal assembly is in sound condition.

Check the cleanliness, connection and condition of the double-contact brake switch and its connector.
Computer track E4 or G3, connector A
Brake pedal

If it still does not work, replace the switch.
Refer to the ABS fault finding procedure if necessary.
AFTER REPAIR
17-89
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
REDUNDANT BRAKE PEDAL (confirmation signal)
ET143
NOTES

Refer to the ABS / ESP and Multiplex network sections in the Workshop Repair Manual.
Carry out fault finding on the ABS and ESP if necessary.
AFTER REPAIR
17-90
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
UPSTREAM SENSOR STATE
ET157
NOTES

Check the fuel vapour absorber bleed and its circuit.
Check the cleanliness, connection and condition of the upstream oxygen sensor connector.
Check the resistance of the upstream oxygen sensor (see the value in the Help section).
With the ignition on, check the presence of + 12 Volts on the upstream oxygen sensor.
Computer track B1, connector B


AFTER REPAIR
17-91
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
DOWNSTREAM SENSOR STATE
ET158
NOTES
Verify the condition and fitting of the downstream sensor.

Check the connection and condition of the downstream oxygen sensor connector.
Check the resistance of the downstream oxygen sensor circuit (see the value in the Help section).
With the ignition on, check the presence of + 12 V on the downstream oxygen sensor.
Computer track A2, connector B


AFTER REPAIR
17-92
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
Fault finding - Interpretation of parameters
17
MANIFOLD PRESSURE
PR001:
NOTES

Check the cleanliness, connection and condition of the sensor and its connection.
Pressure sensor
Pressure sensor
Pressure sensor

Check that the pressure sensor is properly connected pneumatically and that the pipe is in sound condition.
Using a vacuum pump, check the consistency of the manifold pressure.
Check consistency with parameter PR001 in the diagnostic tool.
If PR001 > Maximum at idling speed:
Check the valve clearance.
Check that the fuel vapour absorber bleed is closed at idling speed
Check the cylinder compressions.
AFTER REPAIR
17-93
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
COOLANT TEMPERATURE
PR002:
NOTES
Check the cleanliness, connection and condition of the coolant temperature sensor connector.
Check the resistance of the coolant temperature at different temperatures (see the values in the Help section).
Replace the coolant temperature sensor, if necessary.


AFTER REPAIR
17-94
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
AIR TEMPERATURE
PR003:
NOTES
Check the cleanliness, connection and condition of the manifold air temperature sensor connector.
Check the resistance of the manifold air temperature sensor at various temperatures (see the values in the
Help section).
Replace the air temperature sensor, if necessary.
Manifold air temperature sensor

Manifold air temperature sensor

AFTER REPAIR
17-95
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17

PR004
NOTES
Ignition on

No electrical consumers.
If the voltage is minimum:

Check the battery and the charge circuit (refer to the relevant section in the
Workshop Repair Manual).
If the voltage is maximum:
Check that the charge voltage is correct and that no consumers are on (see the
relevant section in the Workshop Repair Manual).
At idle speed
If the voltage is minimum:

Check the battery and the charge circuit (refer to the relevant section in the
Workshop Repair Manual).
If the voltage is maximum:
Check that the charge voltage is correct and that no consumers are on (see the
relevant section in the Workshop Repair Manual).
AFTER REPAIR
17-96
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
PINKING SIGNAL
PR013
NOTES
The pinking sensor should give a signal which is not zero, to prove that it is recording the mechanical
vibrations of the engine.
Check that the fuel in the fuel tank is of the correct type.
Check the conformity of the spark plugs.
Check that the pinking sensor is tightened.
Check the cleanliness, connection and condition of the sensor and the connector.
Computer track A2, connector B
Pinking sensor
Pinking sensor
Pinking sensor screening

If the fault persists, replace the pinking sensor.
AFTER REPAIR
17-97
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
MEASURED THROTTLE POSITION

PR017
IMPORTANT:
NOTES
Check that there are no foreign bodies at the throttle valve level.


Check that the resistances of tracks 1 and 2 of the throttle potentiometer follow their curves correctly, by
moving the throttle from no load to full load (check the values in the Help section).
AFTER REPAIR
17-98
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
RICHNESS ADAPTIVE OPERATION

PR030
NOTES

If the PR030 or PR031 is near the min. stop, there is too much petrol.
If the PR030 or PR031 is near the max. stop, there is insufficient petrol.

Check the spark plugs and the entire ignition circuit.
Check that there are no leaks in the fuel vapour absorber bleed circuit,
Check the lsealing of the inlet manifold and the complete exhaust system.
Check the petrol supply circuit and its filter.
If idling is irregular, check the valve clearances and the timing.

Check the cleanliness, connection and condition of the connector for the upstream oxygen sensor.
With the ignition on, check for the presence of + 12 V on track A of the upstream oxygen sensor connector.

Replace the oxygen sensor if the fault persists.
AFTER REPAIR
17-99
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
MEASURED ACCELERATOR PEDAL POSITION

PR112
NOTES

Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer
Pedal potentiometer

Check that the resistances of the pedal potentiometer, tracks 1 and 2 correctly follow their curves of
resistance.
(See the values in the "HELP" section).
Replace the potentiometer pedal if the fault persists.
AFTER REPAIR
17-100
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
Fault finding - Interpretation of controls
17
FUEL PUMP RELAY

AC010
NOTES

Replace the fuse if necessary.
Check the connection and condition of the fuel pump relay connector.
Disconnect the relay.
With the ignition on, check for the presence of + 12 V on track 1 of the fuel pump relay, connector side.
Check the resistance of the fuel pump relay on tracks 1 and 2 (see the value in the Help section).
Replace the fuel pump relay if necessary.
Computer track D1 connector C
Fuel pump relay

If the fault persists, replace the relay.
AFTER REPAIR
17-101
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
CANISTER BLEED SOLENOID VALVE

AC016
NOTES
Check the cleanliness and condition of the fuel vapour absorber bleed solenoid valve connector.
With the ignition on, check for the presence of + 12 V on the fuel vapour absorber bleed solenoid valve.
Check the resistance of the fuel vapour absorber bleed solenoid valve (see value in the Help section).
Replace the solenoid valve, if necessary.
Computer track E1, connector C
Canister bleed solenoid valve

If the fault persists, replace the solenoid valve.
AFTER REPAIR
17-102
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
LOW-SPEED FAN RELAY

AC271
NOTES
Check the connection and condition of the low-speed fan assembly relay connector.
section).
Low-speed fan relay

connection.
Check the condition of the fan assembly.
Replace the fan assembly if necessary.
AFTER REPAIR
17-103
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
HIGH-SPEED FAN RELAY

AC272
NOTES
Check the cleanliness, connection and condition of the high-speed fan assembly relay connector.
Check the resistance of the high-speed fan assembly relay on tracks 1 and 2 (see the value in the Help
section).
High-speed fan relay

connection.
Check the condition of the fan assembly.
Replace the fan assembly if necessary.
AFTER REPAIR
17-104
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
MOTORISED THROTTLE
AC612
IMPORTANT:
NOTES
Check the cleanliness of the throttle unit and that the throttle rotates correctly.
Check the cleanliness, connection and condition of the connections.


AFTER REPAIR
17-105
vnx.su
INJECTION
SAGEM2000
Program No.: A3
Vdiag No.: 0C
17
ELECTRICAL RESISTANCE OF COMPONENTS
Resistance values of components at 20C:
Injectors
1.8 5%
Actuator relays
65 10%
Throttle valve motor
1.5 5 %
Fuel vapour absorber bleed

solenoid valve
25 10%
Ignition coils
Primary: 0.5
Ignition coils
Secondary: 11 k 20%
17-106
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
17
Flywheel sensor
230 20%
Oxygen sensor heater
Upstream: 9 10%
Oxygen sensor heater
Downstream: 9 10%
High-speed fan assembly relay
65 10%
Low-speed fan assembly relay
65 10%
17-107
vnx.su
INJECTION
SAGEM2000
Program No.: A3
Vdiag No.: 0C
17
Values for variable resistance components:
Temperature in C
Manifold air temperature
sensor, in
Coolant temperature sensor,
in
- 10
25
50
80
110
10450
to
8585
2120
to
1880
860
to
760
2360
to
2140
850
to
770
290
to
275
117
to
112
Accelerator pedal potentiometer (20C)

No load position,
track 1
Tracks G2 and H2,

connector A of computer
2300 20%
Tracks H3 and H2,

1290 20%
Full load position,

track 1
Tracks G2 and H2,

1250 20%
Tracks H3 and H2,

computer connector A
2270 20%
No load position,
track 2
Tracks F2 and F3,

2900 20%
Tracks F3 and F4,

1240 20%
Full load position,

track 2
Tracks F2 and F3, computer

connector A
2200 20%
Tracks F3 and F4, computer

connector A
2000 20%
17-108
vnx.su
INJECTION
SAGEM2000
Program No.: A3
Vdiag No.: 0C
17
Throttle potentiometer VDO (20C)

Throttle limp-home
position, track 1
(Throttle position with
engine stopped)
Throttle fully open

position, track 1
(Keep throttle open
manually)
Throttle limp-home
position, track 2
(Throttle position with
engine stopped)
Throttle fully open

position, track 2
(Keep throttle open
manually)
Tracks G3 and G2,

connector B of computer
1350 20%
Tracks G3 and G4,

775 20%
Tracks G3 and G2,

computer connector B
500 20%
tracks G3 and G4,

1300 20%
Tracks D3 and G2,

600 20%
Tracks D3 and G4,

1150 20%
Tracks D3 and G2,

1250 20%
Tracks D3 and G4,

440 20%
17-109
vnx.su
INJECTION
SAGEM2000
Program No.: A3
Vdiag No.: 0C
17
Only consult the customer complaints after a complete check using the
diagnostic tool.
NOTES
NO DIALOGUE WITH THE COMPUTER
CHART 1
THE ENGINE WILL NOT START
CHART 2
IDLE SPEED FAULTS
CHART 3
FAULTS WHEN DRIVING
CHART 4
AFTER REPAIR
Perform a test using the diagnostic tool.
17-110
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
No dialogue with the computer
CHART 1
NOTES
None.
Check the condition of the battery and the vehicle earths.

Check the condition of the diagnostic lead.
Check the cleanliness and condition of the diagnostic socket and its connections.
Try the diagnostic tool on another vehicle.
Check the injection, engine and passenger compartment fuses.
Check, on the vehicle, the cleanliness and condition of the diagnostic socket and its connections.
Use the diagnostic socket to check the following tracks:
Track 1
+ After ignition
Track 16
+ Battery
Tracks 4 and 5
Earth
Injection computer track H1, connector C
Earth
Injection computer track H4, connector A
Earth
Injection computer track G4, connector A
Earth
Injection computer track B4, connector A
Diagnostic socket track 7
Injection computer track A4, connector B
+ After ignition
Injection computer track G2, connector C
+ After ignition
Check the connection and condition of the injection actuator relay connector.
Check the resistance of the injection actuator relay (see the value in the Help section).
Replace the actuator relay, if necessary.
Check the presence of + 12 V on track 1 of the injection actuators relay.
Repair the wire to the fuse.
Check the insulation and continuity of the connection between:
Injection computer track D4, connector B
Injection actuator relay.
AFTER REPAIR
17-111
vnx.su
17
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
CHART 2
The vehicle will not start
NOTES
Follow CHART 2 after performing a complete check using the diagnostic tool.
(Use the Workshop Repair Manual for more information on certain operations).
If the starter motor does not engage, there may be an engine immobiliser fault.
Check the "Immobiliser" function using the diagnostic tool.
Check that the impact sensor is not switched on.
Check that it is working.
Check the cleanliness and condition of the battery.

Check that the battery is correctly earthed to the vehicle body.
Check + battery connections.
Check the battery charge.
Check that the starter motor is properly connected.

Check that the starter motor is operating correctly.
Check the condition and cleanliness of the pencil coils.

Check the condition and conformity of spark plugs.
Check the secondary ignition circuits.
Check the mounting, cleanliness, condition and air gap of the flywheel signal sensor.
Check the condition of the flywheel.
Check that the air intake circuit is not clogged up.

Check that the throttle is rotating correctly
Check whether there is fuel in the tank (fuel gauge fault).

Check that the tank vent is not blocked.
Check that the fuel is of the correct type.
Check that there is no leak in the fuel circuit, from the fuel tank to the injectors.
Check that no hoses are pinched (especially after a removal operation).
Check the condition of the fuel filter.
Check that the fuel pump is operating correctly.
Check that the injectors are working.
Check that the exhaust system is not blocked nor the catalytic converter clogged.
Check the timing.
AFTER REPAIR
17
17-112
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
Idle speed faults
CHART 3
NOTES
Follow CHART 3 after performing a complete check with the diagnostic tool.
Check on the dipstick that the oil level is not too high.

Check the condition and cleanliness of the flywheel.

Check that there is no leak in the brake servo circuit.

Check that throttle unit is not clogged.
Check that the throttle is rotating correctly.

Check the timing.
AFTER REPAIR
17
17-113
vnx.su
SAGEM2000
Program No.: A3
Vdiag No.: 0C
INJECTION
Faults when driving
CHART 4
NOTES
Follow CHART 4 after performing a complete check using the diagnostic tool.
Check on the dipstick that the oil level is not too high.
Check that the exhaust manifold is not leaking.

Check the condition and cleanliness of the flywheel.

Check that there is no leak in the brake servo circuit.

Check that the throttle valve unit is not clogged.
Check that the throttle is rotating correctly.

Check the timing.
AFTER REPAIR
17
17-114
vnx.su
CLUTCH
120
Identification
VEHICLE
TYPE
ENGINE
TYPE
MECHANISM
PLATE
21 splines
D = 240 mm
E = 7.1 mm
XL0B
XL0C
20
F9Q
215 CPOE 4400
20-1
vnx.su
CLUTCH
Mechanism - Plate
F9Q ENGINE
20
REPLACEMENT
This operation is carried out after the gearbox has been disconnected from the engine.
Mot.
1677 - 01
Locking tool
REFITTING

Mechanism mounting bolt
REMOVAL
Fit flywheel locking tool Mot. 1677-01.
Precautions that must be taken when repairing the

clutch:
De-grease the friction face of the flywheel.
Insert the disc (offset (A) from the hub on the flywheel
side).
Remove the mechanism mounting bolts and the

mechanism along with the clutch plate.
Check and replace any faulty parts.
20-2
vnx.su
F9Q ENGINE
CLUTCH
Mechanism - Plate
ALIGNMENT
Use the plastic centring tool found in the clutch kit.
Gradually tighten the bolts in the order indicated in the

diagram above, then lock the mechanism securing
bolts to torque.
Remove flywheel locking tool Mot. 582-01.
20-3
vnx.su
20
CLUTCH
Thrust bearing
F9Q ENGINE
REPLACEMENT
This operation is carried out after the gearbox has
been disconnected from the engine.
REMOVAL
Remove:
the bleed screw (screw A),
the thrust bearing (screw B).
REFITTING
Refit:
the thrust bearing,
the bleed screw.
Ensure the thrust bearing slides correctly.
20-4
vnx.su
20
CLUTCH
Flywheel
F9Q ENGINE
20
REPLACEMENT
This operation is carried out after the gearbox has been uncoupled from the engine and after the clutch has been
removed.
Mot.
582 - 01
Locking tool
REFITTING

Steering wheel bolt
REMOVAL
Fit flywheel locking tool Mot. 582-01.
Loosening the flywheel mounting bolts is not
permitted.
Clean the crankshaft mounting bolt threads.

Degrease the bearing face of the flywheel on the
crankshaft.
Cement the flywheel bolts using Loctite
FRENETANCH and tighten them to the
recommended torque.
Replace the flywheel if it has been damaged.
20-5
vnx.su
F9Q ENGINE
CLUTCH
Clutch shaft bearing
REPLACEMENT
This operation is carried out after the gearbox has
been uncoupled and after the clutch and flywheel have
been removed.
EQUIPMENT REQUIRED
Bearing extractor
REMOVAL
Use a general purpose puller to remove the bearing.
REFITTING
Fit the new bearing. The bearing is lubricated, so only
clean the external diameter.
Coat the external bearing diameter with loctite
FRENBLOC.
Fit the bearing with a tube applying pressure on the
outer cage.
20-6
vnx.su
20
MECHANICAL ELEMENT CONTROLS

137
Clutch master cylinder
REMOVAL
37
Remove the master cylinder from the bulkhead,

turning it clockwise a quarter of a turn (bayonet-type
fixing) using tool Emb. 1596.

In the passenger compartment
Disconnect the master cylinder ball joint from the
clutch pedal.
In the engine compartment
Drain the brake fluid reservoir until the level is below
the master cylinder supply port.
Place a cloth under this port then disconnect the pipe
from the brake fluid reservoir and fit plugs.
Remove the master-slave connecting pipe holding clip
(1) on the master cylinder.
Place a cloth under the master cylinder then

disconnect the master cylinder connection pipe and fit
plugs to each port.
37-18
vnx.su

Clutch master cylinder
37
REFITTING
Check the condition of the seals.
The master cylinder is fitted with a foolproofing device.
Top up the brake fluid reservoir.

Check that the clutch system is operating correctly.

Bleed the hydraulic circuit:
connect a pipe linked to a reservoir containing brake
fluid to port (C),
fit the bleeding device,
operate the bleeding device,
wait until the air is completely expelled from the
hydraulic circuit.
37-19
vnx.su

Clutch slave cylinder
the union (C) of the clutch slave cylinder, removing

clip (3).

Retaining bolt of the slave cylinder on the
clutch housing
37
0.8
REMOVAL
The clutch slave cylinder can only be removed after
the gearbox has been removed.
Disconnect:
the master-slave connecting pipe, disconnecting clip
(2) on the union (A),
Remove the three clutch slave cylinder mounting

bolts (B), then remove the cylinder.
WARNING:
Never operate the system when the slave cylinder
is removed (even if it is connected to the clutch
pedal). There is a risk that the hydraulic piston and
the stop will be ejected from the slave cylinder.
37-20
vnx.su
PK 6

Clutch slave cylinder
37
REFITTING
Tighten the two slave cylinder mounting bolts to a
torque of 0.8 daNm.
Top up the brake fluid reservoir.

Check that the clutch system is operating correctly.
IMPORTANT:
To avoid damaging the slave cylinder, do not coat the
gearbox output shaft with grease.
NOTE:
To prevent leaks, replace the slave cylinder after
replacing the clutch mechanism.
fluid to port (C),
hydraulic circuit.
37-21
vnx.su

Clutch control pipework
REMOVAL
Drain the brake fluid reservoir until the liquid level is
below the master cylinder supply port.
Place a cloth under this port then disconnect the pipe
from the brake fluid reservoir and fit plugs.
(A) on the master cylinder.
Place a cloth under the master cylinder then
disconnect the master cylinder connection pipe and fit
plugs to each port.
37-22
vnx.su
37

CLUTCH PIPEWORK SYSTEM
37-23
vnx.su
37

(2) on the slave.
37
REFITTING
WARNING:
When refitting:
do not damage the various pipes,
take care to connect them correctly,
position the various mounting clips correctly.
fluid to port (D),
hydraulic circuit.
Place a cloth under the slave cylinder then disconnect

the slave cylinder connection pipe (C) and fit plugs to
each port.
Carefully remove the master-slave connecting pipe
taking care not to damage anything.
20456
37-24
vnx.su

Declutching pedal
the clutch pedal return spring clip (D) and withdraw

the retaining pin,
the pedal retaining bolt (E),
the pedal.

Clutch pedal pump mounting bolts
37
4.4
REMOVAL
The clutch pedal is removed without removing the
steering elements.
Set the vehicle wheels straight.
Remove support (A) of the lighting rheostat control to
gain access to the master cylinder ball joint and the
clutch pedal sensor.
Disconnect the master cylinder ball joint (B) from the
clutch pedal.
Remove:
the connector (C) of the clutch pedal sensor, turning
a quarter of a revolution,
REFITTING
WARNING:
Do not forget to replace the clutch pedal sensor
support plate when replacing the pedal.
Tighten the bolt to a torque of 4.4 daNm.
37-25
vnx.su
MANUAL GEARBOX
121
Ratios
21
PK 5 GEARBOX
Suffix
Vehicle/engine
Differential
ratio
Reverse
gear
PK5-011
Primastar/F9Q
16/67
11/51
17/38
31/43
41/40
41/31
27/47
PK 6 GEARBOX
Suffix
Vehicle/engine
Differential
ratio
Reverse
gear
PK6-008
Primastar/F9Q
17/67
11/51
19/40
31/40
41/37
41/29
47/30
27/47
21-1
vnx.su
MANUAL GEARBOX
Lubricants
OIL CHANGE FREQUENCY
CAPACITY (in litres)

PK5
PK6
2,70 0,15
No oil change
VISCOSITY GRADE
TRANSELF TRP 75 W80W
The check is carried out using dipstick B. Vi. 1675
(minimum/maximum level mark C).
1 Drain plug
2 Filler plug
5 Oil volume
6 Gearbox type
21-2
vnx.su
21
MANUAL GEARBOX
Consumables
21
PK5/PK6
Type
Packaging
Component
MOLYKOTE BR2
1 kg tin
Right-hand sunwheel splines
RHODORSEAL 5661
100 g tube
Threaded plugs and switches
Parts to be replaced systematically

If they have been removed:
the lip seals;
the O-rings.
21-3
vnx.su
MANUAL GEARBOX
Special notes
GEAR SELECTION GRIDS
21
WARNING: it is FORBIDDEN to remove the breather

valve (D) to fill the gearbox with oil.
PK6
To select reverse gear, lift the collar (A) and shift the
lever.
PK5
21-4
vnx.su
MANUAL GEARBOX
Removal - Refitting
21

Mot. 1453
Engine retaining device
T. Av. 476
B. Vi. 1531
Tool for centring flywheel

EQUIPMENT REQUIRED
Hydraulic jack

Wheel bolt
Brake caliper column bolt
Shock absorber base bolt
Driveshaft nut
Suspended mounting bolt to body
Suspended mounting bolt on gearbox
Sub-frame front mounting bolt
Sub-frame rear mounting bolt
Rear sub-frame tie-rod mounting bolt
Engine tie-bar bolt to sub-frame
Engine tie bar bolt to engine
Starter motor bolt
Bolts around the gearbox
Filler plug
Drain plug
21-5
vnx.su
14.2
3.5
3.7
10.5
18
28
4.4
8.5
10.5
12
10.5
18
10.5
4.4
4.4
0.4
2.2
MANUAL GEARBOX
Removal - Refitting
REMOVAL
21
the preheating unit, without separating the two hoses

to free the lifting bracket on the flywheel side,
the expansion bottle from its mounting (without
touching the hoses) keeping it attached but mobile.

Open the bonnet and remove:
the particle filter housing (A),
the coolant unit (B),
the air-air exchanger hoses,
Use a syringe to drain the brake fluid reservoir down to

the union where the clutch master cylinder pipes
connect to it.
Disconnect:
hoses (E) and (F),
connectors (G), (H) and (I).
21-6
vnx.su
MANUAL GEARBOX
Removal - Refitting
Disengage the air inlet pipe from its filter.
21
Unclip the two electric wiring harnesses from their

gearbox mounting (C).
Disconnect the clutch slave cylinder pipe (1).

Unclip the breather pipe (2).
Attach the two electric wiring harnesses to make it

easier to remove the gearbox.
Remove:
the upper soundproofing from the gearbox (be
careful not to disengage the air duct),
the reverse gear connector (A),
the gear control cables (B).
21-7
vnx.su
MANUAL GEARBOX
Removal - Refitting
Remove:
the front wheels,
the engine undertray protections (front and centre),
the gearbox soundproofing housings (inner and rear
sections).
21
Drain the gearbox.

Remove:
the wheel arch liner left and right side protectors,
the brake callipers, securing them to the suspension
spring to protect the hose,
the wheel speed sensor wires (ABS components).
Left-hand side of the vehicle
Remove:
the driveshaft mountings on the gearbox,
Disconnect the fan.

Disconnect the radiator cross member by removing
bolt (A), and tilt the assembly towards the front, attach
it so that you can remove the gearbox soundproofing
housing (front section). Leave the radiator/ventilator
assembly on the cross member during the operation.
NOTE: this operation is for vehicles fitted with air
conditioning (for the front soundproofing housing).
the lower ball joints using an elbow Allen key if the

nut cannot be slackened.
X = 25 mm
21-8
vnx.su
MANUAL GEARBOX
Removal - Refitting
Remove:
the track rod ends using tool T. Av. 476,
the shock absorber base mountings (C),
the driveshaft.
Take care to protect the gaiters.
21
Right-hand side of the vehicle

Remove:
the two bearing bolts (A),
the intermediate bearing on the motor arm.
the lower ball joint,

the steering ball joint,
the shock absorber base mountings,
the driveshaft,
the torque reaction arm,
the TDC sensor.
21-9
vnx.su
MANUAL GEARBOX
Removal - Refitting
Remove the sub-frame with its lower arms.
21
Remove:
the expansion chamber (bolt A) and attach it,
the tachometer connections (B),
the electrical harness earth from the oxidation
cylinder metal support,
Unscrew the rear bolts on the two sub-frame stiffener

bars.
Remove:
the lower nuts on the anti-roll bar return tie-rod,
the heat shield on the steering rack,
the steering rack mounting bolts on the sub-frame.
Position a hydraulic jack under the sub-frame.
Remove:
the two sub-frame front mounting bolts,
the two sub-frame rear mounting bolts.
Turn the two sub-frame stiffener bars towards the
outside.
Lower the sub-frame, arm and anti-roll bar assembly
whilst turning the anti-roll bar to make sure it does not
hook on to the steering rack.
21-10
vnx.su
the oxidation cylinder metal support (C),

the starter electrical connections,
the starter mountings,
the starter motor (slide it back and secure it),
the turbocharger outlet pipe (D).
MANUAL GEARBOX
Removal - Refitting
21
Attach the two electric wiring harnesses to make it

easier to remove the gearbox.
Fit the bonnet strap.
Fit the engine support Mot. 1453 using tool
Mot. 1453-01.
Refit the gearbox mounting (see the information on

Suspended engine mounting in Section 19).
Remove:
the nut (A),
the two bolts for the rubber mounting (B),
the rubber mounting,
the upper mountings of the gearbox,
the gearbox mounting.
Tilt the engine and transmission assembly.
Detach the gearbox mounting hydraulic pipes.
Remove the gearbox mounting.
Position the hydraulic jack.
Proceed in the reverse order to removal to complete
the operation.
Remove:
the lower mountings of the gearbox.
the gearbox.
Refill:
the gearbox (full volume),
the brake fluid reservoir.
REFITTING
If the clutch has been removed, refer to Section 20.
Ensure that the engine/gearbox centring dowels are
fitted.
IMPORTANT: do not grease the clutch shaft splines.
Separate the wiring harnesses and remove the harness
centring pin from the gearbox.
Bleed the clutch system.

IMPORTANT: attach the brake hoses to the shock
absorber base correctly.
21-11
vnx.su
PK5/PK6
MANUAL GEARBOX
Clutch shaft lip seal
21
REPLACEMENT
This operation is carried out after the gearbox has been disconnected from the engine.

B. Vi. 1236
Primary shaft oil seal fitting tool
REMOVAL
REFITTING
Drill a hole in the seal with a 2.5 mm diameter drill.
Fit a new seal along with its protector using tool

B. Vi. 1236.
WARNING: DO NOT SCRATCH THE SHAFT OR

THE SEAL BEARING SURFACE.
Insert a screw into the seal and extract the seal using a
pair of pliers.
Remove the protector.

Refit the guide tube.
21-12
vnx.su
MANUAL GEARBOX
Differential output seal
21
CONSUMABLES
Loctite FRENBLOC
Brake caliper mounting bolt
MOLYKOTE BR 2
Right-hand sunwheel splines
Remove the flange from the intermediate bearing.

Shock absorber base mounting bolts
18
Wheel bolt
14.2

Drain the gearbox.
Remove:
the wheel arch liner side protectors,
the front right wheel,
the upper bolt (3) of the shock absorber base and
slacken the lower bolt (4),
ABS wheel speed sensor.
Tilt the stub axle carrier and disconnect the driveshaft

(take care not to damage the gaiters during this
operation - see Section 29).
21-13
vnx.su
MANUAL GEARBOX
Differential output seal
21
REPLACING THE SEAL

Remove the O-ring from the sunwheel.
Tap the base of the lip seal using a drift and a small
hammer to pivot it in its housing.
When the seal is dislodged, remove it with pliers taking
care not to damage the splines of the sunwheel.
Position the driveshaft in relation to the sunwheel.

Pivot the stub-axle whilst inserting the driveshaft into
the sunwheel.
The seal is refitted with tool B. Vi 1235.
Tighten the nuts, bolts and studs to the recommended

torques.
Oil the tool before inserting it into the splined part of

the sunwheel.
Fill the gearbox.
Fit the lip seal then the O-ring and coat the splines with
MOLYKOTE BR2 grease.
21-14
vnx.su
MANUAL GEARBOX
121
Identification
A: the gearbox type.

B: the oil volume.
21-1
vnx.su
21
MANUAL GEARBOX
Section and tightening torques in daNm
Description
Torque in daNm
Gearbox casing bolt
2.40
Differential crownwheel
13
Reversing switch
2.3
Cable sleeve stop mounting
2.3
Switch
1.5
Concentric stop
0.8
Rear cover (if fitted)
0.8
Tachometer (PK5 gearbox)
21-2
vnx.su
21
MANUAL GEARBOX
Ratios
21
PK 5 GEARBOX
Suffix
Vehicle/engine
Torque
1st
2nd
3rd
4th
5th
Reverse
PK5-011
Primastar / F9Q
16:67
11:51
17:38
31:43
41:40
41:31
27:47
PK 6 GEARBOX
Suffix
Vehicle/engine
Torque
1st
2nd
3rd
4th
5th
6th
Reverse
PK6-007
Primastar / G9Ut
16:67
11:43
19:40
31:43
41:40
41:31
47:28
27:47
PK6-008
Primastar / F9Q
17:67
11:51
19:40
31:40
41:37
41:29
47:30
27:47
PK6-009
Primastar / F4R
17:82
11:43
19:40
31:43
41:40
41:31
47:30
27:47
21-3
vnx.su
MANUAL GEARBOX
Consumables
Types
Packaging
Directions
Gearbox oil
ELF TRP 75W80W

or
TEXACO ETL 8275
Immerse all components
Rhodorseal
100g tube
Use on housing
CAPACITY (in litres)

PK5
PK6
2.70 0.15
PK5 - PK6
The check is carried out using dipstick B.Vi. 1675 (min / max level mark C).
Parts always to be replaced

If they have been removed:
the lip seals,
the O-rings,
the bearing circlips,
the hub springs,
the roll pins.
21-4
vnx.su
21
MANUAL GEARBOX
Special tooling
B. Vi. 31-01
Set of punches for roll pins
B. Vi. 1235
Differential oil seal fitting tool
B. Vi. 1236
Primary shaft oil seal fitting tool
B. Vi. 1417
Housing supports and chassis
B. Vi. 1418
Adjustable support for fitting bearing races
B. Vi. 1419
Bearing race positioning tool
B. Vi. 1510
Gearbox repair tool set
B. Vi. 1510-01
ABHI J -
Differential small bearing positioning tool

Differential bearing race positioning tool
Differential bearing race positioning tool
Differential large bearing positioning tool
Bearing race positioning tool
(clutch housing side)
LMNOPQR-
Tube for sprocket removal

Tube for positioning primary shaft bearings
Tube for positioning idle sprocket rings
Tube for positioning secondary shaft bearings
Fork shaft needle bearing positioning tool
Fork shaft needle bearing positioning tool
Control shaft needle bearing positioning tool
RECOMMENDED TOOLS
General purpose puller 42 (example: U49M + U49D8 Facom)
18 (example: U49M + U49D4 Facom)
General purpose claw puller.
21-5
vnx.su
21
MANUAL GEARBOX
Repairing the gearbox
21
Modifying the chassis plate for the mechanism

housing
Fit housing support B. Vi. 1417 on a Desvil plate.

With housing support B. Vi 1417 in a horizontal
position, place the engine side of the gearbox against
the plate.
Clamp the gearbox to mounting B. Vi. 1417 on holes;

G2 and Z2.
Make two additional 10 mm holes and thread with

M 12 x 175 as shown in the diagram.
A = 16 mm
B = 144 mm
C = 28 mm
D = 78 mm
21-6
vnx.su
MANUAL GEARBOX
OPENING THE GEARBOX
21
Remove the selector finger (1), the control cable

mounting (2) and the reversing light switch (4).
Disconnect clutch slave cylinder union (C) by removing

clip (3).
Remove the gearbox edge bolts.

Manoeuvre the gear lever at the same time as raising
the housing to disengage the control finger. Remove
the control finger.
Remove the three slave cylinder mounting bolts (B)

then remove the cylinder.
NOTE: never operate the system when the slave

cylinder is removed (even if it is connected to the
clutch pedal). There is a risk that the hydraulic
piston and the slave cylinder stop will be ejected.
21-7
vnx.su
MANUAL GEARBOX
IMPORTANT: keep the setting washer (A) from the
selector unit.
21
Remove:
the reverse gear sliding shaft assembly (B),
the 3rd/4th gear fork (C),
It is matched to the unit and may remain bonded to the

housing.
the 1st/2nd and 5th/6th gear reverse switch, and the

short secondary shaft.
Manoeuvre the control unit while disengaging the
spring above the bushing and remove the unit from the
top.
21-8
vnx.su
MANUAL GEARBOX
Remove:
the long secondary shaft assembly with fork and the
primary shaft,
the crownwheel.
21-9
vnx.su
21
MANUAL GEARBOX
REMOVING THE GEARING
21
Remove from the press the gear assembly

(rings, pinions, hubs) taking support under the 6th or 5th
gear, depending on the gearbox type, using tool
B. Vi. 1510-01L and a separator.
IMPORTANT: the gear supporting rings are fitted so

tightly to the shaft that a force between 10 and
15 tonnes is required to remove them. Ensure you
have good equipment available (e.g. a support
press).
Long secondary shaft
Remove the circlip.
NOTE: break the bearing race to remove the circlip.
Place a cloth around the bottom of the tool to cushion

the shaft when it drops.
Remove from the press the sprocket assembly (rings,

pinions, hubs), using a separator to place the weight on
the 2nd gear pinion.
21-10
vnx.su
MANUAL GEARBOX
Short secondary shaft
Remove the circlip.
21
Remove from the press the assembly (rings, pinions,

hubs) taking support under the 3rd gear using tool
B. Vi. 1510-01L.
NOTE: break the bearing race to remove the circlip.
Place a cloth around the bottom of the tool to cushion

the shaft when it drops.
21-11
vnx.su
MANUAL GEARBOX
REMOVING - REFITTING BEARINGS
21
Refit the bearings using tool B. Vi. 1510-01O.
Long secondary shaft
Short secondary shaft
Remove the bearings with the press using the bearing

extractor tool.
21-12
vnx.su
MANUAL GEARBOX
Primary shaft
21
Refit the bearings using tool B. Vi. 1510-01M.
Use a separator to extract the bearings on the press.
21-13
vnx.su
MANUAL GEARBOX
21
CHECKING PARTS
The pinion and claw teeth should not be chipped or excessively worn.
Also make sure that the shaft surfaces and inner pinion surfaces are free from marks and any signs of unusual wear.
SLIDING SHAFT HUBS
We recommend that you mark the position of the sliding shafts in relation to the hubs.
BEARINGS
The bearings should be replaced if they show any sign of scratches, scorch marks or excessive wear.
21-14
vnx.su
MANUAL GEARBOX
PK 6 GEARBOX
21-15
vnx.su
21
MANUAL GEARBOX
PK 5 GEARBOX
21-16
vnx.su
21
MANUAL GEARBOX
21
REFITTING THE SPROCKETS

IMPORTANT: if you replace parts such as:
the gear support rings,
or the hubs
you must modify the settings using the following method:
Method: measure the height of the original part (to be replaced) and the new (replacement) part.
When the gap between the two parts is greater than 0.025 mm, you must alter the shim setting:
increase the shim if the new part is smaller than the old part,
decrease the shim if the new part is bigger than the old part.
The table contains an example of the shim values to be set using the formula after replacing gear support rings or
hubs.
Replacing rings or hubs for a long secondary shaft
Part
Original part
New part
6th gear support ring
Hub (5th/6th gear)
2nd gear long ring
Hub (1st/2nd gear)
Shim
X = x (a-A) (b-B) (c-C) (d-D)
Replacing rings or hubs for a short secondary shaft

Part
Original part
New part
Reverse gear support ring
Hub (3rd-4th gear)
Reverse gear hub
Shim
X = x (A-a) (B-b) (C-c) (D-d)
Example: replacing the reverse gear support ring for a short secondary shaft.
Part
Original part
New part
Reverse gear support ring
b (30.802)
B (30.830)
Hub (3rd-4th gear)
Reverse gear hub
Shim
Result
Difference
+0.028
X = x (A-a) (B-b) (C-c) (D-d)
2.10
x = 2.10-0.028 = 2.028
Knowing that shim size varies between 0.020 and 0.020, you would have to use a 2.02 shim for this example.
21-17
vnx.su
MANUAL GEARBOX
21
REFITTING THE LONG SECONDARY SHAFT

SPROCKET
Fitting
1
Fit the needle bearing (A), 6th gear idle sprocket

(B) and its blocking ring (PK6).
Use B. Vi. 1510-01N to fit 6/5th gear sliding shaft

hub (C) (align the hub notches with those of the
blocking ring).
Use B. Vi. 1510-01N to fit the 5th gear idle sprocket

ring (D) (apply a pressure of 5 tonnes when
securing).
Fit the needle bearing (E), the 5th gear idle

sprocket and its blocking ring (F).
Fit the grooved washer (G).
Use B. Vi. 1510-01N to fit the 2nd gear idle

sprocket ring (H) (apply a pressure of 5 tonnes
when securing).
21-18
vnx.su
Fit the needle bearing (I), the 2nd gear/reverse

gear idle sprocket (J) fitted with a three-cone
blocking ring.
MANUAL GEARBOX
21
10 Fit the needle bearing (M) and the 1st gear idle
sprocket (N) fitted with three-cone blocking rings.
IMPORTANT: make sure that the notches on the

three-cone ring are correctly positioned.
11 Fit the grooved washer pin (O).
Use B. Vi. 1510-01N to fit the 1st/2nd gear sliding

shaft hub (K), align the hub notches with those of
the blocking ring.
IMPORTANT: the long hub support should be placed

on the pinion side of the 2nd gear.
9
Use B. Vi. 1510-01N to fit the 1st gear idle sprocket

ring (L) which has pin holes at the top (apply a
pressure of 5 tonnes when securing).
12 Fit the bearing using B. Vi. 1510-01O.
Select and fit a new circlip just inside the neck (it
should not be able to move once it has been fitted).
21-19
vnx.su
MANUAL GEARBOX
21
REFITTING THE SHORT SECONDARY SHAFT

SPROCKET
Fit the needle bearing (E) and the 4th gear idle
sprocket and its blocking ring (F).
Fitting:
Fit the grooved washer (G).
Use B. Vi. 1510-01N to fit the reverse gear idle

sprocket ring (H) (apply a pressure of 5 tonnes
when securing).
Fit the needle bearing (I) and the reverse gear idle
sprocket (J) fitted with a blocking ring.
Use B. Vi. 1510-01N to fit the reverse gear sliding

shaft hub (K).
Fit the needle bearing (A) and the 3rd gear idle
sprocket (B) fitted with three-cone blocking rings.
Use B. Vi. 1510-01N to fit the 3/4rd/th gear sliding

shaft hub (C).
IMPORTANT: make sure that the notches on the

three-cone ring are correctly positioned.
Use B. Vi. 1510-01N to fit the 4th gear idle sprocket

ring (D) (apply a pressure of 5 tonnes when
securing).
21-20
vnx.su
MANUAL GEARBOX
9
Fit the bearing using B. Vi. 1510-01O.
Select and fit a new circlip just inside the neck

(it should not be able to move once it has been fitted).
21-21
vnx.su
21
MANUAL GEARBOX
21
DIFFERENTIAL
REMOVAL
Remove the tripod sunwheel stop ring (A) and remove the shim (B).
Remove the tripod sunwheel.
Lock the unit in a vice with clamping jaws and remove the crownwheel.
Remove the planet wheels and the sunwheel and attach the support washers to their respective planet wheels.
CHECKING PARTS
Check the condition:
of the teeth (crownwheel - planet wheels - sunwheels),
the washers (planet wheels - sunwheels),
and the unit.
21-22
vnx.su
MANUAL GEARBOX
Use a general purpose puller to remove the large
bearing.
Use a general purpose puller to remove the small

bearing.
21-23
vnx.su
21
MANUAL GEARBOX
DIFFERENTIAL
the large bearing using B. Vi. 1510I.
REFITTING
All the cleaned and checked parts should be oiled as
they are fitted.
The stop ring is always replaced.
Tighten the crownwheel bolts to a torque of 13 daNm.
Refit:
the small bearing using B. Vi. 1510A.
21-24
vnx.su
21
MANUAL GEARBOX
INTERNAL CONTROLS
21-25
vnx.su
21
MANUAL GEARBOX
21
BEARING RACES IN THE MECHANISM HOUSING
REFITTING
REMOVAL
Fit adjustable support B. Vi. 1418 under the

mechanism housing that corresponds to each line.
Place the housing on the chassis of B. Vi. 1417 and

secure it with the three bolts.
Fit the setting shims corresponding to each line.
Use a 42 diameter general purpose puller and an

inertia extractor to remove the shaft bearing races.
Use B. Vi. 1419 to fit the shaft bearing races.
Use B. Vi. 1510H to refit the differential bearing race.

WARNING: take care not to mix up these three setting
shims.
Use a pin punch to remove the outer race of the large
differential bearing.
21-26
vnx.su
MANUAL GEARBOX
21
BEARING RACES IN THE CLUTCH HOUSING
REFITTING
REMOVAL
Fit the housing on the press plate.
Use a general purpose puller with three claws to

remove the secondary shaft bearing races.
Fit adjustable support B. Vi. 1418 under the housing

that corresponds to each line.
Use B. Vi. 1510J and B. Vi. 1510B to fit the shaft
bearing races.
Use a 42 diameter general purpose puller and an

inertia extractor to remove the primary shaft and
differential bearing races.
NOTE: remember to fit a new deflector under the small
diameter differential bearing race.
21-27
vnx.su
MANUAL GEARBOX
21
REMOVING THE NEEDLE BUSHINGS ON THE

HOUSING
Clutch housing side
Mechanism housing side
Use a 14 diameter general purpose puller to remove

the bushings.
Remove the gear shift finger and use a 14 diameter

general purpose puller to remove the bushings.
Refit the bushings using B. Vi. 1510-01R.
Refit the bushings using B. Vi. 1510-01Q.
21-28
vnx.su
MANUAL GEARBOX
21
Fit:
the 3rd/4th gear fork and the sliding shaft - fork reverse gear shaft assembly,
REFITTING THE SHAFTS

Fit the differential and the long secondary shaft primary shaft with fork assembly.
the control unit and engage the unit in its housing;

then turn it to 3rd/4th gear position and shift the
spring above the bushing.
Fit the 1st/2nd and 5th/6th gear reverse switches and

the short secondary shaft.
21-29
vnx.su
MANUAL GEARBOX
Check that the unit setting washer (A) is correctly
fitted.
21
Position the bolts around the unit.

Pretighten bolts (2) and (14) to 1 daNm.
Apply a line of silicone around the gasket face (B).

Turn the primary shaft while shifting the gears.
Tighten all the bolts to 2.4 daNm in the order shown in
the diagram below.
Offer up the mechanism housing while moving the

gear shift finger towards the front and engage it.
Adjust the controls to engage the finger in the unit fork.
Refit the selector finger (1), the control cable mounting
(2) and the reversing light switch (3).
21-30
vnx.su
MANUAL GEARBOX
Fit:
the differential output lip seals using tool B. Vi. 1235,
21
Refit the slave cylinder and tighten the three bolts (B)
to 0.8 daNm.
the primary shaft output lip seals using tool

B. Vi. 1236.
Couple union (C) and the clipper together with clip (3).
21-31
vnx.su

External control cables
EXPLODED VIEW
37-26
vnx.su
37

The control unit
Engine side
37
Passenger compartment side

REMOVAL

Unit mounting bolt
2.1
Gearbox cable guide plate mounting bolt
2.1
This operation is carried out after having removed the

centre console (see relevant chapter).
Lift the protective foam cover from the control cables in
order to unscrew the two nuts (C) holding the gearbox
cable guide in place.
REMOVAL
Open the bonnet.
Remove:
the top sound insulation box of the gearbox (where
fitted) fixed by a clip,
the two external gearbox control ball joints (A),
the two external gearbox control cable clips (B),
37-27
vnx.su

The control unit
Remove:
the earth bolt (D) of the gearbox control unit,
the three nuts (E) of the gearbox control unit,
the gear selection control cables and the control unit.

REFITTING
NOTE:
When replacing the top gearbox sound insulation box,
check for the presence of the gearbox air duct.
37-28
vnx.su
37

External gear control
Engine side
REMOVAL OF THE GEAR CHANGE AND GEAR

SELECTION CABLES
REMOVAL
37
This operation is carried out after having removed the

centre console (see relevant section).
REMOVAL
Open the bonnet.
Lift the protective foam cover from the control cables in

order to unscrew the two nuts (C) holding the gearbox
cable guide plate in place.
Remove:
the top sound insulation box of the gearbox (where
fitted) fixed by a clip,
the two external gearbox control ball joints (A),
the two external gearbox control cable clips (B),
37-29
vnx.su

REMOVAL OF THE GEAR LEVER SUPPORT
PROTECTIVE PLATE
37
the two internal gearbox control cable ball joints (A),

the two internal gearbox control cable clips (B),
Remove:
the nut (E),
the lower bolt (F),
the two circlips (G) holding the gear lever support
protective plate in place,
the gear lever support protective plate,
Withdraw the two cables completely.

REFITTING
NOTE:
When replacing the top gearbox sound insulation box,
check for the presence of the gearbox air duct.
37-30
vnx.su

37
CHECKING
2)
Position the gear lever in 4th.
With the lever in neutral, check using a set of shims.
3)
Lock the yellow clip from the end piece/cable

connection system.
4)
Check the clearance:

the 4.35 mm shim does not clear,
the 3.30 mm shim clears.
5)
If it is not correct: replace the entire control.
The clearance of line 3/4.

The correct clearance is:
the 4.35 mm shim does not clear,
the 3.30 mm shim clears.
In the opposite case a readjustment is necessary.

ADJUSTMENT
1)
Unlock the yellow clip from the end piece/cable

connection system.
37-31
vnx.su
DRIVESHAFTS
129
Exploded view
PK GEARBOX DRIVESHAFT
29-1
vnx.su
29
DRIVESHAFTS
Front driveshaft
29

T. Av. 476

Shock absorber lower bolt
Track rod end nut
18
3.7
Hub nut
28
Wheel bolt
14.2
Mounting bolt on gearbox
4.4
Mounting bolt on intermediate bracket
4.4
Stud on gearbox
0.8
REMOVAL - WHEEL SIDE

Remove:
the wheel hubcap,
the hub nut,
the front wheels,
Push the driveshaft back into the stub-axle carrier,

whilst tilting the stub-axle carrier.
the track rod end nut (B),

the shock absorber lower mounting bolts (C).
29-2
vnx.su
DRIVESHAFTS
Front driveshaft
29
REMOVAL - GEARBOX SIDE
Left-hand side
Right-hand side
Drain the gearbox.
Remove:
the two mounting bolts (A) of the intermediate
support,
Remove:
the three gaiter mounting bolts on the gearbox,
the driveshaft on the gearbox side.

the driveshaft on the gearbox side.
29-3
vnx.su
DRIVESHAFTS
Front driveshaft
REFITTING
29
NOTE: the differential output lip seal must always be

replaced.
Left-hand side
With the protector in place, coat the splines of the seal,
gearbox end, with MOLYKOTE BR 2 grease.
Remove the plastic protector from the bearing gaiter

and insert the driveshaft as horizontally as possible.
Position the driveshaft and insert it.

The driveshaft should enter freely until the thread
protrudes allowing the stub axle nut to be fitted.
The driveshaft should enter freely until the thread

protrudes allowing the stub axle nut to be fitted.
Right-hand side
Clean the bore of the bearing into which the bearing is
inserted.
Check the condition of the contact surface of the lip
seal on the relay shaft.
29-4
vnx.su
REAR AXLE
Bearing
33

T. Ar. 1623
Tool kit for replacing the rear

bearings
REMOVAL
Remove:
the brake disc (refer to the relevant procedure),
the brake disc circlip.
the bearing using tools A and C.
NOTE:
It is essential to fit a new bearing.
REFITTING
Refit:
the bearing using tools B and C,
the brake disc circlip,
the brake disc (refer to the relevant procedure).
33-7
vnx.su
FRONT AXLE
Stub-axle carrier
31

T. Av. 476
Rou. 604-01
Hub locking tool

Shock absorber base mounting nut
18
3.7
10.5
Driveshaft nut
28
Unclip the wheel sensor ABS equipment).
REMOVAL
Remove:
the driveshaft nut,
the brake disc (consult the relevant procedure),
Remove:
the steering ball joint mounting nut,
the lower ball joint mounting nut,
the shock absorber base lower mounting nuts.
31-5
vnx.su
FRONT AXLE
Stub-axle carrier
Release:
the lower ball joint of the stub-axle carrier.
Disengage the driveshaft
Remove:
the mounting bolts of the base of the shock absorber
(using a mallet),
the stub-axle carrier.
REFITTING
Refit:
the stub-axle carrier,
the driveshaft,
the shock absorber base mounting bolts,
the lower mounting nuts of the base of the shock
absorber,
the lower ball joint of the stub-axle carrier,
the lower ball joint mounting nut,
the steering ball joint mounting nut,
the driveshaft nut,
the wheel sensor ABS equipment).
Tighten the bolts and nuts to the recommended torque.
pistons into contact with the brake pads and discs.
Check the brake fluid level.
31-6
vnx.su
31
FRONT AXLE
Stub-axle carrier bearing
31

T. Av. 1624
Tool kit for replacing the front

bearings
REMOVAL
IMPORTANT:
It is essential to fit a new bearing which has been
cleaned to remove grease from the interior and
exterior surfaces in contact with the stub-axle
carrier and hub.
Remove:
the stub-axle carrier (refer to the relevant procedure),
IMPORTANT:
It is essential to clean the surfaces of the stubaxle carrier and the hub (in contact with the
bearing) to remove grease from them.
REFITTING
the hub using tools A and B,
the bearing using tools B, C and D.
31-7
vnx.su
FRONT AXLE
Stub-axle carrier bearing
Refit the bearing into the stub-axle carrier using tools

D, E and F, with the black ABS target positioned on the
interior side of the stub-axle carrier.
NOTE:
It is essential to make sure that the ABS sensor holder
is correctly positioned (A = 48 5 with the
horizontal).
Refit:
the hub using tools B, C and D,
the stub-axle carrier (refer to the relevant procedure).
31-8
vnx.su
31
FRONT AXLE
Spring and shock absorber assembly
31

Anti-roll bar return tie-rod nut
Shock absorber base mounting nut
4.4
18
Shock absorber rod nut

Wheel bolt
6.2
14.2
Coolant tank bolt
REMOVAL
Left-hand side
Remove the coolant tank mounting bolt.

Disconnect the coolant tank to gain access to the
shock absorber rod nut.
Left or right-hand side
Remove the wheel .
Unclip the wheel sensor wire (ABS equipment).
Remove:
the shock absorber rod upper nut
the noise suppression washer,
the mounting nuts of the base of the shock absorber,
the upper nut on the anti-roll bar return tie-rod.
Disconnect the anti-roll bar return tie-rod.
Remove:
the mounting bolts of the base of the shock absorber
(using a mallet),
the spring and shock absorber assembly,
the filter block (this remains on the vehicle during
removal of the assembly).
31-9
vnx.su
FRONT AXLE
Spring and shock absorber assembly
REFITTING
Left or right-hand side
Refit:
the filter block on the assembly,
the assembly and its filter block on the vehicle,
the noise suppression washer,
the shock absorber rod upper nut,
the shock absorber base mounting bolts,
the mounting nuts of the base of the shock absorber,
the upper tie-rod of the anti-roll bar return tie-rod,
the upper nut on the anti-roll bar return tie-rod,
the wheel sensor wire (ABS fitting).
Refit the wheel.
Tighten the wheel bolts to the recommended torque.
Left-hand side
Refit:
the coolant tank,
the coolant tank mounting bolt.
31-10
vnx.su
31
FRONT AXLE
Spring and shock absorber
31
EQUIPMENT REQUIRED
Spring compressor
NOTE:
Shock absorbers are stored horizontally. Under these
conditions, it is possible that shock absorbers
designed to work vertically become drained.

Shock absorber rod nut
As a result, you just need to manually pump the shock

absorber rod a few times in a vertical position before
fitting the spring.
REFITTING
Refit:
the dust seal,
the spring,
the upper cup,
the bearing (take care to observe the direction of
fitting: collar of the interior cage turned towards
the base of the shock absorber),
the washer,
the spacer,
the shock absorber rod nut.
Tighten the shock absorber rod nut to the
recommended torque.
Position the spring in the stops of the upper and lower
cups.
REMOVAL
Decompress the spring.
Remove the spring and shock absorber assembly

(refer to the relevant procedure).
Fit the spring and shock absorber assembly vertically
in a vice.
Refit the spring and shock absorber assembly (refer to

the relevant procedure).
Press down on the spring until it detaches onto the cup

mountings.
Remove:
the shock absorber rod nut,
the spacer,
the washer,
the bearing,
the upper cup,
the spring,
the dust seal.
31-11
vnx.su
FRONT AXLE
Lower suspension arm
31

T. Av. 476

REFITTING

10.5
Lower arm bolt on sub-frame
18
Wheel bolt
14.2
Refit:
the lower arm,
the arm mounting bolts on the sub-frame,
the lower ball joint nut,
the wheel sensor wire (ABS equipment).
Refit the wheel.
REMOVAL
Remove the wheel.
Unclip the wheel sensor wire (ABS equipment).
Remove:
the arm mounting bolts on the sub-frame.
Release the lower ball joint.
Remove the lower arm.
31-12
vnx.su
FRONT AXLE
Anti-roll bar
31

T. Av. 476

EQUIPMENT REQUIRED
Component jack

4.4
Lower arm bolt on the sub-frame
18
12
10.5
Steering rack mounting bolt
18
Engine tie bar mounting bolt
10.5
Bearing mounting bolt

Sub-frame tie-rod mounting bolt (stiffener
bar)
Mounting bolt on the heat shield
Wheel bolt
2.1
10.5
1.5
14.2
REMOVAL
Remove the wheels.
Unclip:
the wheel sensor wires (ABS equipment),
the brake pipes on the sub-frame.
Remove:
the steering rack mounting bolts on the sub frame,
the engine tie bar.

bars.
31-13
vnx.su
FRONT AXLE
Anti-roll bar
31
NOTE:
Ensure the correct positioning of the sub-frame with
relation to the casing and the front silentbloc fittings.
Refit:
the two sub-frame stiffener bars,
the two sub-frame rear mounting bolts,
the two sub-frame front mounting bolts.
Tighten to the recommended torque:
the rear bolts of the two sub-frame stiffener bars.
Remove the component jack.
Position the component jack beneath the sub-frame
and fix it firmly into place.
Refit:
the engine tie bar,
the steering rack mounting bolts on the sub-frame,
Remove:
outside.

Refit the wheels.
Lower the sub-frame and anti-roll bar assembly by

20 centimetres, pivoting the anti-roll bar to prevent it
from attaching to the steering rack.
Remove:
the four bearing mounting bolts.
the anti-roll bar and bearings
REFITTING
Refit:
the anti-roll bar and bearings,
Tighten the four bearing mounting bolts to the correct
torque.
Refit the sub-frame, and anti-roll bar assembly whilst
turning the anti-roll bar to make sure it does not make
contact with the bulkhead.
31-14
vnx.su
FRONT AXLE
Engine sub-frame
31

T. Av. 476

EQUIPMENT REQUIRED
Component jack

4.4
10.5
18
12
10.5
18
10.5
2.1
Sub-frame tie-rod mounting bolt
10.5
1.5
Wheel bolt
Loosen the rear bolts on the two sub-frame stiffener

bars.
14.2
REMOVAL
Remove the wheels.
Unclip:
the wheel sensor wires (ABS equipment)
31-15
vnx.su
FRONT AXLE
Engine sub-frame
31

Release the two lower ball joints.
Remove:
outside.
Lower the sub-frame, arm and anti-roll bar assembly
hook on to the steering rack.
Remove:
the engine tie bar.
31-16
vnx.su
FRONT AXLE
Engine sub-frame
Remove:
the four arm mounting bolts,
the two arms,
the four bearing mounting bolts,
the anti-roll bar and bearings.
31

REFITTING
Refit:
the engine tie bar,
Refit:
the two arms,
the four arm mounting bolts,
the anti-roll bar and bearings,
Tighten the four bearing mounting bolts to the correct
torque.
Refit the sub-frame, arm and anti-roll bar assembly

make contact with the bulkhead.
Refit the wheels.

NOTE:
Ensure the correct positioning of the sub-frame with
Refit:
31-17
vnx.su
REAR AXLE
Spring
EQUIPMENT REQUIRED
Spring compressor
REMOVAL
Press down on the spring until it detaches onto the cup
mountings.
Remove the spring and the tool.
REFITTING
Replace the spring and the tool.
Decompress the springs.
33-8
vnx.su
33
REAR AXLE
Shock absorber
REFITTING

Shock absorber mounting bolt
REMOVAL
Put the car on a four-post lift.

Remove:
the shock absorber mounting bolts,
the shock absorber.
33
18
Refit:
the shock absorber,
the shock absorber mounting bolts, without
tightening them.
Measure dimension X between the shock absorber

mounting bolt centreline.
Compress or load the vehicle to obtain the
measurement:
X = 397 2 mm.
Torque-tighten the shock absorber mounting bolts.
33-9
vnx.su
REAR AXLE
Rear axle assembly
33
EQUIPMENT REQUIRED
Hydraulic jack
Spring compressor
Wheel bolt
14.2
Brake pipes
1.4
Shock absorber mounting bolt
1.8
Anti-lock Braking System sensor

mounting bolt
0.8
Tie-rod mounting bolt
10.5
Rear axle mounting bolt
10.5
REMOVAL
Put the car on a two-post lift.
Fasten the vehicle on a two-post lift.
Activate the brake pedal using a pedal press (this has
the effect of limiting the flow of brake fluid).
the wheel sensors (Anti-lock Braking System

equipment),
the compensator control lever nut (except Anti-lock
Braking System equipment),
the handbrake cables,
the flexible brake pipe hoses.
Remove:
the wheels;
the springs (refer to the relevant procedure),
the shock absorber mounting bolts,

the shock absorbers,
33-10
vnx.su
REAR AXLE
Rear axle assembly
Remove:
the tie-bar mounting bolts,
the tie-rod.
33
Measure dimension X between the shock absorber

mounting bolt centreline.
Position the hydraulic jack beneath the rear axle and

fix it firmly into place.
Compress or load the vehicle to obtain the

measurement:
X = 397 2 mm.
Remove:
the rear axle mounting bolts,
the rear axle.
Tighten to torque:
the shock absorber mounting bolts.
REFITTING
Bleed the brake circuit (refer to the relevant method).
Refit:
the rear axle,
the tie-rod,
the tie-rod mounting bolts (bolt head towards the
rear of the vehicle),
the flexible brake pipe hoses,
the handbrake cables,
the wheel sensors (Anti-lock Braking System
equipment),
the compensator control lever sensors (except Antilock Braking System equipment),
the shock absorbers,
the shock absorber mounting bolts, without
tightening them,
the springs,
the wheels.
Adjust the handbrake control (refer to the relevant

procedure).
Check the angles of the rear axle geometry.
33-11
vnx.su
GENERAL INFORMATION
130
General diagram of braking circuits
30
NOTE:
the diagram below shows the general principle; in no case should it be taken as reference for the circuit
connections and allocations. When replacing one of the components of the brake circuit on a vehicle, always mark
the pipes before removing them so that they can be connected back in their original positions.
"X" TYPE BRAKING

WITH load sensitive compensator
30-1
vnx.su
GENERAL INFORMATION
Brake unions and pipes
30
The connection of the pipes between the master

cylinder, callipers, compensator, and hydraulic
assembly is made by means of threaded unions with
metric thread.
Consequently, only parts listed in the Parts Catalogue
for this vehicle should be used.
Identification of parts:
SHAPE of the steel or copper PIPE end piece (A),
SHAPE of THREADED CASINGS on components
(B),
pipe UNIONS coloured GREEN or BLACK: external
hexagon measuring 11 mm or 12 mm (C).
Brake fluid
BRAKE FLUID REPLACEMENT INTERVAL
Braking technology, in particular for disc brakes (hollow pistons which transfer little heat, low volume of fluid in the
cylinder, sliding callipers avoiding the need for a fluid reservoir in the least cooled area of the wheel), has allowed us
to avoid the risk of vapour lock as far as possible, even if the brakes are used intensively (in mountainous areas).
Modern brake fluids still degrade slightly during the first few months of use due to a small uptake of humidity and
replacement of the fluid is therefore recommended (refer to vehicle's Servicing booklet).
Topping up the level
Wear of the brake pads and shoes will cause a gradual drop in the fluid level in the reservoir. This drop should not be
compensated for since the level will rise again when the pads are changed. The level should not however be allowed
to fall below the minimum mark.
Approved brake fluids:
Mixing two incompatible brake fluids in the circuit will cause a risk of major leaks, mainly due to deterioration of the
cups. To avoid such risks, it is essential to keep to brake fluids which have been checked and approved by our
laboratories and which conform to Standard SAE J 1703 dot 4.
For optimized use of vehicles equipped with an Electronic Stability Program, Nissan recommends a brake fluid with
low viscosity in cold conditions (maximum 750 mm2/s at - 40C).
30-2
vnx.su
GENERAL INFORMATION
Dimensions of the main braking components
30
LUCAS FRONT BRAKES (mm)

40-45
Slave cylinder diameter

Disc diameter
305
Disc thickness
28
Minimum disc thickness
24
0.07
Maximum run-out of discs

Brake pad thickness (including mounting)
18
Minimum thickness of brake pads (including mounting)
LUCAS REAR BRAKES (mm)

Diameter of brake cylinders
41
Disc diameter
280
Disc thickness
12
Minimum disc thickness
10
0.07
Maximum run-out of discs

Brake pad thickness (including mounting)
17
Minimum thickness of brake pads (including mounting)
MASTER CYLINDER (mm)

X stroke diameter
30-3
vnx.su
Left-hand drive
25.4 x 36
Right-hand drive
20.6 x 52
Electronic Stability Program
20.6 x 52
GENERAL INFORMATION
Bleeding of the brake circuit (except ABS)
30

Brake circuit bleeding device
On vehicles fitted with a brake servo, it is important that the servo system is not actuated while the system
is being bled, regardless of which method is being used to bleed the system.
The bleeding is done on a four-post lift, wheels on the ground.
Connect the bleeding device to the brake circuit bleed valves.
Start the bleeding device in accordance with its instruction manual.
Adjust the output pressure to 2 Bar.
This vehicle is fitted with an X-type braking circuit, so proceed as follows:
Open:
the bleed screw of the rear right-hand wheel and let the fluid flow out for around 20 seconds,
the bleed screw of the front left-hand wheel and let the fluid flow out for around 20 seconds.
Ignore the air bubbles in the pipes of the bleeding device.
Open:
the bleed screw of the rear left-hand wheel and let the fluid flow out for around 20 seconds,
the bleed screw of the front right-hand wheel and let the fluid flow out for around 20 seconds,
Check the firmness of the brake pedal when depressed (press several times).
Repeat the bleeding operation if necessary.
Top up the brake fluid level in the reservoir having disconnected the bleeding device.
Check the tightness of the bleed screws and that the sealing caps are all present.
The effectiveness and balance of the vehicle braking system may be checked on a suitable brake test
bench.
(Refer to Section 38 for information on bleeding a braking circuit equipped with an Anti-lock Braking
System).
30-4
vnx.su
GENERAL INFORMATION
130
Specifications of the front anti-roll bars
Rod diameter (mm)
Marking colour
22
none
30-5
vnx.su
30
GENERAL INFORMATION
Tightening torques (daNm)
BRAKE
AXLE ASSEMBLY
FRONT
CONTROL
Servo mounting nuts
Master cylinder mounting nuts
Master cylinder outlet pipes
Compensator mounting bolt
Compensator inlet pipes
Compensator outlet pipes
Hydraulic assembly mounting bolt
Hydraulic assembly inlet pipes
Hydraulic assembly outlet pipes
Lower wishbone nut on sub-frame

Sub-frame rear mounting bolt on the shell
Sub-frame front mounting bolt on the angle
frame
Angle frame mounting bolt on the shell
Lower wishbone bolt on sub-frame
Anti-roll bar bearing nuts
Lower ball joint nuts
Wheel bolt
Shock absorber base mounting bolt
Driveshaft nut
Shock absorber rod upper mounting bolts
Shock absorber linkage mounting bolts
2.1
2.5
1.4
1.8
1.4
1.4
0.9
1.4
1.4
FRONT
Brake bleed screw,
Calliper inlet pipes
Brake calliper guide bolts
Calliper mounting bolt
0.9 to 1.1
1.4
10.5
3.5
10.5
12
10.5
6.2
18.0
2.1
10.5
14.2
18.0
28.0
6.2
4.4
REAR
Shock absorber upper mounting bolt
Shock absorber lower mounting bolt
Fork mounting bolt on the shell
Fork mounting bolt on the axle
Wheel bolt
Hub mounting bolt
Hub nuts
REAR
Brake bleed screw
Calliper inlet pipes
Brake calliper guide bolts
Protective flange bolt
30
0.9 to 1.1
1.4
18.0
3.3
0.8
18
18
10.5
10.5
14.2
10.5
28.0
STEERING
STEERING COLUMN
Steering wheel mounting bolt
Steering column upper mounting bolt
4.4
2.1
STEERING RACK
Fork connection mounting bolt
Steering ball joint nuts
30-6
vnx.su
18.0
2.1
3.7
GENERAL INFORMATION
Underbody height
30
VEHICLE
At the front
H1 - H2 =... mm
At the rear
H4 - H5 =... mm
Dimension X (in mm)

Left and right
FL0X
49
14
JL0X
52
30
Tolerance: 7.5 mm
The difference between the right-hand side and the left-hand side of the same axle of a vehicle must not exceed
5 mm, the driver's side always being higher.
Any alteration to the underbody height also requires adjustment of the brake compensator and of the headlights.
30-7
vnx.su
GENERAL INFORMATION
Underbody height
MEASUREMENT POINTS
Measurements H1 and H4 are taken on the wheel shaft.

Measurement H2 is taken under the jacking point.
Measurement H5 is taken at the rear axle mounting shaft.
30-8
vnx.su
30
GENERAL INFORMATION
130
Influence of geometry
30
The influence of different geometry on tracking and vehicle tyre wear.

CAMBER
The comparison between the left and right-hand geometry is vital. A difference greater than one degree
between the two sides will cause the direction to be offset, making steering wheel corrections necessary and
causing excessive tyre wear.
The value of this geometry is usually small: in the region of 1.
CASTOR
The comparison between the left and right-hand geometry is essential. A difference greater than one degree
between the two sides will cause the direction to be offset, making steering wheel corrections necessary and
causing excessive tyre wear.
This is characterised by drifting with the speed being stabilised on the side where the angle is smallest.
STEERING HEIGHT
This travel affects the wheel alignment variation during suspension travel.
Variations in alignment between the right hand and left hand wheels will lead to the following (with the steering wheel
remaining in the same position):
drift to one side under acceleration,
drift to the other side under braking,
track changes on uneven road surfaces.
WHEEL ALIGNMENT
This adjustment has little effect on the road holding.
Note:
a significant toe-out excess leads to symmetrical wear on the inside of both tyres,
a significant toe-in excess leads to symmetrical wear on the outside of both tyres.
30-9
vnx.su
GENERAL INFORMATION
Geometry testing principle
PRELIMINARY CHECKS
Fit the measuring equipment with the wheels in this

position and make the checks.
Before checking the axle geometry, you must check

the following points and remedy them if necessary:
When adjusting the wheel alignment, be aware of the

symmetry of the ball joint box X lengths with the
steering links.
symmetry of the tyres on the same axle:

dimensions,
pressures,
degree of wear.
joints:
condition of cushions and elastic bearings,
ball joint gaps,
bearing gaps.
run-out of wheels: must not exceed 1.2 mm (it will be
compensated for by the measuring equipment).
symmetry of underbody heights (condition of the
suspension).
DETERMINING THE STEERING CENTRE POINT
The steering centre point must be set before
checking and adjusting the front axle in order to
avoid drifting problems.
Remove the ignition switch key.
Straighten the wheels.
Lock the steering: the centre point position is

obtained.
30
30-10
vnx.su
GENERAL INFORMATION
Front axle checking and adjustment
30
CHRONOLOGICAL SEQUENCE OF OPERATIONS

Due to the geometric arrangement of the front axles,
a modification of one of the angles (castor, camber,
pivot, alignment and variation) has repercussions to
a greater or lesser extent on the values of the other
angles. (The castor angle is the one which has the
greatest effect).
It is therefore essential to work in the following
order:
fit the equipment on the vehicle according to the
manufacturer's instructions,
locate the steering centre point (see preceding
paragraph) and lock the steering wheel,
raise the vehicle underbody,
compensate for wheel rim run-out,
place the vehicle on pivoting plates,
fit the brake pedal press,
adjust the suspension to bring the vehicle to its
maximum height,
check that the X lengths on the ball joint units are
symmetrical with the steering links,
1 Correct symmetry of X lengths:

the dimension (A) must be evenly distributed.
2 Incorrect symmetry of X lengths:

plot the dimensions (A) on the right-hand and lefthand side, subtract them from one another and
distribute the result with half on each side.
Example:
Right-hand side value: 16
Left-hand side value: 10
16 - 10 = 6
6: 2 = 3
plot the A values on the reading scale.
Adjust the steering links in order to balance the values

(A) of both sides:
A = 13
once in this position, set the pivoting plates to zero,
and check the following in sequence:
castor,
pivot,
camber,
wheel alignment.
30-11
vnx.su
GENERAL INFORMATION
Front axle checking and adjustment
30
ADJUSTING THE WHEEL ALIGNMENT

There are several situations that can arise:
Alignment
Distribution
Correction to be made
OK
NOT OK
Make the same number of turns with the adjuster (or sockets)
but in the opposite direction on the left and right to get the
same value (A) on both sides.
NOT OK
OK
NOT OK
NOT OK
Set the alignment to the same value on the right and left,
ensuring that the values (A) are always identical on both
sides.
Carry out an initial distribution in order to equalize values (A)
on each side, then adjust the alignment as shown in example
no. 2
Front axle fault finding

Faults
Possible causes
Incorrect castor
Bent arm
Bent side member or axle sub-frame
Correct camber + pivot but

Incorrect camber
Incorrect pivot
Bent arm
Bent side member or axle sub-frame
Correct camber
but
Incorrect pivot
Stub-axle carrier twisted
Correct pivot
but
Incorrect camber
Stub-axle carrier twisted
Alignment variation faults
See castor
Incorrect alignment more than 6 mm
Right or left stub-axle carrier twisted
30-12
vnx.su
Bent arm
Bent side member
GENERAL INFORMATION
Brake fault finding
30
This fault finding procedure covers all types of circuit

and braking components for the current range of
vehicle not fitted with the Anti-lock Braking System.
For vehicles fitted with the Anti-lock Braking System,
refer to Section 38.
Only those components belonging to the vehicles
which are covered in this Workshop Repair Manual
should be included in the fault finding procedure.
This fault finding procedure is produced in two
separate parts, making it easier to find the relevant
section.
I
II
I
Symptom noted at the pedal

Symptom noted in driving behaviour
SYMPTOM NOTED AT THE PEDAL
Faults
Possible causes
Stiff pedal:
substantial force produces poor deceleration
Servo-assistance failure
Brake shoes may be:
dirty,
glazed, incorrect type
which heat up under prolonged braking with the
pedal constantly depressed (descending
a mountain), not in good order
Piston seized
Crushed pipes
Spongy pedal:
Presence of air in the circuit: incorrect bleeding
NOTE:
The level of assistance on current vehicles has been
improved meaning that it gives the impression of
a spongy pedal. In order to find out whether this has
arisen as a result of a fault or normal use, two tests must
be carried out.
Internal leak in the brake circuit
1.
Vehicle running
Subjective test: pedal travel / deceleration ratio
2.
Vehicle stationary with the engine turned off

Additional test on pedal travel: press the brake
pedal 5 times, to clear the brake servo, before
taking account of the results of the test.
Lack of fluid in the reservoir (from the brake circuit

leaking to the outside)
30-13
vnx.su
GENERAL INFORMATION
Brake fault finding
Spongy pedal
Incorrectly adjusted shoes
Test to be performed on a stationary vehicle with the

engine turned off
Disc and drum brakes
30
Automatic adjustment: handbrake cable is too taut

NOTE:
It is necessary to depress the brake pedal 5 times in
order to clear the brake servo before taking account of
the results of the test.
NOTE:
Automatic compensation is operated via the brake
pedal, if there is no abnormal tension in the handbrake
cable when it is not in use.
Significant asymmetrical wear of brake shoes
(convex or concave)
Excessive clearance in the master cylinder
Fluid at boiling point or overheated.
II
Pedal to the floor
Hydraulic leak (check seal)
Test to be performed on a stationary vehicle with the

engine turned off
Poor seal of the cup between two of the master

cylinder circuits
NOTE:
It is necessary to depress the brake pedal 5 times in
order to clear the brake servo before taking account of
the results of the test.
Boiling fluid
SYMPTOM NOTED IN DRIVING BEHAVIOUR
Faults
Brakes engage
Possible causes
Lining needs grinding
Brake shoes are slightly dirty
Springs need to be changed
Brakes judder
Drums out of round

Brake discs are too warped
Brake discs are not of even thickness
Abnormal deposit on the brake discs (oxidization
between the brake shoe and the brake disc)
30-14
vnx.su
GENERAL INFORMATION
Brake fault finding
Drifting on braking (front)
30
Front axle suspension, check steering

Piston seized*
Tyres (wear - pressure)
Crushed pipes*
*IMPORTANT:
On vehicles with front axle with negative offset, pulling
on one side affects the opposite circuit.
Braking offset (rear)
Compensator or brake limiter (function control)

Piston seized
Incorrectly adjusted shoes
Automatic adjustment: handbrake cable is too taut
NOTE:
Automatic compensation is operated via the brake
pedal, if there is no abnormal tension in the handbrake
cable when it is not in use
Recall spring
Brakes heat up
Insufficient master cylinder clearance, which

does not allow the master cylinder to return to its
rest position
Seized or slow piston
Crushed pipes
Seized handbrake control
Poor adjustment of the handbrake control
30-15
vnx.su
131
FRONT AXLE
Brake pads
31

Fre. 823
Brake calliper piston return tool

Wheel bolt
Brake calliper mounting bolt (small
column)
14.2
3.5
Check:
the condition of the brake pads (if they need
replacing, it is essential to change the pads on
the opposite side as well),
the condition and fitting of the piston dust covers,
the condition of the dust seals of the guides,
the condition of the brake discs.
Clean the calliper mountings and callipers.
REFITTING
Reinsert the pistons in the callipers using tool
Fre. 823.
Refit:
the new brake pads,
the callipers,
the calliper mounting bolts,
the brake pipes.
Tighten the calliper mounting bolts to the
recommended torque.
REMOVAL
Refit the wheels.
Remove:
the front wheels,
the lower calliper mounting bolts.
Loosen the upper calliper mounting bolts.

Unclip the brake pipes.
Turn the callipers upwards.
Remove the pads.
31-1
vnx.su
FRONT AXLE
Brake calliper
31

Fre. 823

Calliper brake pipe
Wheel bolt
1.4
14.2

column)
3.5
Check:
the condition of the hose and replace it if necessary,
Clean the calliper mounting and the calliper.
REFITTING
Fre. 823.
Screw the calliper onto the hose without twisting the
hose.
Refit:
the brake pads,
the calliper,
the hose.
Bleed the brake circuit (refer to the relevant
procedure).
Depress the brake pedal using a pedal press (this has

REMOVAL
Remove the front wheel.
Loosen the calliper brake pipe

Replace the front wheel.
Remove the calliper mounting bolts.

Disconnect the calliper and the brake pads.
Remove the calliper, turning it without twisting the
hose.
31-2
vnx.su
FRONT AXLE
Brake calliper mounting
31

Fre. 823

Wheel bolt
column)
14.2
3.5
10.5
Check:
Clean the calliper and the mounting.
REFITTING
Fre. 823.
Refit:
the calliper mounting,
the brake calliper mounting bolts,
the brake pads,
the calliper,
the calliper mounting bolts.
the calliper bolts.
REMOVAL
Remove:
the front wheel,
Replace the front wheel.


Suspend the calliper without bending the brake pipe.
Remove:
the calliper mounting.
31-3
vnx.su
FRONT AXLE
Brake disc
31

Fre.823

Wheel bolt
column)
Brake disc mounting bolt
14.2
3.5
10.5
2.1
Check:
the condition of the disc (if it needs replacing, it is
essential to change the disc on the opposite side
as well, plus the pads),
the condition of the dust seals of the guides.
Clean the bearing surfaces of the brake disc, the
calliper and the support.
REFITTING
Reinsert the piston in the callipers using tool Fre. 823.
Refit:
the brake disc,
the brake disc mounting bolt,
the brake pads,
the calliper,
the calliper bolts.
REMOVAL
Remove:
the front wheel,
Refit the front wheel.
Suspend the calliper without bending the brake pipe.

Remove:
the brake disc mounting bolt,
the brake disc.
31-4
vnx.su
133
REAR AXLE
Brake pads
33

Fre. 1190-01
Rear brake calliper piston return

tool

Wheel bolt
Brake calliper bolt
REMOVAL
Remove:
the rear wheels,
the upper calliper mounting bolts.
Unscrew the lower calliper mounting bolts.
14.2
3.3
Turn the callipers downwards.

Remove the brake pads from both sides of the vehicle.
Check:
the condition of the guide dust covers,
the brake discs.
REFITTING
Fre. 1190-01.
Refit:
the new brake pads,
the callipers,
the brake hoses.
Tighten the calliper bolts to the recommended torque.
Depress the brake pedal several times so that the
pistons make contact with the pads.
Refit the wheels.
33-1
vnx.su
REAR AXLE
Brake calliper
33

Fre. 1190-01

tool

Calliper brake pipe
Wheel bolt
Brake calliper bolt
1.4
14.2
3.3
Actuate the brake pedal using a pedal press (this has

Check:
replacing, it is essential to replace the pads on
the brake discs.
REFITTING
Reinsert the calliper pistons using tool Fre. 1190-01.
Screw the calliper onto the hose without twisting the
hose.
Refit:
the brake pads,
the calliper,
the handbrake cable.
the hose.
Bleed the brake circuit (refer to the relevant method).
Check the travel of the handbrake control lever.
REMOVAL
Refit the rear wheel.
Remove the rear wheel.
Separate the handbrake cable.

Loosen the brake pipe on the calliper side.
Unscrew the calliper mounting bolts.
Release the calliper and the brake pads.
Remove the calliper by turning it without twisting the
hose.
33-2
vnx.su
REAR AXLE
Brake calliper mount
33

Fre. 1190-01

tool

Wheel bolt
Brake calliper bolt
14.2
3.3
18
Check:
the brake discs.
Clean the calliper mounting and the calliper.
REFITTING
Refit:
the calliper support,
the calliper support bolts,
the brake shoes,
the calliper,
REMOVAL
Remove:
the rear wheel,

Refit the rear wheel.
Disconnect the calliper and the brake shoes.

Suspend the calliper without bending the hose.
Remove the calliper mounting bolts.
Remove the calliper mounting.
33-3
vnx.su
REAR AXLE
Brake discs
33

Fre. 1190-01

tool

Hub nut
28
Wheel bolt
14.2
Brake calliper bolt

3.3
18
Check:
the condition of the disc (if it needs replacing, it is
essential to replace the disc on the opposite side
as well, plus the pads),
the condition of the guide dust covers.
Clean the bearing surfaces of the brake disc, the
calliper and the support.
REFITTING
Refit:
the disc,
the calliper support,
the brake pads,
the calliper,
the hub nut,
REMOVAL
Refit the rear wheels.
Remove the calliper support (consult the relevant

procedure).
Remove:
the hub nut,
the disc.
33-4
vnx.su
REAR AXLE
Brake disc protective flange bolt
REFITTING

Flange mounting bolt
33
0.8
REMOVAL
Remove:
Refit:
the flange,
the three flange mounting bolts.
Tighten the three flange mounting bolts to the correct
torque.
Refit the brake disc (refer to the relevant procedure).
the three flange mounting bolts,

the flange.
33-5
vnx.su
REAR AXLE
Rear brake disc hub
REFITTING

Hub mounting bolt
33
10.5
REMOVAL
Remove:
the brake disc protective flange (consult the relevant
procedure),
Refit:
the hub,
the four hub mounting bolts,
Tighten the four hub mounting bolts to the correct
torque.
Refit the brake disc protective flange (consult the
relevant procedure),
the four hub mounting bolts,

the hub.
33-6
vnx.su

137
Master cylinder
37
REFITTING

Pipe connections on the master cylinder
1.4
Reservoir mounting bolt
0.8
2.5
WARNING:
The seal must be replaced between the master
cylinder and the brake servo.
WARNING:
The clutch master cylinder pipe seal should be
replaced in the pipe (not on the reservoir) before
refitting. If the seal of the clutch master cylinder pipe
is damaged, it must be changed.
REMOVAL
Remove:
the brake fluid level connector,
the brake fluid reservoir cap.
Place a container beneath the master cylinder to
collect the used brake fluid.
Disconnect and collect the brake fluid:
from the clutch master cylinder pipework (A),
the brake pipes (B),
the brake pipes (C) for vehicles without Anti-lock
Braking System.

Tighten the mounting bolts and nuts to the correct
torque.
Bleed the brake and clutch circuits (consult the
relevant procedure).
Remove:
the reservoir mounting bolt,
the reservoir,
the master cylinder mounting nuts (D),
the master cylinder.
37-1
vnx.su

Brake servo
37
REFITTING

Pipe connections on the master cylinder
1.4
Reservoir mounting bolt
0.8
2.5
Brake servo mounting nuts
2.1
IMPORTANT:
The brake servo mounting nuts must be replaced.
WARNING:
The seal must be replaced between the master
cylinder and the brake servo.
REMOVAL
WARNING:
The clutch master cylinder pipe seal should be
replaced in the pipe (not on the reservoir) before
refitting. If the seal of the clutch master cylinder pipe
is damaged, it must be changed.
torque.
Bleed the brake and clutch circuits (consult the
relevant procedure).
Check the sealing ring of the vacuum circuit (consult
the relevant procedure).
Remove:
the master cylinder (consult the relevant procedure),
the brake pedal shaft clip (A),
the brake pedal shaft,
the two brake servo mounting nuts (B),
the brake servo.
37-2
vnx.su

Brake servo
37
CHECKING SEALING
Mot. 453-01
Set of hose clamps

EQUIPMENT REQUIRED
Vacuum pump
Check the sealing of the brake servo, ensuring a perfect seal between this and the master cylinder. If there is a leak,
replace the seal (A).
The tightness of the brake servo seal should be

checked on the vehicle, with the hydraulic circuit in
perfect working order.
Connect the vacuum pump in the pneumatic circuit
(between the brake servo and the vacuum source)
using a three-way union and a hose as short as
possible.
If the vacuum falls quickly, one of the constituent

components of the circuit and/or the assembly is faulty.
Check the sealing:
of the unions,
of the joints between components,
of the components.
Run the engine at idling speed for one minute to

establish a normal working vacuum.
Clip the hose (clip Mot. 453-01) between the threeway union and the vacuum source.
Turn the engine off.
37-3
vnx.su

Vacuum pump
37
REFITTING

2.3
2.3
Clean the surfaces of the seals.

WARNING:
Abrasive products or sharp tools must not be used
when cleaning the surfaces of the seals.
REMOVAL

torque.
Connect the vacuum pump hoses.
Disconnect the vacuum pump hoses.

Remove:
the mounting bolts and nuts,
the vacuum pump.
37-4
vnx.su

Brake pedal
REFITTING

Brake pedal shaft bolt
37
4.5

Tighten the brake pedal shaft bolt to the correct torque.
REMOVAL
NOTE:
It is not necessary to remove the steering column.
Remove:
the brake pedal shaft clip (A),
the brake pedal shaft,
the brake pedal shaft bolt (B),
the brake pedal.
37-5
vnx.su

Handbrake control
37

Handbrake control lever mounting bolt
4.4
REMOVAL
Put the vehicle on a lift.
Disconnect the cable (B).

Unclip the cable (C).
Slacken the handbrake cable, turning the compensator
adjusting nut (A).
Remove:
the handbrake control lever mounting bolts (D),
the handbrake control lever.
REFITTING
tighten the handbrake control lever mounting bolts to
the correct torque.
Adjust.
37-6
vnx.su

Handbrake control
ADJUSTMENT
Apply the lever five times to bring the cables to normal
conditions of use.
Measure the dimensions X on the right and left-hand

callipers. The sum of the measurements should be
between 0.1 and 0.5 mm.
WARNING:
The sum of the measurements should not be greater
than 0.5 mm.
Adjust the dimensions by turning the compensator
adjusting nut.
WARNING:
Always use a self-locking nut with a nylon ring.
Apply the lever five times to bring the cables to normal
conditions of use.
Check the adjustment.
37-7
vnx.su
37
MECHANICAL ELEMENT
137 CONTROLS
Brake compensator
37
REFITTING

Hydraulic pipes
1.4
Compensator mounting bolt
1.8
Bleed and check the brake circuit (consult the relevant

procedure).
Rod adjustment bolt
Rod ball joint nut
Vehicle with wheels suspended.

NOTE:
You must clean the compensator and its surroundings
carefully to prevent foreign bodies entering the brake
circuit.
REMOVAL
Remove the compensator rod ball joint nut.

Disconnect the brake pipes from the compensator.
Remove:
the compensator mountings,
the compensator.
37-8
vnx.su

Brake compensator
37

Fre. 244-03
or
Fre. 1085-01
Pressure gauge for checking the

compensator rating
ADJUSTMENT

Rod adjustment bolt
Calliper bleed screw
0.9 to 1.1

CHECKS (vehicle unladen)
The procedure for adjusting the compensators

currently used in After-Sales is simple and only
involves using two pressure gauges which must be
connected to the braking circuit (front right wheel and
rear left wheel).
Checking and adjustment is carried out with the
vehicle unladen, the fuel tank full and the driver on
board.
After exerting a certain pressure at the front by
depressing the brake pedal, simply read the pressure
at the rear and compare it to the value given in
Section 07. Next, loosen the rod adjusting bolt and
then adjust the compensator rod.
Connect the two pressure gauges Fre. 244-03 or

Fre. 1085-01:
one on the front left-hand side,
one on the rear right-hand side.
Bleed the pressure gauges.
Gradually depress the brake pedal until the pressure
at the front wheels is at the setting pressure (see table
of values). Then read the corresponding pressure on
the rear wheel.
If there is a large difference (values exceed tolerance
ranges), replace the compensator since no repair is
permitted.
This procedure is difficult to carry out when the vehicle

is loaded, as is often the case for a utility vehicle fitted
out with shelves full of spare parts and tools.
In the case of utility vehicles has led to the
development of a different method for adjustment
which uses a deflection calculation (index of crushing)
for the tyres (this is inexpensive but must be carried
out with care). Then, simply refer to the rear pressure
graphs established in accordance with the load (on the
rear axle) and the deflection of the tyres.
37-9
vnx.su

Brake compensator
37
Tooling required:
Readjust the pressure as precisely as possible.
A tape measure on a support (used for measuring

underbody heights).
A precision pressure gauge.
4) Measuring the radius when unladen

Lift the rear wheel so that the tyres are no longer
deformed by the axle load (as soon as the wheels
leave the ground).
1) Preparing the vehicle

The vehicle must remain loaded.
Measure the distance between the ground and the

centre of the wheel using the tape measure.
The operator whose job it is to press the brake pedal

when the compensator is being adjusted must be in
the vehicle when the radius under load of the rear
wheels is measured.
5) Measuring the radius under load of the rear

wheels
Place the vehicle on its wheels.
The vehicle must be on a flat horizontal surface, which

is smooth and clean (use a four-post lift if possible).
Measure the distance between the ground and the

centre of the wheel using the tape measure.
2) Marking the centre of the rear wheels

6) Calculating the tyre deflection
Lift the rear of the vehicle so that the rear wheels can
be turned.
Subtract the two measurements taken previously to

obtain the deflection of the tyre.
Place a piece of chalk on the hub cover or the trim at

the point which seems as close as possible to the
centre of the wheel.
7) Repeat stages 4, 5 and 6 for the other rear wheel

8) Calculating the average deflection of the two
tyres
Turn the wheel quite quickly by hand while pressing

down on the chalk. This operation allows concentric
circles to be marked around the true centre of rotation
on the wheel.
Add together the values of the two deflections

measured for the two rear wheels and divide the value
by two to determine the average deflection.
Mark the centre with a pencil cross on the chalk.

9) Reading the graphs
Repeat the operation for the second rear wheel.
On the first graph read the load on the rear axle in
accordance with the average deflection measured.
3) Correcting the pressure of the rear wheels

The pressure must be adjusted with the wheels on the
ground and someone in the driver's seat.
Refer to the second graph and read the output

pressure P2 (which corresponds to the pressure
applied to each rear wheel) according to the load value
measured on the first graph.
Use a precision pressure gauge at the correct settings

to deflate the two rear tyres until they are at a low
pressure (IMPORTANT: consult the value of this
pressure in the graph corresponding to the make and
type of tyre fitted on the vehicle.
10) Adjusting the compensator

Follow the procedure currently described in AfterSales documentation if the adjustment is incorrect.
Wait a few minutes for the air in the tyres to return to

ambient temperature as it is cooled during deflation
and its pressure has thus been changed.
11) Preparing the vehicle

Restore the vehicle to its normal working conditions
(tyre pressure, correct tightening torques).
37-10
vnx.su

Brake compensator
Load on rear axle/tyre deflection (pressure 1 bar)
GOODYEAR 195/65 R 16 C
X = Deflection (mm)
Y = Load on rear axle (kg)
37-11
vnx.su
37

Brake compensator
X = Deflection (mm)
37-12
vnx.su
37

Brake compensator
X = Deflection (mm)
37-13
vnx.su
37

Brake compensator
CONTINENTAL 195/65 R 16
X = Deflection (mm)
37-14
vnx.su
37

Brake compensator
X = Deflection (mm)
37-15
vnx.su
37

Brake compensator
X = Deflection (mm)
37-16
vnx.su
37

Brake compensator
Adjustment of the compensator output pressure/load on the rear axle
X = Output pressure P2 (bar) (for a pressure of 100 bar at the front)

37-17
vnx.su
37
ELECTRONICALLY CONTROLLED
138 HYDRAULIC SYSTEM
LUCAS ABS
38
SPECIAL NOTES
The system comprises four speed sensors. Each hydraulic braking channel is linked to a sensor on each wheel. This
means that the pressure of each brake piston can be regulated separately. Compensation for the rear piston
pressure on a loaded vehicle is controlled by the computer.
38-1
vnx.su
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEM

LUCAS ABS
HYDRAULIC UNIT
38
NOTE:
It is vital to clean the hydraulic unit and its surroundings
carefully to prevent foreign bodies entering the braking
circuit.

Brake pipes on the unit
1.4
Unit mounting bolt
0.9
Disconnect:
the ABS connector,
the brake pipes on the unit.
The unit is located under the vehicle, on the rear

section of the battery tray.
Fit the protective plugs on the brake pipes and the

hydraulic unit.
It comprises eight solenoid valves.
Remove:
the upper mounting bolt,
the lower mounting bolt,
the hydraulic unit.
REMOVAL
Fit a pedal press to limit fluid loss.
REFITTING
Carry out the removal procedure in reverse.
Tighten the brake pipes to torque.
Bleed the brake circuit.
Markings on the unit
Meaning of the unions
MC1
RR
Master cylinder
Primary circuit
Rear right caliper
LF
Front left calliper
MC2
Master cylinder
RF
Secondary circuit
LR
Front right caliper

Rear left caliper
38-2
vnx.su

Bleeding the brake circuit
38
Brake circuit bleeding device
NOTE:
The hydraulic unit is pre-filled.
This bleeding procedure must be used when one of the following components has been removed:
the hydraulic unit,
the master cylinder,
the pipes (between the hydraulic unit and the master cylinder).
NOTE:
The brake circuit fitted with ABS should be free from faults and must be working correctly. If this is not the case, repair
the ABS, hydraulic and electronic circuits. If, after a road test with ABS regulation, the pedal travel is not correct, bleed
the hydraulic unit.
1. Bleed the braking system conventionally (using the bleeding device).
IMPORTANT: follow the correct order for bleeding by starting with the right-hand rear brake, then the rear left, the
front right and the front left.
2 a) Bleeding the hydraulic unit with the fault finding tool (primary and secondary circuits):
open the brake bleed screw,
pump the brake pedal (approximately 10 times),
keep your foot on the brake pedal and enter the bleed command with the fault finding tool,
AC153: Front left wheel bleed; AC154: Front right wheel bleed; AC155: Rear left wheel bleed,
AC156: Rear right wheel bleed,
pump the brake pedal during the diagnostic bleed phase,
at the end of the bleed cycle using the fault finding tool, continue to pump the brake pedal and close the brake
bleed screw.
b) Carry out the procedure described in 2a) for the left-hand rear, right-hand rear and left-hand front brakes.
c) Check the pedal travel and if it is incorrect, restart the bleeding procedure.
IMPORTANT:
Ensure that there is sufficient brake fluid in the reservoir.
NOTE:
If the brake circuit is an X-type, it is possible to bleed one wheel on its own (in the event of replacing a hose, calliper
etc.).
38-3
vnx.su
ELECTRONICALLY
CONTROLLED HYDRAULIC SYSTEM
138
ABS TRW
Vdiag: 04
Anti-lock braking system
38
FAULT FINDING - INTRODUCTION

This document contains special feature fault finding procedures applicable to all anti-lock braking
system computers fitted to PRIMASTAR vehicles.
The following are thus required for carrying out fault finding on this system:
This section of the PRIMASTAR Fault finding Workshop Repair Manual.
The wiring diagram for the function on the vehicle concerned.
Bornier El. 1620.
Use of one of the diagnostic tools for identifying the system fitted on the vehicle (reading of the electronic control
unit type, programme number, Vdiag number etc.).
Look in the Fault finding documents corresponding to the system identified.
Refer to the information in the Introduction.
DESCRIPTION OF THE FAULT FINDING STAGES
1 - CHECKING THE FAULTS
It is essential to start with this stage before any work is done on the vehicle.
Read the faults stored in the computer memory and use the "Interpretation of faults" section of the documents.
REMINDER:
Each fault is interpreted for a particular type of storage (fault present, fault stored, fault present or stored). The
specified checks for dealing with each fault are therefore only to be performed if the fault declared by the
diagnostic tool can be identified in the document by its type. The storage type should be considered when using
the fault finding tool after the ignition has been switched off and switched back on.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the notes
box. When these conditions are not satisfied, use the fault finding procedure to check the circuit of the faulty part,
since the fault is no longer present on the vehicle. Perform the same operation when a fault is declared as stored
by the diagnostic tool but is only interpreted in the documentation as a present fault.
2 - CONFORMITY CHECK
The conformity check is designed to check the states and parameters which do not display any faults on the
diagnostic tool when they are outside the permitted tolerance values. This stage:
Diagnoses faults that are not displayed which may correspond to a customer complaint.
Checks the correct operation of the anti-lock braking system and eliminates the risk of faults reappearing after
the repair.
This section gives the fault finding procedures for states and parameters and the conditions for checking them.
If a state is not operating normally or a parameter is outside permitted tolerance values, you should consult the
corresponding fault finding page.
3 - RECTIFYING THE CUSTOMER COMPLAINT
If the diagnostic tool check is correct, but the customer complaint is still present, the problem should be dealt
with according to the customer complaint.
This section has fault finding charts, which suggest a series of possible causes of the problem. These lines of
investigation must only be used in the following cases:
No faults appear on the diagnostic tool.
No faults are detected during the conformity check.
The vehicle is not operating correctly.
38-1
vnx.su

ABS TRW
Vdiag: 04
38
WARNING LIGHT STATE
Name of fault
Anti-lock braking
system warning
light
Brake fluid level

warning light
No tyre circumference programmed
Indicator lights
One faulty sensor

(electric, target, speed comparator,
consistency)
Three faulty sensors

(electric, target, speed comparator, plausibility)
Faulty solenoid valve
Faulty solenoid valve
Faulty pump motor
Faulty power relay

(short circuit)
Faulty power relay

(open circuit)
Faulty brake switch
Open circuit or short circuit on ABS and brake

fluid level lights
Wheel speed inconsistency
Faulty computer
Solenoid valve activation time too long
Excess voltage/undervoltage
38-2
vnx.su

ABS TRW
Vdiag: 04
38
Bleeding procedure
NOTE:
The hydraulic unit is pre-filled.
This bleeding procedure must be used when one of the following components has been removed:
the hydraulic unit,
the master cylinder,
the pipework (between the hydraulic unit and the master cylinder).
NOTE: The braking circuit fitted with the anti-lock braking system must not have any faults and must operate
correctly, if it does not, the anti-lock braking system must be repaired from both a hydraulic and an electrical point
of view. If, after a road test with ABS regulation, the pedal travel is not correct, bleed the hydraulic
assembly.
1)
Bleed the braking circuit in a conventional way using your foot or a bleeding kit
IMPORTANT:
Follow the correct order for bleeding by starting with the rear right-hand brake, then the rear left , the front right,
and the front left
2
a) Bleeding the hydraulic assembly using the diagnostic tool (primary and secondary circuits):
open the brake bleed screw,
pump the brake pedal approximately ten times,
keep your foot on the brake pedal and enter the bleed command AC153: with the fault finding tool: Left-hand
front wheel bleed; AC154: Right-hand front wheel bleed; AC155: Left-hand rear wheel bleed AC156: Righthand rear wheel bleed,
pump the brake pedal during the fault finding bleed phase,
at the end of the bleed cycle using the diagnostic tool, continue to pump the brake pedal and close the brake
bleed screw.
b) Follow the procedure as described in 2a) for the left-hand rear brake, the right-hand rear brake and the
front left-hand brake.
c) Check the pedal travel and, if it is incorrect, restart the bleeding procedure.
IMPORTANT: ensure there is sufficient brake fluid in the reservoir.

NOTE: the brake circuit is an X-type, it is therefore possible to bleed one wheel on its own (in the case of
replacing a hose, calliper etc.).
38-3
vnx.su

ABS TRW
Vdiag: 04
38
FAULT FINDING - INTERPRETATION OF FAULTS
FRONT LEFT-HAND WHEEL SPEED SENSOR SIGNAL

DF008
PRESENT
OR
STORED
NOTES
1. DEF : Inconsistent signal

The fault is declared present during:
road test (speed over 6 mph (10 km/h) under acceleration).
Check the connection and condition of the front left-hand speed sensor
connector.
Check that the sensor is correctly positioned.
Check that the target is clean (look for traces of mud etc.).
Clean if necessary.
Connect the bornier (El. 1620) in place of the computer and check the insulation,
continuity and absence of interference resistance of the following connections:
Computer track 19
Track 2 of the front left-hand speed sensor
Computer track 20
Ensure that there is no interference from the mechanical or electrical systems
that could generate a speed signal.
E.g. bearing play, sensor vibrations, iron filings, etc.
Swap the two axle sensors and road test the vehicle to confirm that there is a
wheel sensor fault.
If the fault disappears, the sensor is faulty. If the fault persists, return the sensors to
their original positions and exchange the targets.
AFTER REPAIR
Follow the instructions to confirm that the fault has been repaired.
38-4
vnx.su

ABS TRW
Vdiag: 04
38
REAR LEFT-HAND WHEEL SPEED SENSOR SIGNAL

DF009
PRESENT
OR
STORED
NOTES

Check the connection and condition of the rear left-hand speed sensor connector.
Clean if necessary.
Computer track 21
Track 2 of the rear left-hand speed sensor
Computer track 22
Check that there is no interference from the mechanical or electrical systems
wheel sensor fault.
AFTER REPAIR
38-5
vnx.su

ABS TRW
Vdiag: 04
38
PUMP MOTOR CIRCUIT

DF010
PRESENT
OR
STORED
NOTES

road test (speed over 6 mph (10 km/h)).
Switch the ignition off and on three times in succession, to make sure that no
electronic interference is interfering with the anti-lock braking system.
Check the condition of the wiring and tracks 24 and 25 of the ABS computer
connector.
Repair or replace the wiring if necessary.
Check that there is + 12 V on track 25 and an earth on track 24 of the ABS
computer connector.
Disconnect the computer and check the resistance of the motor between tracks 25
and 24.
Replace the ABS unit if necessary.
If no fault is found, replace the ABS unit.
AFTER REPAIR
38-6
vnx.su

ABS TRW
Vdiag: 04
38
SOLENOID VALVE SUPPLY

1. DEF : Computer internal electrical fault
DF011
PRESENT
NOTES
None.
Clear the faults with the fault finding tool.

Switch the ignition off and on three times in succession to make sure that no
electronic interference is interfering with the anti-lock braking system.
If the fault persists, replace the ABS unit (internal computer fault).
AFTER REPAIR
Road test the vehicle to confirm that the system is in good working order.
38-7
vnx.su

ABS TRW
Vdiag: 04
38
MAIN RELAY
DF014
PRESENT
NOTES
None.
Switch the + after ignition feed on and off three times in succession, to make sure
no external electronic interference is interfering with the ABS, or switch the
ignition off and disconnect the various computers.
Check the condition of tracks 11 and 12 of the ABS computer connector.
Use bornier (El. 1620) to check the insulation and continuity on tracks 11
and 12.
Check that there is + 12 V on track 12 and an earth on track 11 of the ABS
computer connector.
If no fault is found, replace the ABS unit.
AFTER REPAIR
38-8
vnx.su

ABS TRW
Vdiag: 04
38
COMPUTER
DF017
PRESENT
NOTES
None.
Turn the ignition on and off three times to make sure that the electronic systems
are not interfering with the computer.
If the fault persists, replace the ABS unit.
AFTER REPAIR
38-9
vnx.su

ABS TRW
Vdiag: 04
38
FRONT RIGHT-HAND WHEEL SPEED SENSOR SIGNAL

DF028
PRESENT
OU
MEMORISE
NOTES

Check the connection and condition of the front right-hand speed sensor
connector.
Clean if necessary.
Computer track 7
Track 2 of the front right-hand speed sensor
Computer track 8
Ensure that there is no interference from the mechanical or electrical systems
wheel sensor fault.
AFTER REPAIR
38-10
vnx.su

ABS TRW
Vdiag: 04
38
REAR RIGHT-HAND WHEEL SPEED SENSOR SIGNAL

DF029
PRESENT
OR
STORED
NOTES

Check the connection and condition of the rear right-hand speed sensor
connector.
Clean if necessary.
Computer track 9
Track 2 of the rear right-hand speed sensor
Computer track 10
Check that there is no interference from the mechanical or electrical systems
wheel sensor fault.
AFTER REPAIR
38-11
vnx.su

ABS TRW
Vdiag: 04
38
BRAKE LIGHTS AND SWITCH CIRCUIT

DF046
PRESENT
OR
STORED
NOTES

Look to see if the brake lights are working properly. If the brake lights do not light
up, check the bulbs and the condition of the brake lights fuse.
Replace the fuse and bulbs if necessary.
Check the condition of the ABS computer connector and confirm the condition
of track 17.
Repair the connector if necessary.
Check on track 17 of the ABS computer connector that the voltage increases from
0 V to 12 V when the pedal is depressed.
Replace the brake switch if necessary.
AFTER REPAIR
38-12
vnx.su

ABS TRW
Vdiag: 04
38
LEFT-HAND FRONT WHEEL SENSOR CIRCUIT

DF048
PRESENT
OR
STORED
NOTES
1. DEF : No signal

Check that the sensor is properly attached to its mounting.

Check that the sensor is not scraping against the target.
Check the bearing position and play.
Replace the bearing if necessary.
If you replace the bearing, make sure that the target (magnetic part) is facing the
sensor side.
If the results of the tests are correct and the fault persists, clear the faults, swap
the two axle sensors and road test the vehicle.
If the fault remains present, replace the target. If not, the sensor is faulty.
AFTER REPAIR
38-13
vnx.su

ABS TRW
Vdiag: 04
38
RIGHT-HAND FRONT WHEEL SENSOR CIRCUIT

DF049
PRESENT
OR
STORED
NOTES
1. DEF : No signal

Check that the sensor is properly secured to its mounting.

sensor side.
AFTER REPAIR
38-14
vnx.su

ABS TRW
Vdiag: 04
38
LEFT-HAND REAR WHEEL SENSOR CIRCUIT

DF050
PRESENT
OR
STORED
NOTES
1. DEF : No signal


sensor side.
AFTER REPAIR
38-15
vnx.su

ABS TRW
Vdiag: 04
38
RIGHT-HAND REAR WHEEL SENSOR CIRCUIT

DF051
PRESENT
OR
STORED
NOTES
1. DEF: Signal absent


sensor side.
AFTER REPAIR
38-16
vnx.su

ABS TRW
Vdiag: 04
38
FRONT RIGHT-HAND SPEED SENSOR

1. DEF : Open circuit or short circuit
DF059
PRESENT
NOTES
None.
Check the condition of the switches and the connection of the ABS computer
connectors and the front right-hand speed sensor.
Connect bornier El. 1620 in place of the computer and check the insulation,
continuity and absence of interference resistance of the connections between:
Computer track 7
Computer track 8
If the wiring and switches are sound, swap the two axle sensors and road test the
vehicle to confirm that a sensor is at fault.
AFTER REPAIR
38-17
vnx.su

ABS TRW
Vdiag: 04
38
FRONT LEFT-HAND SPEED SENSOR

DF060
PRESENT
NOTES
None.
connectors and the front left-hand speed sensor.
Computer track 19
Computer track 20
vehicle to confirm that a sensor is faulty.
AFTER REPAIR
38-18
vnx.su

ABS TRW
Vdiag: 04
38
REAR RIGHT-HAND SPEED SENSOR

DF061
PRESENT
NOTES
None.
connectors and the rear right-hand speed sensor.
Computer track 9
Computer track 10
vehicle to confirm that a sensor is at fault.
AFTER REPAIR
38-19
vnx.su

ABS TRW
Vdiag: 04
38
REAR LEFT-HAND SPEED SENSOR

DF062
PRESENT
NOTES
None.
connectors and the rear left-hand speed sensor.
Computer track 21
Computer track 22
If the wiring and switches are sound, perform a test with both axle sensors
swapped, in order to confirm the sensor fault.
AFTER REPAIR
38-20
vnx.su

ABS TRW
Vdiag: 04
38
WHEEL SPEED INCONSISTENCY

DF063
PRESENT
OR
STORED
NOTES

If there is more than one fault, deal with DF048; DF049; DF050 and DF051 first.
Check that the vehicle does not have different wheel sizes.
Fit matching wheels if necessary.
Check the condition of the bearing (target) and the sensor mounting.
AFTER REPAIR
38-21
vnx.su

ABS TRW
Vdiag: 04
38
FRONT RIGHT-HAND WHEEL TARGET

DF090
PRESENT
OR
STORED
NOTES


Check the bearing play.
Check that the target is clean (look for traces of mud and filings etc.).
sensor side.
Use the fault finding tool to check that a speed signal is present while turning the
front right-hand wheel.
Check the wheel sensor wiring if necessary.
If the results of the checks are correct, reconnect the computer and the sensors
then clear the computer fault memory. Exit the fault finding procedure and carry
out a road test.
If the fault recurs, it may be caused by a solenoid valve operational fault. It is
therefore necessary to carry out the solenoid valve hydraulic test with the diagnostic
tool commands (refer to the Help section).
If the ten locking/unlocking cycles do not occur on one of the wheels, replace the
hydraulic unit.
AFTER REPAIR
38-22
vnx.su

ABS TRW
Vdiag: 04
38
FRONT LEFT-HAND WHEEL TARGET

DF091
PRESENT
OR
STORED
NOTES


sensor side.
front left-hand wheel.
out a road test.
hydraulic unit.
AFTER REPAIR
38-23
vnx.su

ABS TRW
Vdiag: 04
38
REAR RIGHT-HAND WHEEL TARGET

DF092
PRESENT
OR
STORED
NOTES


sensor side.
rear right-handwheel.
out a road test.
hydraulic unit.
AFTER REPAIR
38-24
vnx.su

ABS TRW
Vdiag: 04
38
REAR LEFT-HAND WHEEL TARGET.

DF093
PRESENT
OR
STORED
NOTES


sensor side.
rear left-hand wheel.
out a road test.
hydraulic unit.
AFTER REPAIR
38-25
vnx.su

ABS TRW
Vdiag: 04
38
COMPUTER SUPPLY VOLTAGE TOO HIGH

DF094
PRESENT
NOTES
None.
Check the voltage at the battery terminals. If the voltage is too high, check that the
battery is to specification.
Replace the battery if necessary.
Check the voltage supplied by the regulator and the connection between the
alternator and the battery.
Replace the regulator if necessary.
AFTER REPAIR
38-26
vnx.su

ABS TRW
Vdiag: 04
38
COMPUTER SUPPLY VOLTAGE TOO LOW

DF095
PRESENT
NOTES
None.
Check the condition of the connector on the ABS computer (water ingress,
ozidation on the terminals, etc.).
Ensure that the battery terminals are not oxidized.
Clean the terminals if necessary.
Check the voltage at the battery terminals.
Recharge the battery if necessary.
Check the wiring between the alternator and the battery.
Check the voltage supplied by the regulator.
Replace the regulator if necessary.
AFTER REPAIR
38-27
vnx.su

ABS TRW
Vdiag: 04
38
ABS / BRAKE FAULT WARNING LIGHT CIRCUIT

DF156
PRESENT
NOTES
None.
Disconnect the ABS computer connector and check that the ABS and Electronic
Brake Distribution warning lights come on when the ignition is switched on.
Check the instrument panel fuses if necessary.
Check the continuity, insulation from earth and + before ignition, on tracks 3
and 15 of the ABS computer connector.
AFTER REPAIR
38-28
vnx.su

ABS TRW
Vdiag: 04
38
SOLENOID VALVE ACTIVATION TIME TOO LONG

DF157
PRESENT
OR
STORED
NOTES
1. DEF : Protection has been activated
None.
The solenoid valves have been operated for too long a period and protection has been activated.
Wait ten minutes without operating the solenoid valves. There is a risk that the valves will overheat.
AFTER REPAIR
38-29
vnx.su

ABS TRW
Vdiag: 04
38
FAULT FINDING - CONFORMITY CHECK
NOTES
Order
Function
Only check the conformity after a complete check with the diagnostic tool.
Test conditions: engine off, ignition on, air conditioning off.
Parameter or state
Check or action
Display and notes
Fault finding
run the fault finding
test
Computer
voltage supply
PR005:
Computer supply
voltage
8 V < X < 14.5 V
DF094: Computer
supply voltage too
high
DF095: Computer
supply voltage too low
Tyre indexing
Vehicle speed
Wheel speed
PR030:
PR038:
Speed sensor index
Vehicle speed
PR001:
Front right-hand wheel

speed
PR002:
Front left-hand wheel

speed
PR003:
Rear right-hand wheel

speed
PR004:
Rear left-hand wheel

speed
195-65R 16 = 85
205-65R 16 = 127
215-65R 16 = 170
X = Value of vehicle
speed in mph / Km/h
In the event of
a problem: refer to the
Interpretation of
parameters section
PR030: Tachometric
index
test
DF063: Wheel speed
consistency
test:
DF008: Front left-hand
wheel signal
X = Value of wheel
speed in mph / Km/h
DF009: Rear left-hand

wheel signal
DF028: Front righthand wheel signal
DF029: Rear righthand wheel signal
Brake lights
switch
ET006:
STATE 1: brake
pedal released

test:
STATE 2: brake
pedal depressed
DF046: Brake lights

and switch circuit
Brake switch
38-30
vnx.su

ABS TRW
Vdiag: 04
38
Test conditions: engine off, ignition on, air conditioning off.
NOTES
Order
Function
Parameter or state
Check or action
Display and notes
Fault finding
Pump motor command

active when engine
running
6
Pump motor
ET015:
Pump motor command
ACTIVE
In the event of a fault,

test:
DF010: Pump motor
circuit
ABS
Electronic
Braking
Distribution
ET018:
ET019:
ABS function
Braking regulation
function
ACTIVE
ACTIVE
ABS function is active

when there are no
present or stored
faults.
In the event of a
problem: fully
research all present
and stored faults.
Electronic Braking
Distribution function
is active when there
are no present or
stored faults on:
3 wheel sensors
solenoid valves
power relay
computer
In the event of a
problem: fully
research all present
and stored faults.
38-31
vnx.su

ABS TRW
Vdiag: 04
38
FAULT FINDING - INTERPRETATION OF PARAMETERS
TACHOMETRIC INDEX
PR030
NOTES
None.
Tyre circumference has to be programmed into the memory of a new computer.

New replacement tyres also need to be programmed into the computer if they are
a different size from the original ones.
The ABS computer calculates the vehicle speed from the speed of the wheels and
the circumference of the tyres fitted on the vehicle.
This consists of entering an "X" index using the TACHOMETRIC INDEX command
of the diagnostic tool.
Tyre part number
Value of the index (in mm)
195-65R 16
85
205-65R 16
127
215-65R 16
170
After entering the index, check parameter PR030 to confirm that the index has been
recognised.
AFTER REPAIR
38-32
vnx.su

ABS TRW
Vdiag: 04
FAULT FINDING - HELP
Allocation of tracks on the speed sensor connector
Facing the speed sensor connector (foolproofing device pointing upwards), position:
track 1 (on the right): Sensor signal
track 2 (on the left): Sensor supply
38-33
vnx.su
38

ABS TRW
Vdiag: 04
38
FAULT FINDING - HELP

USE OF COMMAND MODES:
Control of the wheel solenoid valves in order to check the hydraulic system:
Lift the vehicle so that the wheels can be turned and check that they turn freely. Keep the brake pedal depressed to
prevent the wheel from being turned by hand (do not brake so firmly that full brake power is reached).
Select and confirm the command of the wheel being examined (e.g. Front left-hand wheel solenoid valve, etc.).
The wheel being examined should go through ten locking/unlocking cycles.
If the ten cycles do not occur on a wheel, check the other components, such as the sensors, targets, pipes
etc.
38-34
vnx.su

ABS TRW
Vdiag: 04
38
FAULT FINDING - CUSTOMER COMPLAINTS
NOTES
Only consult the customer complaints after a complete check using the diagnostic tool.
FAULTS DETECTED FOR BRAKING WITH BRAKING REGULATION / ABS
LOCKING OF ONE OR MORE WHEELS
CHART 2
DRIFT
CHART 3
UNEXPECTED ABS OPERATION AT LOW SPEEDS AND WHEN

BRAKE PEDAL IS DEPRESSED SLIGHTLY
CHART 4
UNEXPECTED ABS OPERATION ON A POOR ROAD SURFACE
CHART 5
UNEXPECTED ABS OPERATION WHEN USING SPECIAL

EQUIPMENT (RADIO, TELEPHONE, CB, ETC.)
CHART 6
SPONGY PEDAL
CHART 7
BRAKE PEDAL VIBRATION
CHART 8
PULLING
CHART 9
THE ABS INDICATOR WARNING LIGHT DOES NOT LIGHT UP WHEN

THE IGNITION IS SWITCHED ON
CHART 10
THE ABS AND EBD WARNING LIGHTS FLASH
CHART 11
THE ABS AND EBD WARNING LIGHTS REMAIN LIT AFTER REPAIR
AND THE FAULTS ARE CLEARED
CHART 12
NOISE FROM THE PUMP, THE PIPES OR THE HYDRAULIC UNIT
CHART 13
BRAKE PEDAL TRAVEL LENGTHENED FOLLOWING REGULATION

PHASE (IRREGULAR PEDAL WHEN ENTERING REGULATION)
CHART 14
OTHER CASES
NO DIALOGUE WITH THE ABS COMPUTER
38-35
vnx.su
CHART 1

ABS TRW
Vdiag: 04
38
FAULT FINDING - FAULT FINDING CHARTS
No dialogue with the ABS computer
CHART 1
NOTES
None.
Try to establish dialogue with a computer on another vehicle to make sure that the fault finding tool is not
faulty. If the tool is not faulty and dialogue cannot be established with any other computer on the same vehicle,
it may be that a faulty computer is disrupting diagnostic line K.
Disconnect the computers one at a time to locate the fault.
Check the voltage of the battery and carry out the operations necessary to obtain the correct voltage:
(8 V < Battery voltage < 14.5 V).
Check that the ABS fuses (BP14 in the passenger compartment fuse box and AP5 in the passenger
compartment are present and sound).
Check that the computer connector is properly connected and check the condition of its wiring.
Check the (N26 and N27 ABS earths under the body next to the battery).
Check that the computer is correctly supplied:
Earth on tracks 11 and 24 of the ABS computer connector
+ before ignition on tracks 12 and 25 of the ABS computer connector
+ after ignition on track 23 of the ABS computer connector
Check that the diagnostic socket is correctly supplied:

+ before ignition feed on track 16 of the diagnostic socket
Earth on track 5 of the diagnostic socket
Check and ensure the continuity and insulation of the connection between:
Track 6 of the ABS computer
Diagnostic socket track 7
If dialogue is still not established after these various checks, replace the ABS computer.
AFTER REPAIR
Clear the computer memory, road test the vehicle and test again with the fault finding
tool.
38-36
vnx.su

ABS TRW
Vdiag: 04
38
CHART 2
Locking of one or more wheels
NOTES
Only consult this customer complaint after a complete check using the diagnostic tool.
Reminder: Locking of the wheels on a vehicle fitted with ABS or squealing of tyres, interpreted by the
customer as locking, could be linked to a normal reaction of the system and should not be automatically
considered to be a fault:
Locking is allowed below 4 mph (6 km/h) (the system will not provide regulation).
Braking with ABS regulation on very poor road surfaces (significant squealing).
However, if the wheel(s) is/are actually locking, lift the vehicle so that you can turn the wheels and check to
see if:
The wheel sensors have been incorrectly connected.
Using parameters PR001, PR002, PR003 and PR004, turn the wheels slowly and check the consistency of
the results obtained.
The pipes on the hydraulic unit have been reversed.
Use the front left-hand wheel solenoid valves, front right-hand wheel solenoid valves, rear left-hand wheel
solenoid valves and rear right-hand wheel solenoid valves commands while depressing the brake pedal and
check for the occurrence of ten locking/unlocking cycles on the wheel. If the ten cycles do not occur on
the wheel tested, see if they occur on another wheel (repair the fault if an incorrect connection is confirmed).
If the ten cycles do not occur on a wheel and the pipes are correctly connected, replace the hydraulic unit.
Check the sensor mounting.

If the fault persists following these checks, replace the hydraulic unit.
AFTER REPAIR
Perform a road test followed by a test using the diagnostic tool.
38-37
vnx.su

ABS TRW
Vdiag: 04
38
CHART 3
Drift
NOTES
Disconnect one wheel speed sensor.

Start the engine and check that only the ABS
fault warning light is lit. If the brake fault
warning light is also lit, do not drive the
vehicle as the electronic braking distribution
function is no longer operational. Only perform a
test with the ABS out of service.
yes
Road holding fault not

associated with the ABS.
Check the condition and
conformity of the brake pads,
check the tyre pressures,
the front axle, etc.
Does the fault persist under these

conditions?
no
Normal behaviour linked to the operation of the

system during the regulation phase, in
particular on surfaces with uneven grip or which
are poorly coated.
AFTER REPAIR
38-38
vnx.su

ABS TRW
Vdiag: 04
38
CHART 4
Unexpected ABS operation at low speed

and with light pedal pressure
NOTES
Only refer to this customer complaint after a complete check using the diagnostic tool.
WARNING: ABS regulation is sensitive on slippery surfaces (ice, wet road surfaces,
etc.).
It is possible to feel brake pedal vibrations which are linked to reactions of the system in particular situations:
Crossing rumble strips.
Tight cornering with lifting of the inside rear wheel.
These vibrations may be simply associated with the activation of the braking distributor when pressure on
the rear axle is limited.
If the problem is different, check the speed sensor connectors (micro-breaks).
AFTER REPAIR
38-39
vnx.su

ABS TRW
Vdiag: 04
38
CHART 5
Unexpected ABS operation on a poor road surface
NOTES
On poor road surfaces it is normal to feel hesitation and vibrations of the pedal as well as grating which is more
significant than on good surfaces. The result is the impression of a variation in efficiency which should be
considered normal.
AFTER REPAIR
38-40
vnx.su

ABS TRW
Vdiag: 04
38
CHART 6
Unexpected ABS operation with use of special equipment

(radio, telephone, CB, etc.)
NOTES
Check that the equipment which is causing the problem is approved.
Check that the equipment has been correctly installed with no alteration to the original wiring, in particular
that of the ABS (unauthorised connections to ABS earth and + after ignition / before ignition feed).
AFTER REPAIR
38-41
vnx.su

ABS TRW
Vdiag: 04
38
CHART 7
Spongy pedal
NOTES
Air in the brake circuits.

Carry out a conventional bleed of the circuits, starting with the rear right-hand brake, followed by rear left,
front left and finally front right. Repeat the operation if necessary.
AFTER REPAIR
38-42
vnx.su

ABS TRW
Vdiag: 04
38
CHART 8
Brake pedal vibration
NOTES
Normal reaction of the brake pedal during an ABS regulation phase or limitation of pressure on the rear
axle (braking distribution function).
AFTER REPAIR
38-43
vnx.su

ABS TRW
Vdiag: 04
38
CHART 9
Pulling
NOTES
Disconnect one wheel speed sensor.

Start the engine and check that only the ABS
fault warning light is lit. If the brake fault
warning light is also lit, do not drive the
vehicle as the electronic braking distribution
function is no longer operational. Only perform a
test with the ABS out of service.
yes
If the brake pedal travel is

relatively spongy, bleed
the brake circuit.
If the travel is normal, check
the tyre pressures, the front
axle or look for any leaks in
the circuit.
Does the fault persist under these

conditions?
no
Lift the vehicle so that you can turn the wheels

and check:
the speed sensors have been incorrectly
connected,
the pipes on the hydraulic unit have been
reversed.
For these two tests, refer to and apply the
methods described in CHART 2.
If the fault persists, replace the hydraulic unit.
AFTER REPAIR
38-44
vnx.su

ABS TRW
Vdiag: 04
38
CHART 10
The ABS warning light does not light up when the ignition is
switched on
NOTES
Only refre to this customer complaint after a complete check using the diagnostic tool.
Check the instrument panel fuses on the

passenger compartment fuse board (if the
problem affects all instrument panel operations).
Switch off the ignition. Disconnect the computer,

then switch on the ignition again.
yes
Does the ABS warning light come on?
Test the connections on the

computer connector.
Replace the computer if the
fault persists.
no
Check the condition of the ABS warning light

bulb and its supply.
Check that there is insulation from earth on
track 15 of the computer connector and the
ABS warning light.
If the fault persists, check the operation of the
instrument panel.
AFTER REPAIR
Perform a road test followed by a test using the fault finding tool.
38-45
vnx.su

ABS TRW
Vdiag: 04
38
CHART 11
The ABS and Electronic braking distribution warning lights flash
NOTES
The system is not configured, the tyre circumference is not programmed in the computer memory.
Use the TACHOMETRIC INDEX command to configure the computer according to the tyre type.
After entering the index, check parameter PR030 to confirm that it has been recognised.
AFTER REPAIR
38-46
vnx.su

ABS TRW
Vdiag: 04
38
CHART 12
The ABS and Electronic braking distribution warning lights

remain lit after repairing and erasing the faults
NOTES
Check the instrument panel fuses on the

passenger compartment fuse board.
Drive the vehicle at a speed above 6 mph

(10 Km/h).
yes
Do the warning lights come on?
Normal, as long as the

vehicle does not verify the
system at a speed above
6 mph (10 km/h).
no
Check that there is insulation and continuity on

tracks 15 and 3 of the computer connector and
the warning lights (ABS and electronic braking
distribution).
Check the ABS fuse on the passenger
compartment fuse board.
Check the ABS earths (under the body next to
the battery).
Check the wiring of the instrument panel
connector.
If the fault persists, check the operation of the
instrument panel.
AFTER REPAIR
38-47
vnx.su

ABS TRW
Vdiag: 04
38
CHART 13
Noise from the pump, the pipes or the hydraulic unit
NOTES
Vibration of the unit: check that the unit mounting insulating silentbloc fittings are fitted and are in good
condition.
Vibration of pipes: check that all the pipes are correctly fitted in their securing clips and that there is no
contact between the pipes and the body.
Use the solenoid valves commands: Front left-hand wheel solenoid valves, Front right-hand wheel solenoid
valves, Rear left-hand wheel solenoid valves and Rear right-hand wheel while pressing the brake pedal to
determine where the noise is coming from.
AFTER REPAIR
38-48
vnx.su

ABS TRW
Vdiag: 04
38
CHART 14
Lengthening of the brake pedal travel following ABS regulation

(with a pedal receding when entering ABS regulation phase)
NOTES
Ingress of air from the unit assembly regulation channels to the brake circuits.
Bleed the circuits in accordance with the procedure recommended in the introductory section (use the
command modes on the fault finding tool).
After performing the operation, carry out a road test with ABS regulation.
If the fault persists, carry out the above operation again once or twice.
If the customer complaint is particularly serious, and bleeding the circuit does not improve matters, replace the
hydraulic unit.
AFTER REPAIR
38-49
vnx.su
STEERING ASSEMBLY
136
Axial ball joint
36

Dir.
1305-01
Axial ball joint removal/refitting

tool
Dir.
1306-03
SMI steering rack support tool
T. Av. 476

Turn the wheels so the rack teeth are freed on the
valve side.

Wheel bolt
14.2
3.7
Steering ball joint lock nut
5.3
Axial ball joint
Fit the steering rack support tool, Dir. 1306-03.

In this position, release the axial ball joint using tool
Dir. 1305-01.

REMOVAL
First case: drivers side axial ball joint
Remove:
the drivers side wheel,
the steering ball joint nut
Second case: passenger side axial ball joint
Remove:
the wheels;
the steering ball joint nut
In all cases:
Release the lower ball joint using tool T. Av. 476.
Loosen the wheel alignment adjustment sleeve nut
and unscrew the steering ball joint, holding the axial
ball joint with an open wrench.
Counts the number of turns taken in order to preset the
wheel alignment when refitting.
Withdraw the gaiter retaining clips and remove the
gaiter.
36-1
vnx.su
STEERING ASSEMBLY
Axial ball joint
REFITTING
NOTE:
Before refitting new linkage, clean the screw threads in
order to remove all traces of LOCTITE from the original
fitting and to prevent the threaded parts from seizing
when refitting.
36
Refit the following to rack (4):

stop washer (2),
the stop (3),
the axial ball joint (1), the thread of which will
probably have been coated with LOCTITE
FRENBLOC.
Always replace them all (2). If the ball joint notch (1) is
not warn, it can be reused.
Before the final tightening of the axial ball joint using

tool Dir. 1305-01, check that the tabs of the locking
ring (2) are correctly lined up with the flat surfaces (A)
of the steering rack.
Refit the gaiter with new clips.
Retighten the ball joint housing by the number of
rotations noted when removing.
Refit the ball joint and tighten the nuts to the
recommended torque.
Check, and adjust if necessary, the alignment of the
front wheels.
36-2
vnx.su
STEERING ASSEMBLY
Power assisted steering rack
36

Mot. 453-01
Set of 2 hose clamps
T. Av. 476

EQUIPMENT REQUIRED
Component jack

Wheel bolt
14.2
18
2.1
12
10.5
Sub-frame tie-rod mounting bolts
10.5
10.5
18
Universal joint bolt
2.1
1.5
4.4

bars.
REMOVAL
Secure the vehicle on the two-post lift.
Remove the wheels.
Fit hose clamps Mot. 453-01 in place on the hydraulic
assistance circuit pipes.
Unclip:
the wheel sensor wires (ABS equipment),
Remove the lower nuts on the anti-roll bar return

tie-rods.
36-3
vnx.su
STEERING ASSEMBLY
36

Remove:
the engine tie bar,
Remove:
Lower the sub-frame by 20 centimetres.
Remove the steering rack.
REFITTING
Refit the steering rack.
Tighten the two steering rack mounting bolts to torque.
Refit the sub-frame.
NOTE:
Ensure the correct positioning of the sub-frame in
Refit:
the universal joint mounting bolt (B),

the mounting bolt of the hydraulic assistance circuit
pipe flanges (put plugs in place to prevent loss of
fluid),
the heat shield on the steering rack.
36-4
vnx.su
STEERING ASSEMBLY
Refit:
the engine tie bar,
the universal joint mounting bolt,
the mounting bolt of the hydraulic assistance circuit
pipe flanges,
Remove the hose clamps.
Refit the wheels.
Top up the power assisted steering fluid reservoir and
bleed the assistance circuit.
front wheels.
36-5
vnx.su
36
STEERING ASSEMBLY
Steering column
36

Steering wheel mounting bolt
4.4
Linking fork bolt
2.1
Column mounting bolt
2.1
WARNING:
pyrotechnic systems (airbags and pretensioners)
must not be handled near to a heat source or flame
- they may be triggered.
WARNING:
Before starting to remove the steering column, it is
essential to lock the pyrotechnic systems computer
using the diagnostic tool (refer to Section 88 for
instructions).
REMOVAL
Remove the cover beneath the steering wheel.
Remove the driver's front airbag module.

Disconnect:
the driver's front airbag module connector,
the horn connector,
Remove:
the steering wheel mounting bolt,
the steering wheel.
36-6
vnx.su
STEERING ASSEMBLY
Steering column
Remove:
the instrument panel visor,
36
Disconnect the rotary switch connectors.

Push the switch centring pin to gain access to bolt (B)
and loosen it. Then remove the complete rotary switch.
the two casing mounting bolts (A).

Unlock the steering wheel height adjustment control.
Disconnect and remove the transponder ring.
Disconnect the upper half shell casing, then the lower

one, following directions (1) and (2).
36-7
vnx.su
STEERING ASSEMBLY
Steering column
36
Disconnect the ignition switch connectors (D).
Lift the steering column to disengage the pin (G).
Unclip the wiring harness attachments.
Remove the steering column, first lifting (H) then

pulling (K).
Remove:
the two column mounting bolts (E).
the two linking fork bolts (F).

Push the linking fork downwards.
36-8
vnx.su
STEERING ASSEMBLY
Steering column
REFITTING
Refit:
the column on the locating pin,
the two steering column mounting bolts and tighten
them to torque.
Position the linking fork and tighten the two mounting
bolts to torque.
36
WARNING:
The steering wheel bolt must be replaced and
tightened to the correct torque after each removal.
Tighten the steering wheel mounting bolt to torque.
Connect:
the horn connector,
the driver's front airbag module connector.
Connect the ignition switch connectors.

WARNING:
Take care to remember to remove any foreign
bodies (bolts, clips etc.) when refitting the airbag
modules. On the airbag elements, it is essential to
clip the connectors to the bottom and position the
safety latches.
Replace and clip in place the wiring harness

attachments.
Replace and connect:
the transponder ring,
the rotary switch.
Refit:
the half cowlings,
the steering wheel.
WARNING:
Before unlocking the pyrotechnic systems computer,
carry out a test using the diagnostic tool. If
everything is correct, unlock the computer, if not,
refer to the fault finding section.
WARNING:
Failure to observe these instructions may cause a
fault in the normal operation of the pyrotechnic
systems, i.e. they may be incorrectly triggered.
Refit the driver's front airbag module.
Connect the battery.
front wheels.
WARNING:
The steering wheel splines are made so that the
wheel can be fitted in one position only. The steering
wheel should be inserted freely into the splines.
36-9
vnx.su
STEERING ASSEMBLY
Intermediate shaft
36

Linking fork bolt
2.1
Universal joint nut
2.1
REMOVAL
the universal joint shaft and nut (B).

Unclip the sealing gaiter on the engine compartment
side.
Remove:
the two linkage mounting bolts (A).
the linking fork,
Remove the intermediate shaft, pulling it from the

passenger compartment side.
REFITTING
Proceed as for the removal in reverse, taking care to fit
a new nut to the universal joint.
Tighten the fork mounting bolts to torque.
front wheels.
36-10
vnx.su
INTERIOR SAFETY ACCESSORIES

159
Front seat belt

Mounting bolt A
3.7
Mounting bolt B
2.5
Mounting bolt C
1.9
WARNING:
Pyrotechnic systems (airbags and pretensioners)
must not be handled near to a heat source or a
flame as they may be triggered.
IMPORTANT:
before removing an airbag pretensioner or seat belt
fitted with a pretensioner, lock the electronic unit with
a diagnostic tool, see Section 88 Airbag and
pretensioners.
When this function is activated, all the trigger lines are
disabled and the airbag warning light on the
instrument panel comes on.
59-1
vnx.su
59

Front seat belt
59
REMOVAL of cab pillar seat belts

Remove:
the seat belt mounting for the front seats,
the upper runner trim from the sliding side door,
the door frame seals from the front door and sliding
side door (partially),
Unclip the lining at the top (3), then at the bottom (4).
Remove the seat belt.
REMOVAL of the seat pretensioner
Unclip the two covers (D) to allow removal of the two
mounting bolts for the grab handle.
Using the unclipping tool, unclip the lining at (1), then
(2).
Release the lining carefully in order not to damage the
trim strip (E).
Unclip the seat cover at (1), then at (2).

Disconnect the supply connector from the
pretensioner, then remove it.
59-2
vnx.su

Front seat belt
59
REMOVAL of the seat belt from the front bench

seat
SPECIAL NOTE:
The bench seat will have to be removed on vehicles
fitted with a partition.
Unclip the four head restraint guide covers.
Remove the seat belt mounting bolt (F), under the

bench seat.
Release the front and rear retainer strips (G), for the
seatback cover.
Simultaneously pull back the front and back of the seat

cover upwards on the seatback.
The seat cover is held in place by Velcro (I) in the front
section of the seatback.
NOTE:
You do not need to cut the cover retaining clips (J) to
reach the seat belt inertia reel.
Remove the two bolts (H) from the upper trim strip,
then release it.
59-3
vnx.su

Front seat belt
Unclip the belt guide at (K).

Remove the mounting bolt from the seat belt inertia
reel (L), then release it.
REMOVAL of the bench seat pretensioners
It is not necessary to remove the bench seat to carry
out this operation.
Disconnect the supply connector (M) from the

pretensioners, then remove them.
59-4
vnx.su
59

Rear seat belt

Mounting bolt A
3.7
Mounting bolt B
1.9
WARNING:
Pyrotechnic systems (airbags and pretensioners)
must not be handled near to a heat source or a flame
as they may be triggered.
IMPORTANT:
before removing an airbag pretensioner or seat belt
fitted with a pretensioner, lock the electronic unit with
a diagnostic tool, see Section 88 Airbag and
pretensioners.
When this function is activated, all the trigger lines are
disabled and the airbag warning light on the
59-5
vnx.su
59

Rear seat belt
59
REMOVAL of the seat belt from the first row bench

seat
It is not necessary to remove the bench seat to carry
out this operation.
Remove:
front and rear retainer strips (C), for the seatback
cover,
retainer strip (D) (see photo below).
Remove:
the seat belt mounting bolt (A), under the bench seat,
the two bolts (B) from the upper trim strip, then
release it.
59-6
vnx.su

Rear seat belt
59
REMOVAL of the bench seat belt stalks
Unclip seat belt guide (E).

Remove seat belt inertia reel fastening bolt (F).
Remove the mounting bolt (T30) for the seatbelt stalk.

REMOVAL of the cab seat belts
Release the seat belt buckle.
Using tool Car. 1597 unclip the ten lining mounting

clips (the female part of the clips stays on the wing
panel lining).
Disconnect the supply connector from the socket (G),
then release the lining.
59-7
vnx.su

Rear seat belt
Disconnect the supply connector (H) from the

pretensioner.
Remove the mounting bolt from the seat belt inertia
reel, then release it.
Using the tool (Car. 1597), remove:

net mounting cover (I),
grab handle (J).
Carefully remove the head lining, then remove the
mounting bolt from the seat belt return support (K).
59-8
vnx.su
59
188
WIRING
Airbags and seat belt pretensioners
88
GENERAL INFORMATION
During a front impact of sufficient severity:
These vehicles are fitted with a passive safety system

of the RPS type, comprising:
a driver's front airbag with a Renault Protection
System inflatable cushion,
a passenger front airbag with a Renault Protection
System inflatable cushion,
front pretensioners,
rear pretensioners (pyrotechnic seat belt retractors)
(depending on the version),
dedicated front seat belts with Renault Protection
System, (400 daN)
a computer (75-track).
a fault warning light.
WARNING:
With this system, (Renault Protection System
front airbags), the seat belts are linked to the
airbag function.
The Renault Protection System is calibrated
differently depending on whether the seat belts
are to be fitted in front of an RPS airbag or not
(always check the part number of each
component before replacement).
the seatbelts restrain the driver and passenger.

The pretensioners (front and rear) tighten the seat
belts against the body.
The Renault Protection System limits the force of
the seat belt against the body.
The airbag cushions inflate:
from the centre of the steering wheel to protect the
driver's head,
from the dashboard to protect the front
passenger's head.
WARNING:
Do not put covers on the front seats (except for
NISSAN products).
Do not place objects in the airbag deployment area.
When working on the sill panel (on the bodywork, the
seat belt retractor etc.), it is vital that you lock the
airbag unit using a diagnostic tool and switch off the
ignition.
For special points regarding removal and
replacement of seat trims, it is essential to read the
Bodywork section.
On these vehicles, it is strictly forbidden to fit

RPS seat belts to a seat not fitted with an airbag,
or to disconnect the airbag.
NOTE:
Certain connectors are fitted with a new-generation
locking system. It is essential to unclip the lock before
removing the connector and ensure it is correctly
positioned after fitting. An unlocked connector will not
supply the trigger line.
88-1
vnx.su
WIRING
Precautions during repair
Identification
All operations on airbag and pretensioner systems

must be carried out by qualified trained personnel.
IMPORTANT:
Pyrotechnic systems (airbags and pretensioners) must
not be handled near to a heat source or flame as they
may be triggered.
Vehicles fitted with front airbags are identified by:

labels located in the lower corners of the windscreen,
on both sides,
by the wording RPS airbag in the centre of the
steering wheel and on the dashboard.
IMPORTANT:
It is vital that pyrotechnic systems (pretensioners,
front and side airbags) are checked using the
diagnostic tools:
after an accident which has not caused triggering,
after theft or attempted theft of the vehicle,
before selling a used vehicle.
The airbags have a pyrotechnic gas generator with an

igniter and airbag which must not be separated.
IMPORTANT:
Before removing an airbag pretensioner or
computer, lock the computer using a diagnostic tool.
When this function is activated, all the trigger lines
are disabled and the airbag warning light on the
When a side airbag is triggered, the computer locks
permanently and switches on the airbag warning light
on the instrument panel. The computer must be
replaced (certain components lose their nominal
settings after the passage of the ignition power).
After refitting everything, carry out a check using the
diagnostic tool.
If everything is correct, unlock the computer or see the
Fault finding section.
IMPORTANT:
Refer to the section describing the Destruction
procedure when scrapping a pyrotechnic
system that has not been triggered.
88
Warning light on the instrument panel

This warning light confirms correct operation of:
front pretensioners,
rear pyrotechnic seat belt retractors (depending on
the version),
the front airbags,
the battery (checking the supply voltage).
It should light up for a few seconds when the ignition is
switched on, then switch off (and remain off).
If it does not light up when ignition is switched on or
lights up when the vehicle is moving, this signals a fault
in the system (see the Fault finding section).
NOTE:
Under certain starting conditions, the warning light
may come on briefly and then go out.
WARNING:
Depending upon the type of computer, the
airbag warning light may be controlled by a
multiplex connection.
The computer contains sensitive components, so it

must not be dropped.
88-2
vnx.su
WIRING
88
Operation of front pretensioners and airbags
Working on trigger wiring
After ignition, the airbag and pretensioner warning light

comes on for a few seconds and then goes out.
If a fault is detected on one of the wiring harness lines,

the line must be replaced and not repaired.
NOTE:
The airbag warning light may come on because of low
battery voltage.
This safety equipment cannot be subjected to any

conventional wiring or connector repair operations.
The computer is then in standby mode and will

respond to vehicle decelerations using the signal
measured by the integrated electronic decelerometer.
1
During a frontal impact of sufficient severity, the

decelerometer triggers simultaneous ignition of the
pretensioner gas generators after receiving
confirmation of impact detection from the
electronic safety sensor.
If the frontal impact is more severe, the
decelerometer waits for confirmation of the impact
from the electronic safety sensor and then triggers
ignition of the pyrotechnic gas generators on the
front and side airbags.
As the ignition wiring for the airbags and pretensioners

is incorporated into the passenger compartment wiring
harness to facilitate repair, the method of replacing the
wires is to cut the ends of the defective wire and to
make the new wire follow the same routing by running
it alongside the passenger compartment wiring
harness.
IMPORTANT:
When fitting the new wiring, make sure that it is not
chafing and that its original cleanliness is maintained.
IMPORTANT:
When triggered, the pyrotechnic gas generator
produces an explosion combined with light smoke.
NOTE:
Power supply to the computer and ignition modules is
usually provided by the vehicle battery. Nevertheless,
a power reserve capacity is incorporated into the
computer in case of battery failure on impact.
88-3
vnx.su
WIRING
88
COMPUTER
Locking procedure
These computers consist of:

an electronic safety sensor for the front airbags and
the pretensioners,
an electronic decelerometer for the front airbags and
pretensioners,
an ignition circuit for the various pyrotechnic
systems,
a power reserve for the various lines,
a fault finding and detected fault memory circuit,
a control circuit for the warning light on the instrument
panel,
a K communication interface via the diagnostic
socket,
a multiplex communication interface,
an impact detection connection.
Before removing the computer or before any operation

on the airbag and pretensioner systems, it is vital that
you lock the computer:
IMPORTANT:
A computer must be locked using one of the diagnostic
tools before it can be removed.
When this function is activated, all the ignition lines are
disabled and the airbag warning light on the instrument
panel comes on (new computers are supplied in this
state).
With Consult II.

1 Select the Renault vehicle fault finding menu,
2 Select and confirm the vehicle model
3 Select and confirm the system to be checked
Airbag
4 Select the command menu.
5 Select and confirm the Actuators function.
6 Confirm the VP 006 Computer locking line,
7 In the State menu, check that the unit is locked.
The ET073 Computer locked with tool state
must be active and the airbag warning light on the
instrument panel must be on (new computers are
delivered in this condition).
NOTE:
To unlock the computer, use the same method,
confirming the Unlock computer VP007 line.
The ET073 Computer locked with tool state must not
be active and the airbag warning light on the
instrument panel must be off.
NOTE:
In the event of incorrect operation of these systems
during an impact, it is possible to check that no fault
was present before the impact using the diagnostic
tools.
After locking following an impact, it is possible to
check the trigger lines supplied by the control
reading breakdown contexts with the diagnostic
tool.
88-4
vnx.su
WIRING
88
Removal
Refitting
The computer is located behind the centre console

(right-hand side).
When refitting the computer, ensure that it is fitted the

right way up and the right way round. The arrow must
point towards the front of the vehicle.
REMINDER:
A computer must be locked using one of the diagnostic
tools before it can be removed.
Tighten the bolts to a torque setting of 0.8 daNm.
WARNING:
The computer contains sensitive components, so
it must not be dropped.
When working under the vehicle (exhaust system,
bodywork, etc.), do not use a hammer or hits the
floor without having locked the computer using the
diagnostic tool.
Electrical accessories fitted to the vehicle after
sales (speaker, alarm unit and any device which
may generate a magnetic field), must not be
placed in close proximity to the airbag/
pretensioner computer.
Configuring the computers

The new units which can be recognised by the title
ACU3 on the diagnostic tool are delivered as
configured pyrotechnic seatbelt retractors.
If this configuration is not carried out, the airbag
warning light remains lit.
1
2
3
4
5
6
88-5
vnx.su
Select the Fault finding menu,

Select and confirm the vehicle model
Select and confirm the system to be checked
Airbag
Select the command menu.
Select and confirm the Settings line to change the
trigger lines.
It is essential to check the result in the Reading
configurations menu.
WIRING
Connection
61
Yellow 75-track connector
62
Track
Description
63
1
2
3
4 to25
26
27
28
29
30
31
32
33
34
35
Not used
+ Passenger pretensioner (side)
+ Passenger pretensioner (central)
Not used
- Driver's front airbag
+ Driver's pretensioner
- Passenger pretensioner (side)
+ Passenger's front airbag
+ after ignition
Earth
Not used
Not used
Diagnostic line K
- Pyrotechnic seat belt retractor 1st row
on the driver's side
+ Pyrotechnic seat belt retractor 1st row
on the passenger side
- Pyrotechnic seat belt retractor 2nd row
+ Pyrotechnic seat belt retractor 2nd row
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
+ Driver's front airbag
+ Driver's pretensioner
+ Passenger pretensioner (central)
- Passenger's front airbag
Not used
Not used
Not used
CAN H multiplex link
CAN L multiplex link
+ Pyrotechnic seat belt retractor 1st row
64
65
66
67
68
69
70
71
72
73
74
75
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
88
- Pyrotechnic seat belt retractor 1st row

+ Pyrotechnic seat belt retractor 2nd row
- Pyrotechnic seat belt retractor 2nd row
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
NOTE:
The computer has a configuration allowing it to
operate with a bench seat fitted with two pretensioners
or one passenger's seat.
88-6
vnx.su
WIRING
SEAT BELT PRETENSIONER
88
When it is triggered, the system is able to retract the

seat belt catch by up to 100 mm (maximum)
Description
The vehicles are fitted:
with a pretensioner on the driver's seat,
with pretensioners on the passenger seat:
with an igniter if the vehicle is fitted with a single
seat,
two igniters as standard if the vehicle is fitted
with a two place bench seat,
with pretensioners to wind round the seat belts to the
rear side places (depending on the version).
Front pretensioners
NOTE:
The system is operational after the ignition is switched
on.
88-7
vnx.su
WIRING
88
Removal:
IMPORTANT:
Before removing a pretensioner, lock the computer using one of the diagnostic tools. When this function is
activated, all the trigger lines are disabled and the airbag warning light on the instrument panel comes on.
NOTE:
Removing pretensioners does not entail removal of the seats.
IMPORTANT:
Refer to section describing the Destruction procedure when scrapping a pretensioner that has not been
triggered (except for parts to be returned under warranty).
88-8
vnx.su
WIRING
88
Features of the driver's side
Features of the passenger side
The seat belt catch on the driver's side has an

electrical switch which operates a warning light on the
instrument panel to indicate that the belt is not
fastened.
If the vehicle is fitted with a two seater bench seat, it

has two pretensioners supplied in turn by the same
trigger line (in series by the computer). Checking the
computer configuration.
To unclip the connector, remove the mounting bolts

from the two buckle half-shells.
Refitting
Follow the correct routing of the wiring and the wiring
mounting points under the seat.
Connect the pretensioner connector after fitting it and
tightening it to a torque of 3.7 daNm.
After replacing faulty parts and reconnecting the
connectors, carry out a check using the diagnostic
tool.
88-9
vnx.su
WIRING
Rear pretensioners (pyrotechnic seat belt
retractors)
88
Renault Protection System seat belts
Removal:
The front seat belts are fitted with a specific Renault

Protection System (4 daN).
The pretensioners are fitted in the seat belt retractors.

The rear trims need to be removed to remove them.
Refer to the method described in the Bodywork
section.
In this equipment, the seat belts are linked to the

airbag function. (The Renault Protection System is
calibrated differently depending on whether the seat
belts are to be fitted in front of an RPS airbag or not).
When the pretensioners have been triggered the front
seat belt or belts must always be replaced if they were
being worn when pretensioning took place (if there is
any doubt as to whether the belt was being worn it
must be replaced). The physical stresses exerted on
the buckle are transmitted to the inertia reel and may
damage its mechanism.
Refitting
Ensure that the wiring is correctly routed using the
wiring attachment points.
Tighten the mounting bolt to a torque setting of
3.7 daNm.
After replacing faulty parts and reconnecting the
connectors, carry out a check using the diagnostic
tool.
88-10
vnx.su
WIRING
88-11
vnx.su
88
WIRING
DRIVER'S AIRBAG MODULE
88
Insert a screwdriver into opening (1) behind the

steering wheel.
The driver's airbag is fitted with a specific cushion

(airbag with RPS marking) linked to the seat belt
opposite it.
Lift (2) the airbag module in order to slide it.

Unclip the connector safety clips.
The Renault Protection System seat belt is calibrated

specifically and is complementary to this type of airbag
cushion.
Disconnect the two generator power supply

connectors.
Description
It is located in the centre of the steering wheel When
triggered, the inflatable bag deploys by bursting
through the steering wheel cover.
IMPORTANT:
procedure when scrapping an airbag that has
not been triggered.
Refitting
Removal:
NOTE:
When replacing an airbag after an impact, it is
essential to replace the steering wheel and its
mounting bolt (tightening torque: 4.4 daNm).
IMPORTANT:
Before removing a passenger airbag module, lock
the computer using a diagnostic tool.
When this function is activated all the ignition lines
instrument panel lights up when the ignition is
switched on.
Put the connector in place and lock it.

Position the airbag module on the steering wheel.
Slide it backwards in order to clip it in place.
IMPORTANT:
After refitting everything, carry out a check using a
diagnostic tool.
If everything is correct, unlock the computer or see
the Fault finding section.
88-12
vnx.su
WIRING
PASSENGER AIRBAG MODULE
88
IMPORTANT:
When the passenger airbag module is triggered, the
consequent deformation and damage caused to the
attachments always requires the dashboard to be
replaced.
Do not forget to affix the label on the side of the new
dashboard prohibiting a rear-facing child seat to be
fitted on the passenger seat (label available in the
collection with part no. 77 01 206 809).
The Renault Protection System passenger airbag is

fitted with a two-level inflatable cushion linked to the
seat belt opposite it.
The Renault Protection System seat belt is calibrated
specifically and is complementary to this type of airbag
module.
Removal:
The airbag module is attached to the instrument panel
opposite the front passenger but does not need to be
removed.
IMPORTANT:
procedure when scrapping an airbag that has
not been triggered.
IMPORTANT:
Before removing a passenger airbag module, lock
the computer using a diagnostic tool.
When this function is activated, all the trigger lines
Refitting
Carry out the refitting operation in the reverse order to
removal, observing the correct torque values for the
mounting bolts.
bolt (1) to 2 Nm
bolt (2) to 8 Nm
Remove the mounting bolts.
IMPORTANT:
Check for foreign bodies (bolts, clips, etc.) when
fitting the airbag module.
On the module side, make sure that the connector
is properly clipped (powerful clip) and position the
safety lock.
Attach a blue adhesive Tamperproof system
warning light label sold under part no.
77 01 040 153 (other vehicles).
Check the module using the diagnostic tool.

Disconnect the connector.
88-13
vnx.su
WIRING
DESTRUCTION PROCEDURE
88
Destruction of the part fitted to the vehicle

Move the vehicle outside the workshop.
WARNING:
This does not apply if local legislation requires a
specific procedure validated and circulated by the
Procedures, Fault Finding and Repair service.
Connect the destruction tool to the pretensioner after

removing the seat runner cover.
Unwind all the tool wiring so that it is far enough away
from the vehicle (approximately 10 m) during
triggering.
In order to avoid any risk of an accident, the

pyrotechnic gas generators must be triggered before
the vehicle is scrapped or the part is scrapped.
Connect the two supply wires on the tool to a battery.
Triggering tool KV 99106400 and adapter

KV 999R0050 must be used.
After checking that there is no-one nearby, destroy the

pretensioner by pressing the two buttons on the tool at
the same time.
IMPORTANT:
Do not reuse pyrotechnic components as
replacement parts. The pretensioners or airbags on
a vehicle which are to be scrapped must always be
completely destroyed.
Pretensioners
IMPORTANT:
Do not trigger pretensioners which are to be returned
under warranty because of a problem with the seat
belt catch. This makes analysis of the part by the
supplier impossible.
Return the part in the packaging of the new part.
Destruction of the part removed from the vehicle

Proceed in the same way as for the driver's airbag, in a
stack of old tyres (see below).
88-14
vnx.su
WIRING
Front airbag
88
Cover the assembly with a stack of four old tyres.
The part must be removed from the vehicle for

destruction.
Carry out the operation outside the workshop.
After connecting the appropriate wiring, set the airbag
module on two blocks of wood to avoid damaging the
connector on the ground.
Unwind all the tool wiring so that it is far enough away

from the unit (approximately 10 m) during triggering
and connect it to the airbag cushion.
Connect the two supply wires on the tool to a battery.
After checking that there is no-one nearby, destroy the
airbag by pressing the two buttons on the tool at the
same time.
88-15
vnx.su
ACU3
Vdiag No.: 10
188
WIRING
WIRING
Air
Air bags
bags and
and seat
seat belt
belt pretensioners
pretensioners
88
DIAGNOSTICS- PRELIMINARIES
This manual describes the diagnostics for all AIRBAG AUTOLIV ACU3 computers - with VDIAG 10 mounted
on PRIMASTAR.
To carry out fault finding on this system, it is essential to have the following items:
the tools listed in Special tooling required.
GENERAL APPROACH TO FAULT FINDING:

Include information contained in the introductory sections.
Read the faults stored in the computer memory and use the Interpretation of faults section of the documents.
Follow closely the fault finding procedure as described for each present or stored fault. Only the "computer" fault
leads to replacement of the computer whether the fault is present or simply stored.
Perform the conformity check (appearance of possible incorrect operations not yet stated by the system's self
diagnosis procedure) and apply the associated diagnostic strategy according to results.
Use the fault finding procedure for each Customer complaint if the fault persists.
Special tooling required for operations on the air bag and seat belt pretensioner systems:
Consult II diagnostic tools,
Multimeter.
88-11
vnx.su
ACU3
Vdiag No.: 10
WIRING
Air bags and seat belt pretensioners
88
DIAGNOSTICS - PRELIMINARIES
Diagnostic function:
The SRS self-diagnostic function with the airbag indicator lamp does not exist on the Primastar model; technicians
can only find and fix the problem using "Diagnostic Mode".
REMINDER:
During operations on the air bag/seat belt pretensioner systems it is vital that you lock the computer using the
diagnostic tool to prevent any risk of accidental triggering (all the ignition lines will be inhibited). The locked mode is
signalled when the instrument panel warning light comes on.
Without the fault finding tool, switch off the ignition and remove the supply fuse from the system, then wait at least
2 seconds for the power reserve capacity to discharge.
Never take airbag ignition line or pretensioner readings with a multimeter or the CONSULT II tool.
While working, make sure the computer power supply does not drop below 10 V.
88-12
vnx.su
ACU3
Vdiag No.: 10
WIRING
DIAGRAM OF THE SYSTEM
Front and side air bags + pretensioners/inertia reels (front + rear) with central unit.
88-13
vnx.su
88
ACU3
Vdiag No.: 10
WIRING
88
SYSTEM CONFIGURATION DIAGRAM
Central unit
+ 12 V / Ground
Driver's seat
Passenger seat
Buckle pretensioner
Driver's front air bag ignition module
Rear pyrotechnic seat belt retractor, row 1
Passenger's front air bag ignition module
Rear pyrotechnic seat belt retractor, row 2
Front side air bag ignition module

CT
Rotary switch
Warning light/Diagnostic lines

Impact sensors / Impact information
88-14
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
FAULT FINDING - FAULT INTERPRETATION

DF002
PRESENT
NOTES
1.DEF - 2.DEF
1.DEF : Too many micro-breaks

2.DEF : Voltage beyond tolerance
Do not use electrical testing equipment on circuits connected to the SRS, unless
otherwise instructed in the Workshop Repair Manual.
Order of repair: check the SRS system each time a part is replaced.
NOTES
None.
Carry out the operations necessary to obtain the correct computer voltage:
10.5 V 0,1 < voltage OK < 16 V 0.1.
Check the battery charge.
Check the charge circuit.
Check the tightening and the condition of the battery terminals.
Computer earth check.
Check the condition of the computer and that it is locked.
AFTER REPAIR
Deal with any faults detected by the diagnostic tool.

Clear the computer memory.
88-15
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S FRONT AIR BAG CIRCUIT

DF003
PRESENT
NOTES
CC : Short circuit
Lock the computer using the command on the diagnostic tool.

Cut the contact and remove the two driver's front airbag module mounting bolts.
Check that it is correctly connected.
With the ignition switched off, disconnect and reconnect the connector of the rotary switch at the steering
wheel.
Check the connections if the fault has become stored (fault no longer declared present).
Visually inspect the wiring harness connection.
Replace the wiring harness if it is visibly damaged.
Replace the rotary switch.
Replace the driver's front airbag module (it should be opened out before being discarded).
Replace the air bag computer.
Replace the corresponding wiring harness.
AFTER REPAIR
Reconnect the computer and airbag module ignition, then replace the contact.
Erase the computer memory then switch off the ignition.
Carry out the check again using the diagnostic tool and, if there are no faults, unlock
the computer.
Destroy the driver's front airbag module if it was replaced.
88-16
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF003
PRESENT
NOTES
CO : Open circuit

wheel.
AFTER REPAIR
the computer.
88-17
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF003
PRESENT
NOTES
CC.1 : Short circuit to 12 V


Check the condition of the firing lines.
AFTER REPAIR
the computer.
88-18
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF003
SAVE
NOTES
CC
CO
: Short circuit
: Open circuit

wheel.
If the wiring harness is OK, replace the driver's front airbag module (before being removed, it must be opened
out), airbag computer and rotary switch.
AFTER REPAIR
the computer.
88-19
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF003
SAVE
NOTES
CC.1 : Short circuit to 12 V


Check the condition of the firing lines.
If the wiring harness is OK, replace the driver's front airbag module (before being removed, it must be opened
out), airbag computer and rotary switch.
AFTER REPAIR
the computer.
88-20
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
PASSENGER FRONT AIR BAG CIRCUIT

DF004
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit
Short circuit to 12 V

Replace the passenger's front airbag module (it should be opened out before being discarded).
AFTER REPAIR
the computer.
Destroy the airbag module if it was replaced.
88-21
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
PASSENGER FRONT AIR BAG CIRCUIT

DF004
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

Replace the passenger's front airbag module wiring harness if it is visibly damaged.
If the wiring harness is OK, replace the passenger's front airbag module (before it is removed, it must be
opened out) and computer.
AFTER REPAIR
the computer.
Destroy the airbag module if it was replaced.
88-22
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DF010
PRESENT
OR
SAVE
NOTES
FAULT WARNING LIGHT CIRCUIT

1.DEF : Dashboard diagnostics.
Special notes: None.
Apply the diagnostic procedure relevant to this fault in the instrument panel diagnostic information section.
AFTER REPAIR

the computer.
88-23
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
COMPUTER CONFIGURATION
DF016
PRESENT
NOTES
This fault indicates an inconsistency between the computer configuration and the vehicle equipment detected
by the computer. The computer has detected the presence of an element additional to its configuration.
Change the computer configuration using the diagnostic tools "Configuration" command.
AFTER REPAIR

Check again using the diagnostic tool.
88-24
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S PRETENSIONER CIRCUIT.

DF029
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

Switch off the ignition and check that the drivers pretensioner ignition module is connected correctly.
Visually inspect the wiring harness connections.
Replace the pretensioner (turn it off before discarding it).
AFTER REPAIR
Reconnect the computer and pretensioner, then replace the contact.

the computer.
Destroy the pretensioner if it was replaced.
88-25
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S PRETENSIONER CIRCUIT.

DF029
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

Switch off the ignition and check that the drivers pretensioner ignition module is connected correctly.
If the checks on the wiring harness are satisfactory, replace the computer and the left-hand seat belt (the seat
belt pretensioner must be opened out before removal).
AFTER REPAIR
Reconnect the computer and pretensioner, then replace the contact.

the computer.
88-26
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S SIDE SENSOR CIRCUIT

DF039
PRESENT
NOTES

2.DEF : No communication
3.DEF : Disrupted communication

Cut the contact and make sure the sensor is properly connected.
Replace the sensor.
AFTER REPAIR
Reconnect the computer and the driver's side sensor then switch on the ignition again.
the computer.
88-27
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DF039
PRESENT
CONTINUED
NOTES

4.DEF : Faulty sensor
Replace the driver's side computer.
AFTER REPAIR
the computer.
88-28
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF039
SAVE
NOTES


If the wiring harness is OK, replace the computer and sensor.
AFTER REPAIR
the computer.
88-29
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DF039
SAVE
CONTINUED
NOTES

Replace the driver's side sensor.
AFTER REPAIR
the computer.
88-30
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
PASSENGER SIDE SENSOR CIRCUIT

DF040
PRESENT
NOTES


Replace the sensor.
AFTER REPAIR
Reconnect the computer and the passenger's side sensor then switch on the ignition
again.
the computer.
88-31
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DF040
PRESENT
CONTINUED
NOTES

Replace the passenger's side sensor.
AFTER REPAIR
again.
the computer.
88-32
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF040
SAVE
NOTES


If the wiring harness is OK, replace the computer and sensor.
AFTER REPAIR
again.
the computer.
88-33
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DF040
SAVE
CONTINUED
NOTES

Replace the passenger's side sensor.
AFTER REPAIR
again.
the computer.
88-34
vnx.su
ACU3
Vdiag No.: 10
WIRING
MULTIPLEX NETWORK
DF060
PRESENT
NOTES
None.
Apply the diagnostic procedure for the multiplexed network.
AFTER REPAIR

88-35
vnx.su
88
ACU3
Vdiag No.: 10
WIRING
88
CONFIGURATION OF SIDE SENSORS

DF062
PRESENT
NOTES
None.
This fault indicates an inconsistency between the computer configuration and the vehicle equipment detected
by the computer. The computer has detected the presence of an element additional to its configuration.
Change the computer's configuration with the diagnostic tool's "Configuration" command.
AFTER REPAIR

88-36
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
PASSENGER CHEST FRONT SIDE AIR BAG CIRCUIT

DF068
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

Cut the contact and make sure the airbag module is properly connected (the seat cover must be removed for
this procedure).
Replace the airbag module (it should be opened out before being discarded).
AFTER REPAIR
Reconnect the computer and the ignition module of the passenger's front side air bag
module then switch on the ignition.
the computer. Replace the seat cover.
Destroy the chest side airbag module if it was replaced.
88-37
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
PASSENGER CHEST FRONT SIDE AIR BAG CIRCUIT

DF068
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

this procedure).
If the wiring harness is OK, replace the computer and airbag module (the module must be opened out before
removal).
AFTER REPAIR
Reconnect the computer and the ignition module of the passenger's front side air bag
88-38
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S CHEST FRONT SIDE AIR BAG CIRCUIT

DF077
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

this procedure).
Replace the airbag module (it should be opened out before being discarded).
AFTER REPAIR
Reconnect the computer and the ignition module of the driver's front side air bag
88-39
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S CHEST FRONT SIDE AIR BAG CIRCUIT

DF077
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

this procedure).
If the wiring harness is OK, replace the computer and airbag module (the module must be opened out before
removal).
AFTER REPAIR
Reconnect the computer and the ignition module of the driver's front side air bag
88-40
vnx.su
ACU3
Vdiag No.: 10
WIRING
DF094 to DF153
PRESENT
OR
STORED
NOTES
COMPUTER FAULT
None.
Replace the air bag computer (consult the Help section for this operation).
AFTER REPAIR
None.
88-41
vnx.su
88
ACU3
Vdiag No.: 10
WIRING
88
FRONT PASSENGER'S PRETENSIONER CIRCUIT

DF158
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit
Vehicle with 1 or 2 passenger pretensioner(s)

Switch off the ignition and check that the pretensioner ignition module is connected correctly.
Replace the passenger side seat belt(s) (the pretensioner must be deactivated before it is discarded).
AFTER REPAIR
Reconnect the computer and the pretensioner, then switch on the ignition again.
the computer.
88-42
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
FRONT PASSENGER'S PRETENSIONER CIRCUIT

DF158
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit
Vehicle with 1 or 2 passenger pretensioner(s)

If the checks on the wiring harness are satisfactory, replace the computer and the passenger side seat belts
(the seat belt pretensioner must be opened out before being discarded).
AFTER REPAIR
Reconnect the computer and the pretensioners, then switch on the ignition again.
the computer.
88-43
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DRIVER'S SIDE ROW 1 PRETENSIONER CIRCUIT

DF159
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

AFTER REPAIR
the computer.
88-44
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF159
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

If the wiring harness is OK, replace the computer and pretensioner (the seat belt pretensioner must be opened
out before removal).
AFTER REPAIR
the computer.
88-45
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
PASSENGER SIDE ROW 1 PRETENSIONER CIRCUIT

DF160
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

AFTER REPAIR
the computer.
88-46
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF160
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

AFTER REPAIR
the computer.
88-47
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF161
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

AFTER REPAIR
the computer.
88-48
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF161
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

AFTER REPAIR
the computer.
88-49
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF162
PRESENT
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

AFTER REPAIR
the computer.
88-50
vnx.su
ACU3
Vdiag No.: 10
WIRING
88

DF162
SAVE
NOTES
CC
CO
CC.1
CC.0
:
:
:
:
Short circuit
Open circuit

out before being removed).
AFTER REPAIR
the computer.
88-51
vnx.su
WIRING
ACU3
Vdiag No.: 10
88
NOTES
Only carry out conformity check after a full check using the diagnostic tool.
Order
Function
Parameter or state
check or action
Diagnostic tool
dialogue
Computer
conformity
Vehicle type parameter
Computer
configuration
Air bag
Use the following commands:

"configuration of ignition modules"
"configuration of side sensors"
Warning light
operation
4
Computer
initialisation
check.
Switch on the ignition
88-52
vnx.su
Fault
finding
procedure
Display
and notes
Primastar
ACU 3
10
CHART 1
DF094
Ensure that the computer

configuration defined in the
Current column
corresponds to the vehicle
equipment.
None
Warning light comes on for 3

seconds when the ignition is
switched on
DF010
ACU3
Vdiag No.: 10
WIRING
88
DIAGNOSTICS - HELP
Replacing the air bag computer
The air bag computers are sold in locked mode to avoid all risk of accidental triggering (all ignition lines are
inhibited).
The locked mode is signalled when the air bag fault warning light lights up on the instrument panel.
Follow this procedure when replacing an air bag computer:
Ensure that the ignition is switched off.

Replace the computer.
Modify the computer configuration if necessary.
Switch off the ignition.
Carry out a check using the diagnostic tool.
Unlock the computer only no faults are indicated by the diagnostic tool.
88-53
vnx.su
ACU3
Vdiag No.: 10
WIRING
88
DIAGNOSTICS - DIAGNOSTIC CHARTS
Absence of dialogue with the air bag computer
CHART 1
NOTES
None.
Try to establish dialogue with a computer on another vehicle to make sure that the diagnostic tool is not faulty.
If the tool is not causing the fault and dialogue cannot be established with any other computer on the same
vehicle, it may be that a faulty computer is disrupting diagnostic line K .
Disconnect the computers one at a time to locate the fault.
Check the battery voltage and make whatever adjustments are necessary to obtain the proper reading
(10.5 V < battery voltage < 16 V).
Check the presence and condition of the air bag computer supply voltage fuse.
Check that the computer connector is properly connected and check the condition of its wiring.
Check that the computer is correctly supplied:
Disconnect the air bag computer.
Check and make sure + after contact between tracks 30 (+ after contact) and 31 (connector)
ground 75 tracks.
Check that the diagnostic socket is correctly supplied:

+ before ignition on track 16.
Earth on tracks 4 and 5.
Check the continuity and insulation of the lines of the diagnostic socket/air bag computer connection:
Between the terminal marked K and track 7 of the diagnostic socket.
If dialogue is still not established after these various checks, replace the airbag computer (consult the "Aid"
section for this operation).
AFTER REPAIR
When communication is established, deal with any faults indicated.
88-54
vnx.su
SPECIFICATIONS
101
Dimensions
01
Dimensions in metres.
(1) unladen
(2) laden
Van
Version
Combi
Short
Long
Short
Long
3.098
3.498
3.098
3.498
4.782
5.182
4.782
5.182
0.833
0.833
0.851
0.851
1.615
1.615
1.630
1.630
2.232
2.232
H(1)
1.959
1.965
1.958
1.940
1.944
0.543
0.549
0.542
0.521
0.525
K(2)
0.162
0.164
0.158
0.152
0.151
1.387
1.369
1.390
1.390
1.335
1.306
ZI
2.380
2.780
01C-1
vnx.su
0.790
0.150
1.190
SPECIFICATIONS
Engine and equipment
01
Engine
Vehicle type
XL0B
XL0C
Type
Cubic capacity
(cm2 )
F9Q
1870
Gearbox type
PK5
PK6
VEHICLE IDENTIFICATION
Example: FL0B
F
: Body type (Van)
: Project code
0B : Engine suffix

Vehicle
ALL TYPES
Rim
6J16
Tyres
Front
Rear
195/65 R16 C
3.2
3.6
205/65 R16 C
3.6
4.1
215/65 R16 C
3.0
3.4

Rim run-out: 1.2 mm
01C-2
vnx.su
SPECIFICATIONS
Engine and equipment
COLD-MARKING OF THE BODY
If the complete body is being replaced, it must be

marked in compliance with the current regulations.
01C-3
vnx.su
01
SPECIFICATIONS
Lifting equipment
TROLLEY JACK AND AXLE STAND LOCATIONS
01
REAR
NOTE:
Only use the underbody flange for locating the axle
stands.
FRONT
01C-4
vnx.su
SPECIFICATIONS
Lifting equipment
UNDERBODY LIFT
01
2 - REMOVING AND REFITTING HEAVY

COMPONENTS
Various cases have to be considered:

IMPORTANT:
Always use a safety harness if using a two-post lift to
remove heavy components.
1 - REMOVING COMPONENTS
As a general rule, never use a two-post lift when a
four-post lift can be used.
For your safety, take care to ensure that the vehicle is

balanced when placed on a two-post lift.
If this is not possible, place the lifting pads on the jack

supports (A) as shown below:
FRONT
This is because removing heavy components (such as

the engine and transmission assembly, rear axle or
fuel tank, etc.), depending on:
the vehicle load,
its length,
the position of the lifting pads,
may cause the vehicle to become unbalanced.
It is therefore essential to put a strap around or inside
the bodywork and fix it to the arms of the lift between
the pads.
REAR
01C-5
vnx.su
SPECIFICATIONS
Towing
01
FOR TOWING, REFER TO THE LEGISLATION IN FORCE IN THE COUNTRY CONCERNED.

NEVER USE THE DRIVESHAFTS AS AN ATTACHMENT POINT.
The towing points may only be used for towing the vehicle on the road. They should never be used for removing the
vehicle from a ditch or to lift the vehicle, either directly or indirectly.
FRONT
REAR (vehicle with towing equipment)
REAR (vehicle without towing equipment)
01C-6
vnx.su
SPECIFICATIONS
Sub-frame dimensions
01
SUB-FRAME DIMENSION
DESCRIPTION
DIMENSION X DIMENSION Y DIMENSION Z
DIAMETER
ANGLE%
Front left-hand sub-frame rear mounting
390.2
-337
70
24.5; M12
A'
Front right-hand sub-frame rear mounting
390.2
337
70
24.5 x 30; M12
B1
Rear axle leader pin
2321
516
176
20.5
B2
Rear axle assembly front mounting
2441*
654
70
12.5
Front sub-frame front mounting
91.6
432.8
275
18.5
Rear shock absorber upper mounting
3575*
465
235
14.5
90
Front shock absorber upper mounting

(on the lowest section of the fallen edge)
42.7
614
790.3
42
x = 330'
y = 3
Front side member rear leader pin
1240
516
174
14.5; M12
Front side member front leader pin
543.4
528.4
96.3
12.2; M10
Rear side member rear leader pin
3466*
516
203
30 x 30
K1
Front end cross member (front panel
570
590.4
331.6
M8
90
K2
570
466.4
331.6
M8
90
L1
Rear end cross member (end panel)
3685*
516
144
14.5; M10
L2
3740.5*
516
144
14.5; M10
P1
Engine mounting
301.4
535
534.6
12.2; M10
P2
Engine mounting
146.4
513
534.6
12.2; M10
Additional engine mounting (tie-rod)
22.9
458.1
631.5
12.2
Additional rear axle mounting

(side tie-rod)
2933*
455
59
12.2
90
A and B = vehicle trim-setting reference

* Add 400 mm for the L2 version
01C-7
vnx.su
SPECIFICATIONS
Description of parts (exploded view)
INTERNAL STRUCTURE
NOTE: all panels must be electrogalvanized before welding.

HTS: High Tensile Steel
VHTS: Very High Tensile Steel
01C-8
vnx.su
01
SPECIFICATIONS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Radiator support cross member (41 B)

Front end lower cross member (41 A)
Front end side cross member (41 D)
Radiator cross member support (41 C)
Front side member closure panel (front section) (41 F)
Front side member (41 G)
Front section of front side member (41 E)
Front sub-frame rear mounting (41 I)
Engine mounting stiffener (41 H)
Front section of front side member rear reinforcement (41 J)
Cab floor stiffener (41 X)
Cab floor front cross member (41 W)
Front jack support (41 O)
Cab floor (41 V)
Front seat mounting reinforcement (41 Z)
Front cross member under front seat (41 Z)
Sleeve stop (41 AF)
Handbrake lever mounting stiffener (41 AE)
Rear floor front cross member lining (41 AD)
Front side step (41 P)
Inner sill panel (41 M)
Cab sill panel (41 K)
Rear floor, front section (41 AB)
Front cross member of rear floor, front section (41 AC)
Rear floor centre cross member (41 AK)
Rear side step (41 AA)
Rear seat mounting longitudinal reinforcement (41 AJ)
Rear floor centre cross member bracket (41 AL)
Exhaust mounting support (41 AH)
Front section of rear side member (41 AG)
Front side step rear closure panel (41 Q)
Inner sill panel reinforcement (41 R)
Runner housing (41 S)
Rear floor side cross member (41 T)
Rear axle mounting front housing (41 U)
Sill panel under rear side door (41 L)
Rear axle lateral tie-rod attachment (41 AI)
Rear floor, rear section (41 AS)
Rear end lower cross member (41 AU)
Rear floor rear cross member (41 AR)
Rear towing ring (41 AP)
Rear end lower cross member side closure panel (41 AT)
Rear shock absorber attachment (41 AQ)
Rear seat mounting bracket (41 AM)
Rear side member (41 AN)
Rear floor longitudinal reinforcement (41 AO)
Rear inner sill panel (41 N)
01C-9
vnx.su
01
SPECIFICATIONS
UPPER STRUCTURE
HTS: High Tensile Steel
01C-10
vnx.su
01
SPECIFICATIONS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Front (42 C)
Front section of front right wheel arch (42 I)
Front right wheel arch (42 J)
Front section of front left wheel arch (42 I)
Front left wheel arch (42 J)
Front side support (42 D)
Front wing lower mounting support (42 B)
Scuttle side panel (42 E)
Scuttle side panel upper reinforcement (42 F)
Cab A-pillar reinforcement (43 C)
Cab A-pillar closure panel (43 B)
Front wing (42 A)
Bulkhead (42 M)
Windscreen aperture lower cross member (42 K)
Windscreen aperture lower cross member reinforcement (42 L)
Bonnet hinge support (42 G)
Bonnet release control support (42 H)
Windscreen pillar lining (43 D)
Double seal lining (43 A)
Windscreen pillar lining reinforcement (43 E)
Cab side (43 I)
Cab roof front cross member (45 E)
Cab C-pillar lining (43 H)
Front section of side panel lower lining (44 C)
Front section of rear side panel lining (44 A)
Rear B-pillar (44 E)
Cab roof (45 A)
Roof (45 B)
Cab roof rear roof (45 F)
Rear wheel inner arch (45 F)
Front section of side panel upper lining (44 B)
Rear roof drip moulding lining (44 H)
Rear drip moulding (44 G)
Rear section of rear side panel lining (44 F)
Rear section of side panel (44 D)
Rack mounting bridge piece (45 D)
Rear section of rear roof (45 C)
Roof central cross member (45 G)
Rear side panel rain channel (45 H)
Roof rear cross member lining (45 J)
Rear roof rear cross member (45 I)
Rear bumper support cross member (44 N)
Rear end panel (44 M)
Rear section of rear side panel rain channel (44 K)
C-pillar (44 J)
Gas spring ball joint (44 L)
01C-11
vnx.su
01
SPECIFICATIONS
OPENING ELEMENTS STRUCTURE
1
2
3
4
5
6
7
8
9
10
Bonnet (48 A)
Front side door (47 A)
Front side door panel stiffener (47 C)
Front side door panel (48 A)
Fuel filler flap (47 D)
Sliding side door (47 E)
Sliding side door panel (47 F)
Tailgate (48 A)
Rear loading door (48 C)
Rear loading door panel (48 D)
01C-12
vnx.su
01
COLLISION
103
Fault finding
03
Before carrying out repairs to the bodywork of a vehicle, even if the damage seems slight, it is necessary to carry out
a series of tests:
VISUAL INSPECTION
This inspection involves examining the sub-frame of the vehicle where mechanical components are mounted and in
the crumple zones or vulnerable areas in order to detect creases where materials have been damaged.
TRAMMEL GAUGE CHECK
The visual inspection may be completed using a trammel gauge which measures certain deformations by
symmetrical comparisons (for more detail on each point to check, see the bodyjig bench paragraph below).
CHECKING THE ANGLES OF THE RUNNING GEAR
This is the only check which determines whether the impact suffered by the vehicle has or has not affected its road
holding.
IMPORTANT:
In borderline cases, it is essential not to neglect checking the axle assembly components which may also have been
subject to deformation.
In principle, no welded component in the body shell may be replaced without ensuring that the sub-frame was not
affected by the impact.
Chronological order of checks:

FRONT impact:
1: B1 - A1' = B1' - A1
2: A1' - H = A1 - H'
REAR impact:
1: A1' - B1 = A1 - B1'
2: B1' - L2 = B1 - L2'
03B-1
vnx.su
COLLISION
Fault finding
03
GAUGE POINTS
Point A1'
Front body reference point. Start reference point for
checking points (H) and (H').
Point B1'
Rear axle assembly leader pin. Start reference point for
checking points (L2) and (L2').
Point H'
Front end of front side member.
Point L2'
Rear end of rear side member.
REMINDER:
The gauge holes are fitted with blanking covers to ensure that all hollow sections are watertight.
After gauging, it will be necessary to fit them again or replace them if they are damaged to ensure protection of the
sub-frame from corrosion.
03B-2
vnx.su
COLLISION
Part combinations for impacts
03
Replacement part combinations depending on impacts

Without panelwork operations
Additional operations
first degree
Basic operations
(second degree)
front impact
stone shield
bonnet
front
front
bonnet
front
wing
bonnet
front
front door
front wing
sliding side door
front door
sliding side door
stone shield
tailgate or hinged door
side impact
rear impact
tailgate or hinged door
With panelwork operations

Basic operations
first degree
(second degree)
front impact
Radiator cross
member mounting
Front end side cross
member
Front side member
assembly
Scuttle side panel
upper reinforcement
Partial scuttle side panel, front

section
Wheel arch, front section
Front side member, partial front
section
Front side member closure panel
Engine support
Bonnet caliper mounting
Front sub-frame rear mounting
Front side member, complete front

section
Wheel arch, complete
Bulkhead
Front door panel

A-pillar with
reinforcement
Cab C-pillar with
reinforcement
Cab side with
reinforcements
Cab sill panel
Cab roof
Windscreen pillar reinforcement

A-pillar reinforcement
Scuttle side panel upper
reinforcement
Double seal support
Roof front cross members
Roof front cross members
side impact
03B-3
vnx.su
A-pillar lining
Cab C-pillar lining
Sill panel lining
Windscreen aperture pillar lining
Rear screen aperture lower cross
member
Bulkhead
Cab floor
Foot panel
Front side member assembly
COLLISION
03
rear impact
rear side
Side door panel

Front side panel
Rear side panel
Load area roof
B-pillar reinforcement.
Outer rear wheel arch
Rear panel
Lining extension
Upper rail
rear
Rear skirt
Rear door panel
Rear roof
Partial rear floor

Rear end cross member
Rear shock absorber mounting unit
Wing panel
Partial lights support
Partial rain channel
Partial rear panel lining
Partial centre roof
Rear side member, rear section

Rear floor cross member
Rear side member, rear section
03B-4
vnx.su
Inner wheel arch

Panel lining
Complete side member
Rear floor unit
Load floor
Rear axle assembly mounting unit
Side door runner housing
Rear side cross member
COLLISION
1
2
3
4
FRONT
CENTRE
REAR SIDE
REAR
03B-5
vnx.su
03
COLLISION
REAR IMPACT
BASIC OPERATION
ADDITIONAL OPERATIONS (FIRST DEGREE)
03B-6
vnx.su
03
COLLISION
03
ADDITIONAL OPERATIONS (SECOND DEGREE)
SIDE IMPACT
BASIC OPERATION - SIDE IMPACT
AB
CD
BD
DE
03B-7
vnx.su
cutting A-pillar
cutting sill panel below door
cutting sill panel, centre section
cutting B-pillar
COLLISION
03B-8
vnx.su
03
COLLISION
REAR SIDE IMPACT
BASIC OPERATION
ADDITIONAL OPERATIONS (FIRST DEGREE) - REAR SIDE IMPACT
03B-9
vnx.su
03
COLLISION
REAR IMPACT
BASIC OPERATION
03B-10
vnx.su
03
COLLISION
03B-11
vnx.su
03
COLLISION
Rebuilding sub-frame
PARTS REQUIRING A STRAIGHTENING PLATE
03B-12
vnx.su
03
COLLISION
03
POSITIONING REFERENCE POINTS

1 - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE ATTITUDE
A - FRONT SUB-FRAME REAR MOUNTING
This is the main front reference point for setting the
vehicle attitude.
2 - Front mechanical components in place
1 - Front mechanical components removed
The bracket covers the sub-frame mounting bolt.
NOTE:
On the left-hand side the hole is round,on the righthand side it is a slot.
If replacing the sub-frame rear support, this reference
point is replaced temporarily by point (G), located on
the rear part of the front side member, point (A) thus
being used for positioning the replaced part.
Two possible cases can arise:

1 If the rear of the vehicle is being rebuilt, these two
points alone may be used to align and support the
front of the vehicle.
2 For a light frontal impact not requiring removal of the
front axle sub-frame.
IMPORTANT:
If in doubt about the damage to one of the main
reference points (A or B), it is nevertheless advisable
to use the two additional points located in the area not
affected by the impact to confirm the trim level.
03B-13
vnx.su
COLLISION
03
B - REAR AXLE FRONT MOUNTING

This is the main rear reference point for setting the
attitude.
1 - Rear mechanical components removed
2 - Rear mechanical components in place
The bracket is bound into the rear axle mounting fork

(B2') or centred in the axle pilot hole (B1').
The bracket is supported under the rear side member,

centred in the axle pilot hole and covers the rear axle
tie-rod mounting bolt.
If replacing the complete rear side member or the rear

floor unit, this reference point is replaced by point (G)
(see the previous page), located on the front side
member, points (B) being used to position the replaced
component.
03B-14
vnx.su
COLLISION
03
2. ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE ATTITUDE

These are the provisional reference points which are
used when the principle reference points have been
These points allow additional vehicle support to the
main reference point on the impact side, but allow only
a roughly accurate vehicle alignment.
This point is also used as a positioning reference when

replacing a rear section of the front side member.
NOTE:
The tie-rod (1) must be removed to access the hole.
IMPORTANT:
These reference points should only be used in the
cases mentioned above. They are not required when
both the main reference points (points A and B) are
correct.
This additional reference function may also be fulfilled
by the front side member end check points for a rear
impact and vice versa.
G - REAR END OF FRONT SIDE MEMBER
03B-15
vnx.su
COLLISION
03
3.REFERENCE POINTS FOR POSITIONING REPLACED PARTS

C - FRONT SUB-FRAME FRONT MOUNTING
E - REAR SHOCK ABSORBER MOUNTING
The bracket is centred and attached inside the subframe mounting hole.
The bracket is centred and attached inside the shock

absorber shaft.
Use it when replacing part of or a complete front side

member.

member.
03B-16
vnx.su
COLLISION
03
F - FRONT SHOCK ABSORBER UPPER

MOUNTING
J - REAR SIDE MEMBER END
The bracket rests under the shock absorber cup and is

centred in the shock absorber mounting hole.
The bracket rests under the side member and is

centred in the pilot hole.
Use it when replacing the wheel arch.
It can only be used to realign the side member when

the mechanical components are in place, but the
shock absorber has to be removed for this operation.
It is also used with the mechanical parts removed, in
the same conditions, to replace the side member.
03B-17
vnx.su
COLLISION
L - REAR END CROSS MEMBER
03
N - REAR AXLE SIDE TIE-ROD MOUNTING
The bracket rests under the shock absorber mounting

unit and is then centred in the towing hitch mounting
holes.
It is used for replacing the rear end panel assembly,
with or without mechanical components.
03B-18
The bracket is centred in the rear axle side tie-rod

shaft.
It is used when replacing:
a partial or complete front side member,
the tie-rod attachment.
vnx.su
COLLISION
03
P - ENGINE MOUNTING
R - ENGINE TIE-ROD MOUNTING
The bracket is positioned from above the engine

mounting and is centred in the mounting holes of the
pad.
The bracket is placed in the tie-rod yoke, and is fixed in

place of the latter.
It should be used with the mechanical components

removed to replace a front half unit.
03B-19
It is used for setting up the geometrical reference for

the tie-rod yoke.
vnx.su
PAINTWORK
104
Protection of hollow body parts
04
The hollow body parts of the structure of the vehicle

are protected in the factory by injecting hot wax. To
provide an equivalent level of protection after repair,
two additional products must be injected in turn,
available in the "PAC 1, PAC 2" kit.
After injection, all the orifices must be covered using
blanking covers moulded to fit each one.
The products and equipment required for carrying out
this work are available from the Replacement Parts
Central Store:
Product: 77 11 170 744
The blanking covers are available from the Parts
Department.
Equipment: nozzle assembly 77 11 172 528

empty cartridge: 77 11 172 625
04E-1
vnx.su
PAINTWORK
Underbody protection
In addition, the under-floor sub-frame is sprayed with a
special wax: 77 11 172529.
04E-2
vnx.su
04
EQUIPMENT AND
TOOLING
105
Repair bench
05B-1
vnx.su
05

Repair bench
05B-2
vnx.su
05

Repair bench
CELETTE
Supplier parts
Special heads for MZ System
Order from:
CELETTE S.A.
B.P.9
38026 VIENNE (France)
BLACKHAWK
Special heads for MS System
Order from:
BLACKHAWK
Centre Eurofret
Rue de Rheinfeld
67100 STRASBOURG (France)
05B-3
vnx.su
05
GENERAL INFORMATION
140
Procedure symbols
40
These pages cover the changes made to the detailed description of the procedures.
Fundamental repair rules
As a general rule, when replacing a welded bodywork part, the repair must be identical to the original as regards
both the number of weld points and the type of welding used, for reasons of appearance and safety.
If this is not feasible, the replacement solutions will be shown in the repair steps described in the manuals.
These solutions ensure that the repairs have the required mechanical strength and release the repairer from liability.
Consequently, the repair steps will only describe the special welding characteristics which differ from the original,
and the electrical resistance spot welds will not be shown on the drawings.
Most frequently encountered cases when replacing an electrical resistance weld:
1 Plug welding
2 Bead
3 Gluing
4 Riveting
The following will also be shown where necessary:
the tools and equipment used for the operations,
the cross sections of the specific panels requiring an explanation,
the dimensions for positioning certain components,
the location of the cutting lines for partial replacements,
the location of the gluing areas specific to the repair.
IMPORTANT:
when a part is symmetrical (left and right sides are identical), the repair procedure will only describe the procedure
for one side (example: rear floor).
This means that the operations for the other side are the same (number of spot welds, etc.), unless specific
indications to the contrary are given.
The repair steps are carried out on sheet bodies without doors and without mastic.
In the document, the drawings illustrate the replacement of the various parts as clearly as possibly following a typical
impact described in each introduction.
However, some drawings do not follow this rule, in order to display the replaced part more clearly.
40-1
vnx.su
GENERAL INFORMATION
140
Using symbols
40
Example of use of symbols in a part replacement operation

Explanations are shown in italics
UPPER FRONT STRUCTURE

42
The replacement of this part is a complementary operation to the replacement of a scuttle side panel following a side
impact.
This implies that there is a basic operation associated with the replacement of this part, in which the
preliminary operations will be included.
Hence the following phrases:
In the procedure described below, you will only find the descriptions and the joints which are specific to the part
concerned.
The information on the additional parts will be dealt with in their respective chapters (refer to contents).
COMPOSITION OF THE REPLACEMENT PART
Part supplied on its own.
PARTS CONCERNED (thickness in mm):

1
2
3

Front side member closure panel
Wheel arch
0.8
1.5/2.5
2
In the detailed procedure descriptions, where two panel thicknesses are shown for the same part, this
means that the part consists of two original butt welded panels.
Thicknesses are represented from the outside edge of the part going towards the vehicle passenger
compartment (direction of the impact).
40-2
vnx.su
GENERAL INFORMATION
Using symbols
40
L25
"L25" indicates the length in millimetres of the

welding bead required for the connection
concerned.
If several beads are required, the number of beads
is given before the length of the weld.
Where no number is given, only one weld is
required.
For partial replacement using dimpling, the
spacing is given in the introduction.
X3
"X3" specifies the number of spot welds required

for the attachment concerned.
REMINDER:
the connection between the wheel arch and the
shock absorber cup is not shown as the welds to
be made are identical to those made during
manufacture (and are therefore accessible with the
spot welder)
40-3
vnx.su
GENERAL INFORMATION
Using symbols
40
10
" 10" shows the drilling diameter in millimetres, if

necessary, to be used for the relevant connection.
X6
40-4
vnx.su
GENERAL INFORMATION
Key to the symbols used in the document
40
Chisel
Crimping of exterior door panels.
Grind back beads or spot welds. Straight

grinding wheel with 75 bakelite disc,
thickness 1.8 to 3.2 mm.
Lead filler
Hot air torch.
Nozzle output temperature minimum.
600 C Handle + 33% tin solder + tallow
Note: to a large extent, body solder filling
compensates for heat distortion caused
by welding.
Grind back spot welds.

20 000 rpm straight grinder with 10 or 16
mm milling cutter.
Application of weldable mastic.

This mastic is an electrical conductor
which is inserted between two sheets to
be spot welded. It seals the sheets and
prevents corrosion of the spot welds.
Drill the spot welds.

Hardened steel bit.
Speed of rotation 800 to 1000 rpm.
Drill < 8 mm.
Steel drill bit.
Application of aluminium paint.

This is to be applied to the joint faces of
each of the parts to be plug welded. This
paint is conductive and can withstand high
temperatures; it gives anti-corrosion
protection around welds.
Drill > 8 mm.

Tapered mill.
Apply a bead of extruded mastic

Manual or pneumatic spray gun.
One or two-pot mastic for crimped and
butt joints.
Cutting with a saw.

Pneumatic power hacksaw.
Apply mastic by spraying

Spray gun
Dual component anti-chipping and anticorrosion mastic.
Cut out part by grinding off flange or

grinding back remaining traces of spot
weld. Finish surface after welding.
Angle grinder fitted with a rubber pad and a
120 to 180 mm P36 grain fibre disc
Apply a bead of extruded adhesive mastic

Manual or pneumatic spray gun.
Adhesive mastic in one or two parts
Unsoldering
Thermal cleaning of extruded or spray

mastics
MAG stitch welding

Note: for good quality welding, it is
recommended that a gas composed of
Argon + 15% CO2, which is considered to
be an active gas, is used (MAG)
Resistance spot welding
Plug welding with MAG protective gas.
40-5
vnx.su
GENERAL INFORMATION
Tooling
INTRODUCTION
The Car. 1504 tool is used to fit the following inserts:
Nuts
Studs
EM4
part no. 77 01 047 924
EM5
part no. 77 01 047 685
EM6
part no. 77 03 043 020
EM8
part no. 77 01 047 925
GM6
part no. 77 01 047 926
GM5.2
part no. 77 01 047 927
Below you will find the repair methods allowing you to

fit the different inserts.
40-6
vnx.su
40
GENERAL INFORMATION
Tooling
COMPOSITION OF Car. 1504
Parts Store reference:
40-7
vnx.su
40
GENERAL INFORMATION
Tooling
40
NAME
DESCRIPTION
DRILL
DIAMETER
PART
NUMBER
ADAPTED
ANVIL
ADAPTED
TIE-ROD
Nuts
EM4
EM5
EM6
EM8
6. mm
7.1 mm
9.1 mm
11.1 mm
77 01 047 924
77 01 047 685
77 03 043 020
77 01 047 925
EM4
EM5
EM6
EM8
EM4
EM5
EM6
EM8
Studs:
"non-standard"
"non-coated"
GM6
GM5.2
9.2 mm
7.4 mm
77 01 047 926
77 01 047 927
G
G
GM9
GM5.2
Special nut
EMS6
9.2 mm
77 03 043 083
ES
ES
+ strut
Tie-rod mounting
Body
40-8
vnx.su
GENERAL INFORMATION
Tooling
40-9
vnx.su
40
GENERAL INFORMATION
Tooling
1
2
3
4
5
6
7
8
9
40
Tie-rod mounting
Tie-rods
Tightening nut
Body
Anvils
Special nut
Nuts
Studs
Thrust nut
PREPARATION OF Car. 1504

Select the assembly (tie-rod, anvil and insert) adapted for the crimping to be performed.
Screw the tie-rod (2) into the tie-rod mounting (1) (left-hand thread).
Tighten the nut (3) fully against the body (4) (left-hand thread).
Screw the anvil (5) into the body (4) (left-hand thread).
Insert the assembly (1) and (2) into the body of the tool.
Screw the insert (right-hand thread) on to the pulling rod.
NOTE:
To fit the special nut (6), the tie-rod passes through the crimping nut and is screwed to the thrust nut (9).
After drilling and stripping the sheets, an anticorrosion protection operation will be necessary before painting. The
anticorrosion protection should be applied using the following products:
1 Pre-treatment primer 77 01 423 933

Reactive solvent
77 01 423 955
2 Primer (maxima)
77 11 170 344
40-10
vnx.su
GENERAL INFORMATION
Tooling
USING THE TOOL
While holding the body (4), turn the tightening nut (3)
in the direction of the arrow shown in the drawing
above.
Completion of the crimping operation

should be felt by the operator (increase
in the tightening effort).
Crimping of the insert is correct when it no longer has

any rotational play, this should be checked before
removing the tool.
NOTE:
This checking procedure must be performed before
unscrewing the pulling rod/tie assembly.
40-11
vnx.su
40
GENERAL INFORMATION
Electrical and electronic layout
FRONT UNIT
40-12
vnx.su
40
GENERAL INFORMATION
FRONT LEFT SIDE DOOR
40-13
vnx.su
40
GENERAL INFORMATION
FRONT RIGHT SIDE DOOR
40-14
vnx.su
40
GENERAL INFORMATION
CAB REAR PILLAR
40-15
vnx.su
40
GENERAL INFORMATION
RIGHT HAND BODY SIDE
40-16
vnx.su
40
GENERAL INFORMATION
LEFT HAND BODY SIDE
40-17
vnx.su
40
GENERAL INFORMATION
TAILGATE
40-18
vnx.su
40
GENERAL INFORMATION
REAR LOADING DOORS
40-19
vnx.su
40
GENERAL INFORMATION
LOWER STRUCTURE
NOTE:
All the panels have to undergo electro-galvanisation in different areas.
High Elastic Limit Steel
Ultra High Elastic Limit Steel
40-20
vnx.su
40
GENERAL INFORMATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Radiator support cross member (41 B)

Front end lower cross member (41 A)
Front end side cross member (41 D)
Radiator cross member support (41 C)
Front side member closure panel (front section) (41 F)
Front side member (41 G)
Front section of front side member (41 E)
Front sub-frame rear mounting (41 I)
Engine mounting stiffener (41 H)
Front section of front side member rear reinforcement (41 J)
Cab floor stiffener (41 X)
Cab floor front cross member (41 W)
Front jack support (41 O)
Cab floor (41 V)
Front seat mounting reinforcement (41 Z)
Front cross member under front seat (41 Y)
Sleeve stop (41 AF)
Handbrake lever mounting stiffener (41 AE)
Rear floor front cross member lining (41 AD)
Front side foot panel (41 P)
Inner sill panel (41 M)
Cab sill panel (41 K)
Rear floor, front section (41 AB)
Front cross member of rear floor, front section (41 AC)
Rear floor front cross member (41 AK)
Rear side foot panel (41 AA)
Rear seat mounting transversal reinforcement (41 AJ)
Rear floor middle cross member bracket (41 AL)
Exhaust mounting support (41 AH)
Front section of rear side member (41 AG)
Front side foot panel rear closure panel (41 Q)
Inner sill panel reinforcement (41 R)
Runner housing (41 S)
Rear floor side cross member (41 T)
Rear axle mounting front housing (41 U)
Rear side door under sill panel (41 L)
Rear axle side tie-rod attachment (41 AI)
Rear floor, rear section (41 AS)
Rear end lower cross member (41 AU)
Rear floor rear cross member (41 AR)
Rear towing ring (41 AP)
Rear end lower cross member side closure panel (41 AT)
Rear shock absorber attachment (41 AQ)
Rear seat mounting bracket (41 AM)
Rear side member (41 AN)
Rear floor lengthways reinforcement (41 AO)
Rear inner sill panel (41 N)
40-21
vnx.su
40
GENERAL INFORMATION
UPPER STRUCTURE
High Elastic Limit Steel
40-22
vnx.su
40
GENERAL INFORMATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Front (42 C)
Front section of front right wheel arch (42 I)
Front right wheel arch (42 J)
Front section of front left wheel arch (42 I)
Front left wheel arch (42 J)
Front side mounting (42 D)
Front wing lower attachment mounting (42 B)
Scuttle side panel (42 F)
Scuttle side panel upper reinforcement (42 E)
Cab A-pillar reinforcement (43 C)
Cab A-pillar closure panel (43 B)
Front wing (42 A)
Bulkhead (42 M)
Windscreen aperture lower cross member (42 K)
Windscreen aperture lower cross member reinforcement (42 L)
Tailgate torque links support (42 G)
Bonnet release control mounting (42 H)
Windscreen pillar lining (43 D)
Front double seal support (43 A)
Windscreen pillar lining reinforcement (43 E)
Cab side (43 I)
Cab roof front cross member (45 E)
Cab C-pillar lining (43 H)
Front section of side panel lower lining (44 C)
Front section of rear side panel lining (44 A)
Rear B-pillar (44 E)
Cab roof (45 A)
Roof (45 B)
Cab roof rear cross member (45 F)
Inner rear wheel arch (44 I)
Front section of side panel upper lining (44 B)
Rear roof drip moulding lining (44 H)
Rear rail (44 G)
Rear section of rear side panel lining (44 F)
Rear side panel lining, rear section (44 D)
Rack mounting bridge piece (45 D)
Rear section of rear roof (45 C)
Roof central cross member (45 G)
Rear side panel rain channel (45 H)
Roof rear cross member lining (45 J)
Rear roof rear cross member (45 I)
Rear bumper support cross member (44 N)
Rear end panel (44 M)
Rear side panel rain channel, rear section (44 K)
C-pillar (44 J)
Gas strut ball joint (44 L)
40-23
vnx.su
40
GENERAL INFORMATION
OPENING ELEMENTS STRUCTURE
1
2
3
4
5
6
7
8
9
10
Bonnet (48 A)
Front side door (47 A)
Front side door panel stiffener (47 C)
Front side door panel (48 A)
Fuel filler flap (47 D)
Sliding side door (47 E)
Sliding side door panel (47 F)
Tailgate (48 A)
Rear loading door (48 C)
Rear loading door panel (48 D)
40-24
vnx.su
40
GENERAL INFORMATION
Opening clearances
IMPORTANT:
The clearance values are given for information with their tolerance values.
During adjustment, it is essential to follow certain rules in sequence:
maintain symmetry with respect to the opposite side,
ensure even door gaps and flushness,
check correct operation of the opening, and water- and airtightness.
40-25
vnx.su
40
GENERAL INFORMATION
Opening clearances
40-26
vnx.su
40
GENERAL INFORMATION
Opening clearances
40-27
vnx.su
40
GENERAL INFORMATION
Opening clearances
The measurement is made in the outer corner of the

two doors.
40-28
vnx.su
40
GENERAL INFORMATION
Opening clearances
40-29
vnx.su
40
GENERAL INFORMATION
Opening clearances
40-30
vnx.su
40
GENERAL INFORMATION
Opening clearances
40-31
vnx.su
40
GENERAL INFORMATION
Opening clearances
40-32
vnx.su
40
GENERAL INFORMATION
Impact fault finding
40
Before carrying out repairs to the bodywork of a car, even if the damage seems slight, it is necessary to carry out a
series of tests:
VISUAL INSPECTION
This inspection involves examining the sub-frame of the vehicle where mechanical components are mounted and in
the crumple zones or vulnerable areas in order to detect creases where materials have been damaged.
TRAMMEL GAUGE CHECK
The visual inspection may be completed using a trammel gauge which measures certain deformations by
symmetrical comparisons (for more detail on each point to check, see the repair bench paragraph below).
CHECKING THE ANGLES OF THE RUNNING GEAR
This is the only check which determines whether the impact suffered by the vehicle has or has not affected its road
holding.
IMPORTANT:
In borderline cases, it is essential not to neglect checking the axle assembly components which may also have been
subject to deformation.
In principle, no welded component in the body shell may be replaced without ensuring that the sub-frame was not
Chronological order of checks:

FRONT impact:
1: B1 - A1' = B1' - A1
2: A1' - H = A1 - H'
REAR impact:
1: A1' - B1 = A1 - B1'
2: B1' - L2 = B1 - L2'
40-33
vnx.su
GENERAL INFORMATION
40
GAUGE POINTS
Point A1'
Front body reference. Start reference point for checking
points (H) and (H').
Point B1'
Rear axle assembly leader pin. Start reference point for
checking points (L2) and (L2').
Point H'
Front end of front side member.
Point L2'
Rear end of rear side member.
40-34
vnx.su
GENERAL INFORMATION
REMINDER
The underbody holes are fitted with plastic blanking
covers to ensure that all cavities are watertight.
Some of these blanking covers have to be removed
during testing.
If any of the blanking covers are damaged, they must
be replaced in order to maintain the vehicle's anticorrosion warranty.
40-35
vnx.su
40
GENERAL INFORMATION
Sub-frame dimensions
DESCRIPTION
DIMENSI
DIMENSI
DIMENSI
40
DIAMETER
ANGLE%
Front sub-frame rear mounting G
390.2
-337
70
24.5; M12
A'
Front sub-frame rear mounting D
390.2
337
70
24.5 x 30; M12
B1
Rear axle leader pin
2321.2*
516
176
20.5
B2
Rear axle assembly front mounting
2441*
654
70
12.5
Front sub-frame front mounting
91.6
432.8
275
18.5
Rear shock absorber upper mounting
3575*
465
235
14.5
90
Front shock absorber upper mounting (on

the lowest section of the fallen edge)
42.7
614
790.3
42
x = 330'
y = 3
Front side member rear leader pin
1240
516
174
14.5; M12
Front side member front leader pin
543.4
528.4
96.3
12.2; M10
Rear side member rear leader pin
3466*
516
203
30 x 30
K1

mounting)
570
590.4
331.6
M8
90
K2

mounting)
570
466.4
331.6
M8
90
L1
3685*
516
144
14.5; M10
L2
3740.5*
516
144
14.5; M10
P1
Engine mounting
301.4
535
534.6
12.2; M10
P2
Engine mounting
146.4
513
534.6
12.2; M10
Additional engine mounting (tie-rod)
22.9
458.1
631.5
12.2
Additional rear axle mounting (side tie-rod)
2933*
455
59
12.2
90
A and B = vehicle trim-setting reference

* Add 400 mm for the L2 version
40-36
vnx.su
GENERAL INFORMATION
Rebuilding of sub-frame
40
POSITIONING REFERENCE POINTS

1 - PRINCIPLE REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL
A - FRONT SUB-FRAME REAR MOUNTING
This is the main front reference point for setting the
vehicle trim level.
2 - Front mechanical components in place
1 - Front mechanical components removed
The bracket covers the sub-frame mounting bolt.
NOTE:
on the left-hand side the hole is round, on the righthand side it is a slot.
Two possible cases can arise:

1 If the rear of the vehicle is being rebuilt, these two
points alone may be used to align and support the
2 For a light frontal impact not requiring removal of the
front axle sub-frame.
If replacing the sub-frame rear support, this reference

point is replaced temporarily by point (G), located on
the rear part of the front side member, point (A) thus
being used for positioning the replaced part.
IMPORTANT:
If in doubt about the damage to one of the main
reference points (A or B), it is nevertheless advisable
to use the two additional points located in the area not
affected by the impact to confirm the trim level.
40-37
vnx.su
GENERAL INFORMATION
40
B - REAR AXLE FRONT MOUNTING

This is the main rear reference point for setting the trim
level.
1 - Rear mechanical components removed
2 - Rear mechanical components in place
The bracket is bound into the rear axle mounting fork

(B2') or centred in the axle pilot hole (B1').
The bracket is supported under the rear side member,

centred in the axle pilot hole and covers the rear axle
tie-rod mounting bolt.
If the complete rear side member is being replaced,

this reference point is replaced by point (G), located on
the rear section of the front side member, point (B)
being used to position the replaced component.
40-38
vnx.su
GENERAL INFORMATION
40
2. ADDITIONAL REFERENCE POINTS FOR SETTING VEHICLE TRIM LEVEL

These are the provisional reference points which are
used when the principle reference points have been
This point is also used as a positioning reference when

replacing a rear section of the front side member.
NOTE:
The tie-rod (1) must be removed to access the hole.
These points allow additional vehicle support to the

main reference point on the impact side, but allow only
a roughly accurate vehicle alignment.
IMPORTANT:
These reference points should only be used in the
cases mentioned above. They are not required when
both the main reference points (points A and B) are
correct.
This additional reference function may also be fulfilled
by the front side member end check points for a rear
impact and vice versa.
G - REAR END OF FRONT SIDE MEMBER
40-39
vnx.su
GENERAL INFORMATION
40
3. REFERENCE POINTS FOR POSITIONING REPLACED PARTS

C - FRONT SUB-FRAME FRONT MOUNTING
E - REAR SHOCK ABSORBER MOUNTING
The bracket is centred and attached inside the subframe mounting hole.
The bracket is centred and attached inside the shock

absorber shaft.

member.

member.
40-40
vnx.su
GENERAL INFORMATION
40
F - FRONT SHOCK ABSORBER UPPER

MOUNTING
J - REAR SIDE MEMBER END
The bracket rests under the shock absorber cup and is

centred in the shock absorber mounting hole.
The bracket rests under the side member and is

centred in the pilot hole.
Use it when replacing the wheel arch.
It can only be used to realign the side member when

the mechanical components are in place, but the
shock absorber has to be removed for this operation.
It is also used with the mechanical parts removed, in
the same conditions, to replace the side member.
40-41
vnx.su
GENERAL INFORMATION
L - REAR END CROSS MEMBER
40
N - REAR AXLE SIDE TIE-ROD MOUNTING
The bracket is centred in the rear axle side tie-rod

shaft.
The bracket rests under the shock absorber mounting

unit and is then centred in the towing hitch mounting
holes.
It is used when replacing:

a partial or complete front side member,
the tie-rod attachment.
It is used for replacing the rear end panel assembly,

with or without mechanical components.
40-42
vnx.su
GENERAL INFORMATION
40
P - ENGINE MOUNTING
R - ENGINE TIE-ROD MOUNTING
The bracket is positioned from above the engine

mounting and is centred in the mounting holes of the
pad.
The bracket is placed in the tie-rod fork, and is fixed in

place of the latter.
It is used for setting up the geometrical reference for
the tie-rod fork.
It should be used with the mechanical components

removed to replace a front half unit.
40-43
vnx.su
GENERAL INFORMATION
Celette sheet
40-44
vnx.su
40
GENERAL INFORMATION
40-45
vnx.su
40
GENERAL INFORMATION
4. SPECIAL TOOLING PART NUMBERS
CELETTE
Vendor-supplied parts
Special heads for MZ System
Order from:
CELETTE S.A.
B.P.9
38026 VIENNE (France)
BLACKHAWK
Vendor-supplied parts
Special heads for MS System
Order from:
BLACKHAWK
Centre Eurofret
Rue de Rheinsfeld
67100 STRASBOURG (France)
40-46
vnx.su
40
LOWER STRUCTURE
141
Front end lower cross member
The replacement of this part is a basic operation for a
frontal impact.
41

Cross member bolt
The door is a removable component.
4.4
In the procedure described below, you will only find

descriptions of the connections which are specific to
the part concerned.
The information on the additional parts will be dealt
with in the respective sections (refer to contents).
NOTE:
When replacing the cross member only, a bead of
M.J. Pro type mastic (part no.: 77 11 172 676) must
be applied at the interface with the side member in
order to ensure anti-corrosion protection of the
coupling. The part supplied by the Spare Parts Dept is
black and does not need painting when fitted.
REMOVAL
Part supplied with:

Front cross member
Shock absorbing pads
Towing ring mounting
Threaded ring
Towing ring mounting reinforcement
Closure panel component.
Nuts
Removal is by way of the mounting bolts (A) (four on

each side).
REFITTING
If the operation is performed with the engine in place,
it will be necessary to ease the engine away from its
support points in order to replace the cross member
bolts.
IMPORTANT:
the cross member contributes to the rigidity of the
engine compartment structure. Therefore, after any
work on it, it is essential to tighten mounting bolts (A)
to the correct torque values.
41-1
vnx.su
LOWER STRUCTURE
Radiator mounting cross member
The replacement of this part is a additional operation
to the replacement of the front end lower cross
member following a frontal impact.
41
A
B

Cross member bolt
2.2

the part concerned.
REMOVAL - REFITTING
The removal is carried out by undoing mounting bolts
(A) after having released the mechanical components
(radiator, etc).
41-2
vnx.su
LOWER STRUCTURE
Radiator cross member mounting
frontal impact.
Complete replacement
There are two procedures for carrying out this

operation:
complete,
partial, using cut A.
the part concerned.
Part assembled with:
Closure panel component
Towing ring (right-hand side)

1
2
3

Front side member
Front end side cross member
2
2.5
1.5
41-3
vnx.su
41
A
C
LOWER STRUCTURE
Partial replacement
X3
41-4
vnx.su
41
A
C
LOWER STRUCTURE
frontal impact.
the part concerned.
NOTE:
The right-hand part has a different shape but the
procedure is the same.

1
2
3

Front wheel arch, front section
Scuttle side panel
1.5
1
1
on the vehicle
41-5
vnx.su
41
A
D
LOWER STRUCTURE
Front side member, front section
41
A
E
The replacement of this part is a complementary

operation to the support of the radiator cross member
for a frontal impact.
operation:
partial, using cut A,
partial, using cut B.
IMPORTANT:
The use of the body jig bench is essential except for
the partial replacement along cut A.
In the following procedure you will only find the special
notes for cuts.

1

Side member reinforcement
Engine mounting pad spacer
Welded spacer
Cup spacer angle bracket (left-hand side)
Mounting pads (left-hand side)
41-6
vnx.su
2.5
LOWER STRUCTURE
Replace cut A
41
A
E
Partial replacement using cut B
IMPORTANT:
The cut is made in area X2.
NOTE:
It is possible to make the cut under the engine mounting
stiffener, but in this case it will be necessary to unclip it
to make the work easier. For this reason it is
recommended that you order an additional new
stiffener.
The welds of the stiffener on the side member will be
plug welds.
NOTE:
This operation can be carried out without using the
repair bench.
The front end lower cross member can be used as a
gauge for aligning the replaced section.
IMPORTANT:
The cut is made in area X1, but must never be
located on a guide hole or on a crumple zone.
41-7
vnx.su
LOWER STRUCTURE
Front section of front side member closure panel
41
A
F
The replacement of this part is connected to the partial

replacement of the front side member front section.
This operation is additional to the support of the
radiator cross member for a frontal impact and to the
front wheel arch front section for a front side impact.
Partial replacement can be performed using cut A.
NOTE:
The complete replacement of this part is possible, this
being additional to the replacement of the side
member front section, you will find the procedure for
replacement described in that for the replacement of
the front side member.
IMPORTANT:
In the event that side member and its closure panel are
simultaneously partially replaced, the cuts for each
part will have to be offset in order to avoid creating
a weakened area.

1
This operation can be carried out without using the

repair bench.
The front end lower cross member can be used as a
guide for aligning the replaced section.
You will only find the descriptions and the joints which
are specific to the part concerned.
Front end side cross member angle bracket
Mounting pads
Brake pipe angle bracket
Welded studs
41-8
vnx.su
Front section of front side member

closure panel
2.5
LOWER STRUCTURE
Front section of front side member closure panel
Partial replacement
IMPORTANT:
The cut is made in area X1, but must never be
located on a guide hole or on a crumple zone.
41-9
vnx.su
41
A
F
LOWER STRUCTURE
Front side member
41 G
A

frontal impact.
The repair bench must be used.
It will be necessary to unfasten several additional
components to be able to remove the complete side
member:
cab floor partially,
side section of cab floor front cross member,
front section of front side member rear stiffener,
front sub-frame rear mounting.
operation:
complete,
partial, front section only. The rear section must be
released from the replacement part.

1
2
3
4
5
NOTE:
descriptions of and joins involved in the partial
replacement at the fitting of the side member with the
passenger compartment.
Mounting pad
Spacer angle bracket
Sub-frame rear mounting
Sub-frame rear interior mounting
Side member front section
Side member closure panel
Side bracket
Pipe angle bracket
Inner reinforcement
Radiator cross member mounting closure panel
Towing ring (right-hand side)
Engine mounting stiffener (right-hand side)
Welded studs
Sub-frame mounting spacer
Welded nuts
41-10
vnx.su
Front side member

Front side member, rear section
Jack support
Cab floor front cross member
Front side member stiffener, rear section
2.5
2
1.2
1.5
1
LOWER STRUCTURE
Front side member
41 G
A
L40 X2
10
X2
L40 X2
10
X17
X2
41-11
vnx.su
LOWER STRUCTURE
Front side member
41 G
A
X4
10
X2
10
X2
10
X2
41-12
vnx.su
LOWER STRUCTURE
Front side member
41 G
A
10
X2
X2
41-13
vnx.su
LOWER STRUCTURE
Front side member
41 G
A
X17
Diagram for information

NOTE:
The complete replacement of the side member
requires the rear section of the front side member to
be unclipped.
IMPORTANT:
The weight of the side member is considerable
(assembly of very thick panels).
Take the necessary precautions for removing/refitting
operations.
41-14
vnx.su
LOWER STRUCTURE
Engine mounting reinforcement
41
A
H
The replacement of this part is an additional operation

to the front wheel arch front section or to the half unit
for a frontal impact.
The body jig bench must be used.
In the procedure described below, you will only find the
descriptions and the joints which are specific to the
part concerned.
NOTE:
The spot welds on the side member and the
suspension turret must be carried out with plug welds.
41-15
vnx.su
LOWER STRUCTURE
The replacement of this part is an operation linked to
the replacement of the front sub-frame for a frontal
impact to the wheel.
41
AI

operation:
complete,
part concerned.
Inner support
Mounting pad
NOTE:
The complete replacement requires partial unpicking
of the part as indicated above to enable access to the
two points G.

1
2
3
4

1.5
1.5
2.5
2
X2
NOTE:
All the remaining welds must be plug welds.
41-16
vnx.su
LOWER STRUCTURE
41
Partial replacement
L40 X2
X2
41-17
vnx.su
AI
LOWER STRUCTURE
X3
41
X6
NOTE:
Welds B, C and D should be made on both sides.
X3
X2
41-18
vnx.su
AI
LOWER STRUCTURE
NOTE:
X1 = 40 mm
WARNING:
Keep section 1 when making the cut.
41-19
vnx.su
41
AI
LOWER STRUCTURE
Front section of front side member rear reinforcement
41
The replacement of this part is an operation

associated with the replacement of the front side
member for a frontal impact.
part concerned.
NOTE:
All the welding must be by plug welds.
41-20
vnx.su
LOWER STRUCTURE
Cab sill panel
41
A
K

side impact.
operation:
partial under the door, cutting out the section A-B,
partial, cutting out the section A-C.
IMPORTANT:
The sill panel should be cut on the cab side, the cut
sections given in the repair step may be offset
depending on the level of impact.
NOTE:
To carry out the partial operation alond cuts A-C, it will
also be necessary to order the pillar reinforcement
expanding insert.
part concerned.

1
2

Frame drip moulding
Striker stiffener.
Striker plate
Centring stiffener
Wing mounting angle bracket
Pillar reinforcement
Door stop reinforcement
Hinge reinforcement
Pillar upper frame
Pillar lower frame
Welded nuts
41-21
vnx.su
Sill panel
0.9
1.2
LOWER STRUCTURE
Cab sill panel
41
A
K
Partial replacement
IMPORTANT
When performing the cutting operation, take care not
to damage the pillar reinforcement (2).
In the case of even the slightest cut-out in the pillar
reinforcement, it must be re-welded before fitting the
new sill panel.
It will also be necessary to unfasten the pillar
reinforcement from the replacement part, before
refitting the sill panel on the vehicle.
NOTE:
Area X is empty.
41-22
vnx.su
LOWER STRUCTURE
Cab sill panel
Partial replacement under door
REMINDER
The expanding inserts react to temperature when the
body is immersed in the cataphoresis baths during
manufacture. During repairs, these conditions cannot
be reproduced, therefore when replacing an insert it will
be necessary to carry out the following operations in
order to ensure sealing and soundproofing of the
vehicle:
1 Clean the bonding surfaces with heptane
2 Seal the holes in the insert by cutting out a piece of
soundproofing pad (part no. 77 01 423 546)
3 Apply lining sealing mastic (2)
(part no. 77 01 423 330) to the periphery of the
insert (1).
4 Fit the insert by compressing the mastic.
41-23
vnx.su
41
LOWER STRUCTURE
Cab sill panel
41-24
vnx.su
41
A
K
LOWER STRUCTURE
Sill panel under rear side door
41
A
L

side impact.
Complete replacement is an additional operation when
replacing the rear panel, rear section, or cab C-pillar.
operation:
complete,
partial front or rear (using cut A).
NOTE:
The cut shown below may be offset depending on the
level of impact.
Complete replacement is not described in the repair
step.
If necessary, depending on the choice of cut, also

order the sill panel expanding insert.
1
2
3
4

part concerned.
Runner housing
Runner housing closure panel
Mounting angle bracket
Welded nuts
41-25
vnx.su
Sill panel under side door

Rear section of rear side panel
Cab C-pillar
Cab C-pillar lining
0.9
0.8
0.9
1
LOWER STRUCTURE
41
A
L
Partial replacement of the rear section
REMINDER
manufacture. During repairs, these conditions cannot
be reproduced, therefore when replacing an insert it will
be necessary to carry out the following operations in
order to ensure leaktightness and soundproofing of the
vehicle:
1 Clean the bonding surfaces with heptane.
soundproofing pad (part no. 77 01 423 546).
3 Apply lining sealing mastic (2)
(part no. 7701 423 330) to the periphery of the
insert (1).
X6
41-26
vnx.su
LOWER STRUCTURE
Partial front replacement
41
A
L
NOTE:
Fitting the replacement part requires moving aside the
cab pillar panel edge.
X7
41-27
vnx.su
LOWER STRUCTURE
Sill panel closure
This operation can be carried out partially in three
ways:
Partial - front section (along cut A),
Partial - centre section (along cut B),
Partial - rear section (along cut C).
41 M
A

Closure panel component.
Inner sill panel rear closure panel
Closure panel reinforcement (side with sliding
side door)
Welded nuts
Depending on the section replaced, this part is in

addition to:
the cab A-pillar reinforcement, cut (A) front section,
the cab C-pillar lining, cut (B) centre section,
the rear side panel lining, rear section, cut (C).
part concerned.
NOTE:
For standardisation reasons, the Parts Department will
only supply a single part corresponding to the long
wheelbase version.
For short versions, it will be necessary to cut the sill
panel closure panel and to weld the rear closure panel
(see repair step ) which must also be ordered.

1
This operation must be carried out before painting.
Sill panel closure
0.9
Adaptation for short versions
REMINDER:
For the short wheelbase versions, it will be necessary
to cut the sill panel closure panel as shown in the
diagram and to weld the sill panel rear closure
panel (1).
41-28
vnx.su
LOWER STRUCTURE
Sill panel closure
Partial front replacement
on replacement part
on the vehicle
on replacement part
X4
41-29
vnx.su
41 M
A
LOWER STRUCTURE
Sill panel closure
41 M
A
Partial replacement of the centre section
on replacement part
NOTE:
The operations are identical to those described in the
front section partial cut, only the position of the cut is
shown.
X4
Partial replacement of the rear section
on replacement part
NOTE:
In the rear section, the sill panel closure panel is
welded to the rear axle assembly mounting unit.
These welds can be made using electrical welding,
but the use of plug welds on the closure panel side
(zone E) is recommended instead.
on the vehicle
41-30
vnx.su
LOWER STRUCTURE
Inner sill panel rear closure panel
The replacement of this part is an operation
associated with replacement of a rear side panel lining,
front section.
The procedure for replacing this part has no special
procedures, and joints can all be made as originally.
Below is a view of the part in its correct position on the
vehicle, for information.
41-31
vnx.su
41
A
N
LOWER STRUCTURE
Front jack support
41 O
A

to the replacement of a sill panel for a front side
impact.
part concerned.
Jacking point stiffener

1
2
Front jack support

1.2
2
L30 X3
41-32
vnx.su
LOWER STRUCTURE
Front jack support
41-33
vnx.su
41 O
A
LOWER STRUCTURE
Front side foot panel
41

operation to the replacement of the inner sill panel for
a side impact.
part concerned.

1
2
3
4

Cab floor
Front jack support
Seat attachment mounting
0.8
0.8
1.2
2
X2
X2
41-34
vnx.su
A
P
LOWER STRUCTURE
Front side foot panel rear closure panel
a side impact.
NOTE:
There are no special notes for replacing this part, and
joints can all be made as originally. However, it is
possible to use plug welds at places which are difficult
for the spot welder to access.
Below is a view of the part in position, for information.
41-35
vnx.su
41 Q
LOWER STRUCTURE
Inner sill panel closure panel reinforcement
41

a side impact.
part concerned.

1
2
Inner sill panel closure panel

reinforcement
Rear side member, front section
1.5
1.5
X3
41-36
vnx.su
A
R
LOWER STRUCTURE
Runner housing
to the replacement of the sill panel for a front side
impact.
NOTE:
Below is a diagram of the part in position, for
information.
Closure panel
Housing mounting bridge piece
Welded nut
41-37
vnx.su
41
A
S
LOWER STRUCTURE
Rear floor side cross member
41

a side impact.
part concerned.

1
2
3

Rear axle mounting front unit
2
2
1.5
X4
41-38
vnx.su
A
T
LOWER STRUCTURE
X8
41
X3
X3
41-39
vnx.su
A
T
LOWER STRUCTURE
Rear axle mounting front unit
to the replacement of the sill panel for a front side
impact.
NOTE:
Below are diagrams of the part in its correct position on
the body, for information.
Mounting cross member
Connecting angle bracket
Mounting connecting arch
Brake cable flexible angle bracket
Jacking point stiffener
Outer bracket
Connecting flange
Reinforcement
41-40
vnx.su
41
A
U
LOWER STRUCTURE
Cab floor
to the replacement of a front side sill for a frontal side
impact or associated with the replacement of a front
side member.
41
A
V

1
Cab floor
0.8
Partial replacement using cut A
This operation can be carried out in several ways:

partial, using cut B,
or complete.
IMPORTANT:
The cut positions are given as indications, they can be
offset depending on the deformation due to impact.
descriptions and connections which are specific to the
part concerned during partial cuts.
Below is a diagram of the part in position, for
information.
on replacement part

Battery flap reinforcement
Control mounting reinforcement
Housing mounting
Welded bolts
Mounting angle bracket
Mounting reinforcement
Welded studs
Floor reinforcement
on the vehicle
replacement part
41-41
vnx.su
LOWER STRUCTURE
Cab floor
NOTE:
the number of plug welds is not specified in the
procedure.
A distance of approximately 50 mm must be
maintained between the welds.
After welding, apply a bead of glue in the flange to
ensure leaktightness. Use M.J.Pro type glue
(part number: 77 11 172 676)
The remaining welds are plug welds.
NOTE:
When carrying out cutting operations on the vehicle,
take care not to damage the cross members and the
stiffeners.
Partial replacement using cut B
NOTE:
This partial replacement avoids numerous spot welds
on the side member on the side opposite the impact.
The procedure is identical to the short partial
replacement, only the position of the cut changes.
41-42
vnx.su
41
A
V
LOWER STRUCTURE
to the replacement of the sub-frame rear mounting for
a frontal side impact.
41 W
A
Short partial replacement
This operation can be carried out in several ways:

short partial,
NOTE:
The position of the cut cannot be altered, it is given
according to the position of the stiffeners and apertures
in the cross members.
It can be performed symmetrically depending on the
side or the extent of the impact.
part concerned.
NOTE:
This operation is associated with replacement of a
front side member.

Cross member compartment
Anti-intrusion side cross members
Welded stud
Only the side section 1 of the cross member is

unfastened.
All the welding must be by plug welding.

1
Cab floor
1.5
41-43
vnx.su
LOWER STRUCTURE
41 W
A
NOTE:
Partial replacement using cut A avoids unpicking on the
opposite side at the sub-frame rear mounting.
Complete replacement of the part is possible, in this
case it will be necessary to replace both sub-frame
mountings.
IMPORTANT:
It will be necessary to repeat the welding bead inside
the cross member after applying the outside bead.
41-44
vnx.su
LOWER STRUCTURE
Cab floor stiffener
Replacement of this part is a complementary operation
to replacing the cab floor.
NOTE:
The repair procedure contains a diagram of the part in
its correct position on the vehicle, for information.
41-45
vnx.su
41
A
X
LOWER STRUCTURE
Front cross member under front seat
Replacement of this part is an operation associated
with replacement of the cab floor for a frontal side
impact.
NOTE:
Part supplied with:
Mounting brackets
Welded studs
41-46
vnx.su
41
A
Y
LOWER STRUCTURE
Front seat mounting reinforcement
with replacement of the cab floor for a frontal side
impact.
NOTE:
41-47
vnx.su
41
A
Z
LOWER STRUCTURE
Rear side foot panel
a side impact.
Side without sliding side door
NOTE:
Side with sliding side door
41-48
vnx.su
41 AA
A
LOWER STRUCTURE
Rear floor, front section
to the replacement of the rear side sill for a rear
impact.
41 AB
A

operation:
or complete.
part concerned.
on replacement part
on the vehicle
NOTE:
Beyond area 1, complete replacement is
recommended.

1
0.8
replacement part
41-49
vnx.su
LOWER STRUCTURE
NOTE:
The number of plug welds is not specified in the procedure.
A distance of approximately 50 mm must be maintained between the welds.
After welding, apply a bead of glue in the flange to ensure leaktightness.
Use M.J.Pro type glue (part number: 77 11 172 676)
IMPORTANT:
When carrying out the cutting operation, take care not to damage the various
cross members and stiffeners.
Adaptations for versions with seats
14.5
For standardisation reasons, the Parts Store only supplies floors for the van
version (without holes).
For the bus and combi versions, it will be necessary to drill the replacement
floor for the seat attachments.
IMPORTANT:
The dimensions are given for information, you are advised to check the
position of the holes by a trial assembly before welding the floor.
41-50
vnx.su
41 AB
A
LOWER STRUCTURE
Rear floor front cross member
to the replacement of a cab C-pillar lining for a side
impact.
Partial replacement

operation:
complete,
partial, side section only.
NOTE:
The side section must be unpickeded on the
replacement part.
part concerned.
Part supplied with:
Cross member
Side cross members
Welded nuts
Side brackets
Mounting pads

1
2
3
4

Cab floor
Front side member
1.5
0.8
2
0.8
41-51
vnx.su
41 AC
A
LOWER STRUCTURE
10
41 AC
A
X5
10
Diagram for information only
41-52
vnx.su
LOWER STRUCTURE
Rear floor front cross member lining
to the replacement of the cab floor for a side impact.
its correct position, for information.
The welding to be used is preferably resistance
welding as originally or alternatively plug welding
depending on the equipment used and the type of
impact.
41-53
vnx.su
41 AD
LOWER STRUCTURE
Handbrake lever mounting stiffener
41 AE
A
Replacement of this part is a basic operation

associated with a fault.
part concerned.
X5

1
2
Sleeve stop
2
1.2
X4
41-54
vnx.su
LOWER STRUCTURE
Sleeve stop
Replacement of this part is a basic operation
associated with an accident.
41 AF
A
Y1 = 53 mm
NOTE:
The dimension is given for information purposes.

part concerned.

1
2
Sleeve stop
2
1.2
X4
41-55
vnx.su
LOWER STRUCTURE
to the replacement of the rear floor, front section.
41 AG
A
Partial replacement

operation:
complete,
partial, using cut A or B.
IMPORTANT:
Cut B is to be used for a frontal impact.
Cut A is to be used for a rear impact.
NOTE:
In the procedure described below you will find only the
cut positions for partial replacement.
For standardisation reasons, the Parts Store will only
supply a single part corresponding to the long
wheelbase version.
For the short versions, it will be necessary to cut the
replacement part.
NOTE:
Cuts A and B avoid unpicking at the side member
fitting.
REMINDER:
Cut B is to be used for a frontal impact.
Cut A is to be used for a rear impact.

1
1.5
41-56
vnx.su
LOWER STRUCTURE
Exhaust attachment mountings
The The replacement of this part is an additional
operation to the replacement of a rear side member,
centre section, or associated with an accident.
41 AH
A
Right-hand side
The Spares Department will deliver the side member

without the exhaust attachment mountings which must
be welded in position using the procedure described
below.
L40
NOTE:
The bead is applied on both sides.
NOTE:
X1 = 25 mm
the dimensions are given for information.
41-57
vnx.su
LOWER STRUCTURE
Exhaust attachment mountings
Left-hand side
L40
NOTE:
The bead is applied on both sides.
NOTE:
X2 = 55 mm
the dimensions are given for information.
41-58
vnx.su
41 AH
A
LOWER STRUCTURE
Rear axle tie-rod attachment
41 AI
A
Replacement of this part is a basic operation on the

rear axle mechanical parts.
NOTE:
The procedure does not present any particular
difficulty.
The repair step contains two views of the part in
position on the vehicle, for information.
NOTE:
All the welds are made using plug welding.
41-59
vnx.su
LOWER STRUCTURE
Rear seat mounting transversal reinforcement
41 AJ

with replacement of a rear floor for a side impact.
NOTE:
Assembled part with mounting pad.
NOTE:
The seat frames can be used as a template for
positioning the stiffeners.
41-60
vnx.su
LOWER STRUCTURE
Rear floor centre cross member
to the replacement of a rear floor for a rear impact.
NOTE:
difficulty.
For this operation, the welds can all be plug welds.
Part assembled with welded nuts.
41-61
vnx.su
41 AK
A
LOWER STRUCTURE
Replacement of this part is an operation linked to
replacement of a rear floor centre cross member or a
rear side member, front section, for a rear impact.
NOTE:
difficulty.
For this operation, the welds can all be plug welds.
41-62
vnx.su
41 AL
LOWER STRUCTURE
Rear seat mounting bracket
Replacement of this part is associated with
replacement of a rear floor, rear section, for a rear
impact.
NOTE:
This part is only used on long wheelbase versions.
There is no specific repair procedure for this part.
Assembled part with mounting pad.
41-63
vnx.su
41 AM
A
LOWER STRUCTURE
Rear side member
41 AN
A

operation to the replacement of the rear end cross
member for a rear impact
operation:
complete,
partial, using cuts A, B or C.
IMPORTANT:
The cut positions shown below cannot be offset, they
are given according to the positions of the inner
stiffeners and holes in the various parts.

descriptions for partial cuts and joining of the side
member.
1
2

Rear end lower cross member side closure panel
Cross member brackets
Exhaust attachment mounting (right-hand side)
Cup reinforcements
Shock absorber mounting spacer
Rear axle side tie-rod mounting (right-hand side)
Attachment closure panel of rear axle side tie-rod
(right-hand side)
Rear shock absorber attachment
Towing ring (left-hand side)
41-64
vnx.su
Rear side member

Rear side member stiffener
2
1.5
LOWER STRUCTURE
Rear side member
41 AN
A
Partial replacement
NOTE:
The three possible cuts A, B and C for partial
replacement are shown in the diagrams.
REMINDER:
The cut positions shown in the procedure cannot be
offset.
IMPORTANT:
The cuts are made simultaneously on the side member
and its stiffener.
41-65
vnx.su
LOWER STRUCTURE
Rear side member
41 AN
A
NOTE:
The side member inner stiffener is used as a guide for
assembly on the vehicle.
To carry out this operation, it is necessary to slightly
raise the floor rear cross members 1 and 2 to ensure
the passage of the brackets welded to the side
member.
If this operation cannot be performed, it will be
necessary to unpick the brackets on the replacement
part.
41-66
vnx.su
LOWER STRUCTURE
Rear floor transversal reinforcement
with replacement of a rear side member for a rear
impact.
NOTE:
Below is a diagram of the part in its correct position on
41-67
vnx.su
41 AN
A
LOWER STRUCTURE
Rear towing ring
operation to the replacement of the rear end lower
cross member for a rear impact.
41 AP
A
Partial replacement of the towing ring bracket only
This operation can only be carried out by partial

replacement.
part concerned.
Part supplied in two sections:
Towing eye reinforcement
Towing eye bracket
NOTE:
All the welds are made using plug welding.

1
2
3
Towing eye reinforcement

Towing eye bracket
Rear side member
2.5
2.5
2
NOTE:
This cutting line avoids shock absorber mounting
spacer 1 and avoids use of the jig bench.
41-68
vnx.su
LOWER STRUCTURE
Rear towing ring
41 AP
A
Preparation of the replacement part
X3L30
Complete replacement with towing ring

reinforcement
X2
NOTE:
Complete replacement (with reinforcement) requires
unpicking of the side closure panel of the rear end
lower cross member (2).
REMINDER:
This operation is possible, but it is more appropriate to
perform a partial replacement of the rear side member.
41-69
vnx.su
LOWER STRUCTURE
Rear shock absorber attachment
operation to the replacement of the rear end lower
cross member for a rear impact.
This operation is pcarried out in a similar way to the
replacement of the towing ring.
There is no advantage in replacing the whole part, in
this case replacement of the partial rear section of the
side member is more appropriate.
41-70
vnx.su
41 AQ
A
LOWER STRUCTURE
Rear floor rear cross member
replacement of a rear floor, rear section, for a rear
impact.
The procedure for replacing this part has no specific
notes, and joints can all be made as originally.
Below is a diagram of the part in its correct position on
41-71
vnx.su
41 AR
A
LOWER STRUCTURE
Rear floor rear section
operation to the replacement of the rear end cross
member for a rear impact
41 AS
A

This operation may be carried out in several ways:

partial, using cuts A and B,
or complete.
The position of the cuts can be altered according to the
level of impact.
part concerned.
For standardisation reasons, the Parts Store only
supplies floors for the van version (without holes).
NOTE:
For short floors, it will be necessary to cut the
replacement floor as shown in the repair step.
For the bus and combi versions, it will also be
necessary to drill the holes for the seat attachments.
41-72
vnx.su
0.8
LOWER STRUCTURE
41 AS
A
Partial replacement using cuts A, B
on replacement part
NOTE:
The number of plug welds is not specified in the
procedure.
A distance of approximately 50 mm must be
maintained between the welds.
After welding, apply a bead of M.J.Pro mastic
(part number: 77 11 172 676) in the flange to ensure
leaktightness.
on replacement part
The remaining welds are plug welds.

REMINDER:
The position of the cuts can be altered according to the
level of impact.
on the vehicle
41-73
vnx.su
LOWER STRUCTURE
Adaptations for versions with seats
14
REMINDER:
For standardisation reasons, the Parts Store only supplies floors for the van
version (without holes).
For the bus and combi versions, it will be necessary to drill the holes for the
seat attachments.
These holes must be drilled in accordance with the marks (bulges) on the
replacement part.
WARNING:
The dimensions are given for information only.
The dimension X1 is measured on the vehicle.
41-74
vnx.su
41 AS
A
LOWER STRUCTURE
Adaptations for short floors
14
REMINDER:
For short floors, it will be necessary to cut the replacement floor as shown in
the diagram.
For the bus and combi versions, it will also be necessary to drill the holes for
the seat attachments.
WARNING:
The dimensions X1 and X2 are measured on the vehicle.
41-75
vnx.su
41 AS
A
LOWER STRUCTURE
41 AT

to the replacement of the rear side panel rain channel.
part concerned.

1
2
3
Rear end lower cross member side

closure panel
Rear towing ring
1.5
2.5
0.8
X6
41-76
vnx.su
LOWER STRUCTURE
X3
X6
41-77
vnx.su
41 AT
LOWER STRUCTURE
Rear end lower cross member
to the replacement of the rear end panel for a rear
impact.
41 AU
A
Partial replacement

operation:
complete,
partial.
NOTE:
In the procedure described below you will only find the
cut position for partial replacement.
The cut position shown below cannot be altered, it is
given according to the positions of the inner stiffeners
and holes in the various parts.
It can be performed symmetrically depending on the
side or the extent of the impact.
IMPORTANT:
To improve holding, it is advisable to make several
additional plug welds at the rear side member mating
surfaces.

1
Rear end lower cross member
1.5
41-78
vnx.su

142
Front wing
The replacement of this part is a basic operation for a frontal and side impact.
In the procedure described below, you will only find the positions of
mountings which are specific to the part concerned together with the
adjustment operations.
The information on the additional parts will be dealt with in the appropriate
sections.
NOTE:
To access the wing mountings, it will be necessary to remove the following:
the side section of the scuttle grille,
the lamp unit,
the complete mudguard,
part of the front bumper.
42-1
vnx.su
42

Front wing
ADJUSTMENT
Fit all the clips onto the component.
Position the wing on the vehicle.
Finger tighten all mountings without tightening them.
REMINDER:
All clearances are given in Section 40.
ADJUSTMENT SEQUENCE:
1 Wing/door adjustment:
Ensure correct clearances and flushness in zone 1 (bolt B).
Align the edge of the wing in relation to the door (bolt B)
Check the adjustment and clamp the area.
2 Wing/door adjustment, upper and lower sections:
Ensure the correct clearances and flushness of areas 2 and 3 (bolts A and
C).
Check the adjustment and clamp the area (bolts A, C and F).
3 Wing/bonnet adjustment
Ensure flushness and even clearances in area 4 (bolt E first), if necessary
adjust bonnet.
4 Wing/light/bumper adjustment
Ensure correct clearances and flushness in area 5 (bolt D).
If necessary, adjust the bumper.
NOTE:
The lamp unit cannot be adjusted, it is fitted into the front panel.
Wing bolt
0.8
42-2
vnx.su
42

Front wing lower mounting bracket
42
The door is a removable component. This part is

changed in addition to changing a wing or front
bumper for a frontal impact.
positions of mountings which are specific to the part
concerned together with the possible adjustment
operations.
with in their respective sections (refer to contents).
OX and OZ adjustment is made using bolts (A).
42-3
vnx.su
A
B

Front
It is made of composite plastic material
(polypropylene).
42
A
C
REMOVAL
This part is changed in addition to changing the

bumper or bonnet for a frontal impact.
operations.
Remove:
the side mounting bolts (B) (two on each side).
the central attachment bolts (A).
REPAIR
To avoid completely replacing the front surface, it is
possible to use repair clamps (1).
These clamps are positioned on the bumper mounting
brackets.
NOTE:
To access the front surface mountings, it is necessary
to remove the following:
the lamp units,
part of the front bumper,
the bonnet catch,
and to remove the various mechanical components
(radiator, air conditioning hoses, etc.).
42-4
vnx.su

Front
REFITTING
Refitting is carried out in the reverse order to removal.

NOTE:
The right-hand side mounting of the fascia is used in
the factory as a reference to position the surface by
aligning it with pilot hole (C) 8 mm.
You are advised to use this guide hole to centre the
side member, using a screwdriver for example.
Additional adjustments of the front surface in height
(OZ) and depth (OY) are possible at the side
mountings.
Side mounting bolt
2.1
42-5
vnx.su
42
A
C

Front side support
42

This part is changed in addition to changing the front
fascia.
operations.
OX and OZ are adjusted with bolts (A) and (B).
42-6
vnx.su
A
D

Scuttle side panel upper reinforcement
42

frontal impact.
part concerned.

1 Scuttle side panel stiffener
2 Cab A-pillar
3 Scuttle side panel
1.5
0.9
1
X3L40
42-7
vnx.su
A
E

Scuttle side panel upper reinforcement
X22
NOTE:
It is necessary to use setting adhesive M.J.Pro
(part number: 77 11 172 676 on interfaces).
IMPORTANT:
Where certain spot welds cannot be made with the
spot welder, they can be replaced by plug welds.
In this case, leave a reserve (absence of adhesive) in
the welding areas.
42-8
vnx.su
42
A
E

Scuttle side panel
Replacement of this part requires removal of the
scuttle side panel reinforcement and is complementary
to replacement of the cab A-pillar for a side impact.
This operation may be carried out in two ways (refer to
the procedure below):
complete (complementary to the cab A-pillar),
NOTE:
The scuttle side panel stiffener needs to be ordered
additionally.
42
A
F

2 Windscreen pillar lining
3 Windscreen aperture lower cross member
4 Sill panel closure panel
5 Front wheel arch, rear section
reinforcement

part concerned.
Welded nut.
Welded stud.
Fuel filter mounting (right-hand side).
42-9
vnx.su
1
1
0.9
1.2
1.2
0.9

Scuttle side panel
42
X2L25
X2
42-10
vnx.su
A
F

Scuttle side panel
42
X3L20
L65
42-11
vnx.su
A
F

Scuttle side panel
42
A
F
Partial replacement
NOTE:
procedure.
You should:
leave a distance of approximately 50 mm between
the welds,
after welding, apply a bead of adhesive to the inner
and outer side of the flange, to ensure sealing.
Use M.J.Pro type adhesive (part no.: 77 11 172 676).
on replacement part
on the vehicle:
replacement part
42-12
vnx.su

Bonnet lid strut
42 G
A

to the replacement of:
the A-pillar for a side impact,
the bonnet for a frontal impact.

complete (complementary to the cab A-pillar),
partial using cut A, complementary to replacement of
the bonnet.
1 Bonnet lid strut mounting


part concerned.
Welded nut
Welded stud
Fuel filter mounting (right-hand side)
X3
42-13
vnx.su
1.2
0.9

Bonnet lid strut
42 G
A
Partial replacement
MJP
REMINDER:
After welding it will be necessary to apply an extruded
bead of mastic to the mating faces to ensure sealing.
Use M.J.Pro type adhesive
(part number: 77 11 172 676)
on replacement part
on the vehicle
on the vehicle:
X3
42-14
vnx.su

Bonnet release control mounting
replacement of the scuttle side panel for a side impact.
42
A
H
REMOVAL

attachment positions for the part concerned.
Release:
the retaining pin (B),
the opening control by turning it a quarter turn
(arrow 1).
The bonnet opening control mounting plate is removed
using bolts (A).
42-15
vnx.su

This part is changed in addition to changing the scuttle
side panel for a front side impact or associated with
partial replacement of the front side member for a
frontal impact.
Left-hand side

the procedure given below):
complete,
partial, right-hand side (depending on the level of
impact).
NOTE:
There is no specific procedure for replacing this part,
and joints can usually be made as originally. However,
it is possible to use plug welds at places which are
difficult for the spot welder to access.
Front wheel arch
Lower connecting component (right-hand side)
Upper connecting component (right-hand side)
Bracket
Engine mounting pad support (right-hand side)
Engine tie-bar mounting reinforcement (right-hand
side)
Right-hand side
42-16
vnx.su
42
AI

Partial replacement (right-hand side only)
NOTE:
Depending on the level of impact, it is possible to
replace the damaged parts of the front section of the
front wheel arch only.
Below you will find an example of replacing the front
lower section (A) of the wheel arch only.
This part is not available separately, it will be
necessary to unfasten it from the wheel arch assembly
supplied by the Parts Department.
42-17
vnx.su
42
AI

Front wheel arch
42
A
J
This part is changed in addition to changing the scuttle

side panel for a front side impact or associated with
partial replacement of the front side member for a
frontal impact.
NOTE:
There is no specific procedure for replacing this part,
and joints can usually all be made as originally.
However, it is possible to use plug welds at places
which are difficult for the spot welder to access, and at
the shock absorber turret.

Front wheel arch
Lower connecting component (right-hand side)
Upper connecting component (right-hand side)
Bracket
Engine mounting pad support (right-hand side)
Engine block mounting reinforcement (right hand side)
Engine tie-bar mounting (right-hand side)
Engine tie-bar mounting reinforcement (right-hand
side)
Shock absorber cup
Shock absorber cup height adjuster
Height adjuster blanking plate
Unit mounting angle bracket (left-hand side)
Mounting
1
2
3
4
5
Front wheel arch

Windscreen pillar lining
Windscreen aperture lower cross member
Sill panel closure panel
Front wheel arch, rear section
1
1
0.9
1.2
1.2
Left-hand side
REMINDER: it is advisable to apply the plug welds to

the shock absorber cup (A).
42-18
vnx.su

Front wheel arch
42
A
J
IMPORTANT:
It is necessary to use M.J.Pro type setting adhesive
(part no.: 77 11 172 676) on the mating face with the
bulkhead.
Right-hand side
NOTE:
Depending on the level of impact, it is possible to
replace only the damaged parts.
For example, the wheel arch, rear section (B) can
remain in position.
This part is not available separately, it will be
necessary to unfasten it from the wheel arch assembly
supplied by the Parts Department.
NOTE:
The replacement procedure is the same for the lefthand side.
Only the tie-rod mounting (C) is additional, this should
be plug welded to the bulkhead.
42-19
vnx.su

Rear screen aperture lower cross member
42
A
K

windscreen aperture lower cross member
reinforcement for a side impact.
complete,
descriptions and the joints which are specific to partial
replacement.
Complete replacement does not present any particular
difficulty.
IMPORTANT:
The cut is made on the wiper mounting stiffener (C),
indicated by the dotted line on the diagram.
Part supplied with:

Bonnet strut mounting
Cross member
Welded studs
Do not damage the reinforcement during the cutting

operation.

2 Windscreen wiper mounting reinforcement
0.9
1
42-20
vnx.su
X4

Windscreen
aperture
lower cross
member
Windscreen
aperture
lower
crossreinforcement
member
42

complete wheel arch for a frontal impact and of the Apillar for a side impact.
There is no advantage in performing a partial
replacement of this part.
part concerned.
Part supplied with:
Welded nuts

reinforcement
0.9
1
1
42-21
vnx.su
X2L25
A
L

Windscreen
aperture
lower cross
member
Windscreen
aperture
lower
crossreinforcement
member
L65
42-22
vnx.su
42
A
L

Bulkhead
This part is changed in addition to changing the front
half unit for a frontal impact, or of the scuttle side panel
for a side impact.
42 M
A
Partial replacement (right-hand side)
There are two methods of carrying out this operation:

complete,
part concerned.
Part supplied with:
Bulkhead stiffener
Pedal mounting reinforcement
Windscreen wiper mounting centre reinforcement
Welded bolts
Welded studs
Welded nuts
on replacement part
on the vehicle
NOTE:
It is necessary to apply the plug welds to the mating
face with the wiper mounting centre stiffener.

1
2
3
4
Bulkhead
Central floor front cross member
Impact detector mounting
Cab floor
1
1.5
1.5
0.8
X8
42-23
vnx.su

Bulkhead
42 M
A
on the vehicle
on the vehicle
on replacement part
NOTE:
procedure.
You should:
the welds,
after welding, apply a bead of adhesive to ensure
sealing (operation ).
Use MJP type adhesive (part no.: 77 11 172 676)
X4
42-24
vnx.su

Bulkhead
X8
NOTE:
The cut is made in the same place for replacement on
the left-hand side.
42-25
vnx.su
42 M
A
UPPER SIDE STRUCTURE

143
Cab A-pillar
side impact.
To perform this operation, the following must also be
ordered:
double seal mounting rivets,
double seal mounting,
the three cab side expanding inserts,
the cab pillar reinforcement (for cuts B-C only),
scuttle side panel reinforcement.
NOTE:
For reasons of standardization at the Spare Parts
Department, the A-pillar of the cabin must be cut in the
cabin side, the latter covering several sales modes
(e.g., A-pillar, sill panel, C-pillar, etc.).
43

Part supplied with:
Frame drip moulding
Frame stiffener
Striker stiffener
Striker plate
Centring stiffener
Hinge reinforcement
Pillar upper frame
Pillar lower frame
Welded nuts
This operation can be carried out partially in two ways:

using cuts A-C.
under the upper hinge of the door, using cuts A-B or
B-C.
IMPORTANT:
The positions of the cuts given in the procedures
cannot be altered, they are determined according to
the positions of the linings and reinforcements, except
for cut C which can be altered along the deformation
caused by impact.

part concerned.
1 Cab A-pillar
2 Pillar reinforcement
43-1
vnx.su
0.9
1.2

Cab A-pillar
43
Partial replacement using cuts A-B
REMINDER:
Cut A should be carried out above the A-pillar
reinforcement.
IMPORTANT:
To carry out this operation it is necessary to remove
the seal mounting beforehand.
To refit use rivets of 4.8 mm, and head length of
12 mm.
IMPORTANT:
This part is within an area of bodywork that sustains a
considerable amount of stress.
the spot welds not shown in the repair procedure can
be made as originally.
However, for safety reasons, it is advisable to make
additional plug welds in zone (B) to maintain its
mechanical properties.
43-2
vnx.su

Cab A-pillar
43
REMINDER:
manufacture.
When repairing, it is impossible to reproduce these
conditions. It is therefore necessary to perform the
following operations when replacing an insert to
ensure optimum sealing and guarantee vehicle
soundproofing:
soundproofing pad (part number: 77 01 423 546)
3 Apply lining sealing mastic (H) (part number:
77 01 423 330) to the periphery of the insert (G).
43-3
vnx.su

Cab A-pillar
43
Partial replacement under upper hinge of door

using cut B-C
NOTE:
For every altered cut, it is essential to:
unpick the pillar reinforcement from the replacement
part,
unpick the pillar reinforcement on the vehicle,
also order a separate replacement part
reinforcement.
NOTE:
Area X is empty.
The lower cut is not specified, it is identical to the long
partial replacement (see section C).
IMPORTANT:
It is not advisable to re-use the reinforcement once
removed.
IMPORTANT:
When performing the cutting operation take care not
to damage pillar reinforcement (2).
43-4
vnx.su

Cab A-pillar closure panel
This part is replaced in addition to changing the cab Apillar for a side impact.
IMPORTANT:
This part is within an area of bodywork that sustains a
considerable amount of stress.
the spot welds not shown in the repair procedure can
be made as originally.
However, for safety reasons, it is advisable to make
additional plug welds to maintain the mechanical
properties.
part concerned.

1 Cab A-pillar closure panel
2 Pillar reinforcement
0.9
1.2
43-5
vnx.su
43
A
B

Cab A-pillar reinforcement
with partial replacement of the cab A-pillar for a side
impact.
This operation is only performed in a partial
replacement using cut A.
There is no advantage in replacing the complete part,
replacement of the cab A-pillar is more appropriate.
For more detail, refer to the method of replacing the
cab A-pillar.
43-6
vnx.su
43
A
C

43
This part is changed in addition to changing the cab

A-pillar for a side impact.
part concerned.

3 Centre pillar lining
4 Roof front cross member
1
1
1
0.8
X3L 20
43-7
vnx.su
A
D

Special notes with cab roof in position
43
Special notes with cab top in position
on replacement part
on replacement part
X4
X4
43-8
vnx.su
A
D

Windscreen aperture pillar lining reinforcement
This part is replaced in addition to replacing the cab
side front section for a side impact.
Partial replacement

complete,
The procedure for replacing this part has no special
In the step described below you will only find the cut
position for partial replacement.
Partial unpicking of this part may be useful for
smoothing the windscreen pillar lining when
straightening.

1 Windscreen pillar lining reinforcement
0.8
43-9
vnx.su
43
A
E

Cab body top
43
A
F
Replacement of this part can only be performed after

removing the rear side panel, front section, and the
cab roof.
To carry out this operation, it will be necessary to also
order the rivets for the double seal mounting.
NOTE:
using cuts A-B,
using cuts A-C.
Only the special features of the partial cut A-C are
shown, the method for cut B is identical to that for cut C.
IMPORTANT:
the positions of the cuts given in the procedures
the positions of the linings and reinforcements.

1 Cab top

part concerned.
Frame drip moulding
Frame stiffener
Striker stiffener
Striker plate
Centring stiffener
Hinge reinforcement
Pillar upper frame
Pillar lower frame
Welded nuts
43-10
vnx.su
0.9

Cab body top
43
A
F
Partial replacement using cut A-C
IMPORTANT:
The position of the cut must be more than 150 mm
from the seat belt mounting bolt.
IMPORTANT:
Cut A should be carried out above the A-pillar
reinforcement.
43-11
vnx.su

Cab body top
Partial replacement using cut A-B
NOTE:
The partial replacement of C allows you to avoid
unclipping the front section of the rear side panel.
REMINDER:
As with the previous operation, cut A must be made
above the A-pillar reinforcement.
43-12
vnx.su
43
A
F

Cab C-pillar
removing the rear side panel, front section.
43 G
A
To perform this operation, the two side expanding

inserts must also be ordered.
NOTE:
using cuts A-B,
using cuts A-C.
Only the special notes for the partial cut A-C are shown,
the method for cut B is identical to that for cut C.

Frame drip moulding
Frame stiffener
Striker stiffener
Striker plate
Centring stiffener
Hinge reinforcement
Pillar upper frame
Pillar lower frame
Welded nuts
IMPORTANT:
The positions of the cuts are given for information
purposes and can be altered according to deformation
caused by impact, except for cut C which must be
observed exactly.
part concerned.

1 Cab C-pillar
43-13
vnx.su
0.9

Cab C-pillar
Partial replacement using cut A-B
43-14
vnx.su
43 G
A

Cab C-pillar
43 G
A
REMINDER:
manufacture.
ensure optimum sealing and guarantee vehicle
soundproofing:
soundproofing pad (part number: 77 01 423 546)
3 Apply lining sealing mastic (part number:
77 01 423 330) to the periphery of the insert.
NOTE:
Insert (D) must be positioned on the replacement part
before welding (left-hand side only).
43-15
vnx.su

Cab C-pillar
Partial replacement using cut A-C
IMPORTANT:
The position of cut C must be observed exactly, and
made at more than 150 mm from the seat belt
anchoring bolt (F).
43-16
vnx.su
43 G
A

Cab C-pillar lining
43
A
H
This part is changed in addition to changing the cab

C-pillar following a side impact.
features, and joints can all be made as originally.
NOTE:
The cab C-pillar lining is composed of three parts:
seat belt shoulder harness reinforcement (A),
pillar lining (B),
pillar lower lining (C).
It is possible to replace each of these parts separately
depending on the impact.
For example, in the procedure described below, you
will find the replacement of the lower section of the
pillar lining.
Replacement of the lower section

Pillar lining 1.2
Adjustment pad
Inertia reel reinforcement
Shoulder harness reinforcement
Pillar lower lining
Welded nuts
NOTE:
The damaged part (C) will be unclipped from the lining
supplied by the Spare Parts Department.
43-17
vnx.su

Cab side
43
AI

removing the rear side panel, front section, and the
scuttle side panel stiffener.
To perform this operation, the following must also be
ordered:
double seal mounting rivets,
double seal mounting,
the three cab side expanding inserts.
Partial replacement is performed using cuts A-B.
IMPORTANT:
the positions of the cuts given in the procedures
the positions of the linings and reinforcements.
part concerned.
1 Cab A-pillar
2 Roof drip moulding stiffener

Frame drip moulding
Frame stiffener
Striker stiffener
Striker plate
Centring stiffener
Hinge reinforcement
Pillar upper frame
Pillar lower frame
Welded nuts
0.9
0.9
Partial replacement
NOTE:
The position of the cuts is given for information in the
diagram.
For the operations to be performed, repeat the method
of replacing the cab A-pillar and the cab C-pillar.
43-18
vnx.su

Cab side
43
AI
Special feature of complete replacement
NOTE:
There is no specific method for the complete
replacement and unclipping of the cab roof.
It is nevertheless possible to completely replace the
cab side at the roof drip moulding reinforcement to
avoid unpicking the cab roof.
In this case, it will be necessary to leave the roof drip
moulding reinforcement (A) in position on the vehicle
and unpick the roof drip moulding reinforcement on the
side of the cab where the replacement part is to be
fitted.
X5
43-19
vnx.su
UPPER REAR STRUCTURE

144
Front section of rear side panel
side impact.

complete (additional to roof replacement),
partial upper, using cut A,
partial lower, using cut C,
partial, specific to the glazed panel, using cuts B.

1 Rear side panel, front section
2 Cab side
3 Rear side panel, rear section
In all cases, it will also be necessary to order the

expanding insert located in the rear lower section.
44

part concerned.
For the bonded sections, it will be necessary to use
M.J.Pro type setting mastic (Part No.: 77 11 172 676).
Panel tensioner
Damper (panel version)
44-1
vnx.su
0.8
0.9
0.8

44
on the vehicle
replacement part
NOTE:
procedure.A distance of approximately 70 mm must
be used between the welds.
At places where plug welds are not possible, it will be
necessary to apply welding beads to the outer side of
the vehicle.
X2
NOTE:
The two plug welds must be applied on each side.
44-2
vnx.su

44
on the vehicle
replacement part
REMINDER:
Refer to the method described in Vehicle Innovations
for replacement of the expanding insert.
Upper partial replacement
NOTE:
The number of plug welds is not specified. It will be
necessary to leave a gap of approximately 60 mm
between the welds, then after welding, apply a bead of
mastic in the flange to ensure leaktightness.
Use M.J.Pro type mastic (Part No.: 77 11 172 676)
on replacement part
44-3
vnx.su

44
Lower partial replacement
replacement part
on replacement part
on the vehicle
NOTE:
The number of plug welds is not specified. It will be
mastic in the flange to ensure leaktightness.
44-4
vnx.su

Partial replacement (FOR GLAZED VERSION
ONLY)
NOTE:
In the repair procedure, you will only find special notes
concerning the cuts, the rest being identical to the
panel version.
44-5
vnx.su
44

Upper lining of rear side panel, front section
This part is replaced in addition to replacing the rear
side panel, front section.
44
Adaptation for glazed versions

adaptations to be made according to the vehicle
version.
For reasons of standardisation, the Parts Store will

supply one part for all versions.
For glazed versions, it will be necessary to cut the
panel stiffeners (A) as shown in the diagram.
44-6
vnx.su

Lower lining of rear side panel, front section
44
This part is replaced in addition to replacing the rear

side panel, front section.
NOTE:
It is possible to unpick the lining only, when
straightening the lower section of the side panel.
In this particular case, spot welds must be replaced by
plug welds and it will be necessary to also order the
expanding insert (see procedure for the panel version).
44-7
vnx.su

side impact.
In all cases, it will also be necessary to order the
expanding insert located in the rear lower section.
complete (in addition to replacement of the roof and
rear side panel, front section),
partial side, using cut B,
partial under rail, using cut C,
partial, specific to the glazed panel, using cuts D.
44
A
D

1
2
3
4
5
6
7
Rear side panel, rear section

Lining of rear side panel
Floor
Rear side panel, front section
Roof rear cross member
Rail attachment reinforcements
Rear roof drip moulding lining

part concerned.
For the bonded sections, it will be necessary to use
M.J.Pro type setting mastic (Part No.: 77 11 172 676).
NOTE:
The component must be replaced completely in
addition to replacement of the rear side panel, front
section, as required by the vehicle design.
44-8
vnx.su
0.8
0.7
0.8
0.8
1
1.2
0.8

44
A
D
X3
REMINDER:
For the replacement of the expanding inserts (1) refer
to the procedure described in the replacement of the
side panel lining, rear section.
X3
44-9
vnx.su

IMPORTANT:
A structural adhesive (MCT 514,
Part No.: 77 11 172 674 type) must be used for
bonding areas C.
44-10
vnx.su
44
A
D

44
A
D
Side partial replacement
NOTE:
procedure, it will be necessary to leave a gap of
approximately 70 mm between the welds.
At places where plug welds are not possible, apply
welding beads to the outer side of the vehicle.
on the vehicle
44-11
vnx.su

44
A
D
NOTE:
The number of plug welds is not specified, it will be
between the welds and then, after welding, to apply a
mastic bead to the edge to ensure sealing.
on replacement part
on the vehicle
replacement part
44-12
vnx.su

44
A
D
Partial replacement under rail
replacement part
on replacement part
on the vehicle
NOTE:
necessary to leave a gap of approxiately 60 mm
smooth mastic to the edge.
IMPORTANT:
Partial replacement under the rail is particularly
recommended for the glazed versions.
This avoids removing the quarter window.
44-13
vnx.su

44
A
D
Partial replacement (FOR GLAZED VERSION

ONLY)
NOTE:
In the repair procedure, you will only find special notes
concerning the cuts, the rest being identical to the
panel version.
X2 L20
IMPORTANT:
It is not possible to apply plunging to stiffeners (6), it
will be necessary to apply a welding bead to the edge.
44-14
vnx.su

Rear B-pillar
44
A
E
Replacement of this part is additional to replacement

of the rear panels, front and rear sections, for a side
impact.
This operation may be carried out in two ways:
complete,
IMPORTANT:
The cutting positions given in the procedures cannot
be altered, they are determined according to the
positions of the linings and stiffeners.
NOTE:
For the glazed versions, partial replacement avoids
completely unpicking the side panels if these are
partially replaced by cutting the window pillars.

1 B-Pillar

features, and joints can all be of original manufacture
type.
position for partial replacement.
Plate cage
Striker plate
B-Pillar
Welded nuts
44-15
vnx.su

Rear B-pillar
Partial replacement
44-16
vnx.su
44
A
E

Rear section of rear side panel lining
44
A
F
Depending on the impact location, replacement of this

part may be additional to replacement of the rear side
panels, rear section and front section, or of a C-pillar.
This operation may be carried out in several ways
depending on the case in question (see procedure
below):
complete, additional to pillar or rear panels,
partial, using cuts A, B and C, additional to rear
panel, rear section, without unpicking of the rear
panel, front section,
partial, of outer wheel arch, using cuts C and D,
additional to rear panel, rear section,
partial, of rear corner (using cuts D and E).
In certain cases, it will also be necessary to order the
four expanding inserts for the C-pillars.
part concerned.
NOTE:
For the long wheelbase versions, the cuts are located
at the same place as for the basic version.

1 Lining of rear side panel

C-Pillar stiffener
Parcel shelf stiffener
Seat belt shoulder harness reinforcement
Rail stiffener
Mounting reinforcement
Seat belt nut
44-17
vnx.su
0.7

44
A
F
REMINDER:
manufacture.
Adaptation for glazed versions

ensure optimum leaktightness and guarantee vehicle
soundproofing:
NOTE:
For reasons of standardisation the Parts Department
will only supply the part for the panel version, therefore
for the glazed version it will be necessary to cut panel
stiffener (A) as shown in the diagram (for the long
wheelbase versions, there are two stiffeners to cut).

2 Apply lining sealing mastic (Part No.: 77 01 423 330)
to the periphery of the inserts (B).
NOTE:
For the four pillar inserts, at the end of the operation it
will be necessary to apply beads of smooth mastic in
each corner, using a brush. Use M.J.Pro type mastic
(Part No.: 77 11 172 676).
44-18
vnx.su

Partial replacement using cuts A, B, C
44
A
F
NOTE:
between the welds.
on replacement part
on the vehicle
NOTE:
For details of the lower cut refer to partial replacement
of the wheel arch below.
on replacement part
44-19
vnx.su

Partial replacement of the outer wheel arch
44
A
F
NOTE:
necessary to leave a gap of 40 mm between the
welds.
on replacement part
on replacement part
on the vehicle
on the vehicle
on replacement part
on replacement part
44-20
vnx.su

44
Partial replacement of the rear corner
on replacement part
on the vehicle
on replacement part
X6
on replacement part
X4
44-21
vnx.su
A
F

Rear roof drip moulding
44 G
A

to the roof.
Double seal support
Roof drip moulding closure panel
on replacement part
X5

1 Rear roof drip moulding
2 Cab side
3 Rear side panel, rear section
0.8
0.9
0.8
on replacement part
X5
44-22
vnx.su

44
A
H

of the roof, rear roof drip moulding or rear side panels.
complete,
partial, using cut A (edge to edge).
NOTE:
The replacement procedure for this part is not
specified, it depends on the type of impact.
Depending on accessibility, it will be necessary to use
the original spot welds, otherwise these can be
replaced by plug welds.
Double seal support
Roof drip moulding closure panel

IMPORTANT:
The position of cut A may vary depending on the
section to be replaced, but it must not be made across
a slot or a stamped section.
44-23
vnx.su

Rear inner wheel arch
44
AI

of the lining of the rear panel, rear section, for a rear
impact.
part concerned.
Wheel arch stiffener
Welded studs

1
2
3
4

Wheel arch stiffener
Rear floor, rear section
Longitudinal floor stiffener
1
1.5
0.8
2
44-24
vnx.su
X4

44
AI
X10
X10
X10
X4
44-25
vnx.su

C-pillar
44
A
J

of the rear panel rain channel, rear section, for a rear
impact.
There are three methods of carrying out this operation:
complete,
partial, using cut B.
IMPORTANT:
NOTE:

1 C-Pillar
positions for partial replacements.

Gas strut reinforcement
Towing eye reinforcements
NOTE:
The part is supplied without hinge reinforcements.
44-26
vnx.su

C-pillar
Partial replacement, using cut A or B
NOTE:
The cuts must be made under the hinge
reinforcements, after unpicking them beforehand.
44-27
vnx.su
44
A
J

Rear section of rear side panel rain channel
44
A
K

of the rear panel lining, rear section, and the rear end
panel for a rear impact.
complete,
partial lower, using cut B.
IMPORTANT:
NOTE:
positions for partial replacements.
1 Side panel rain channel

2 Hinge reinforcement

1.2
1.5

Welded studs
Hinge reinforcements
Welded nuts
NOTE:
The part is supplied with hinge reinforcements.
It will be necessary to apply additional welding beads
at the junction of the stiffeners with the lining, as
shown by the arrows (1).
44-28
vnx.su

44
A
K
X3
NOTE:
It is possible to leave the hinge reinforcement on the
C-pillar, in which case it will be necessary to unpick it
from the replacement part.
on replacement part
on the vehicle
on replacement part
X5
44-29
vnx.su

NOTE:
For this operation, it will be necessary to use M.J.Pro
type setting adhesive (Part No.: 77 11 172 676).
on replacement part
on the vehicle
on replacement part
X5
44-30
vnx.su
44
A
K

Gas strut ball joint mounting
44
Replacement of this part is associated with an incident,

when removing the ball joint base.
If the removal is done at the attachment thread, it is
possible to replace the original thread with a
castellated security nut, refer to the method for
replacing inserts described in section 40.
positions of the mountings specific to the component.'
Wedge the tailgate in the open position.

Remove:
the gas strut (body side only),
the two bolts (A).
44-31
vnx.su
A
L

Rear skirt
rear impact.
44 M
A

1 Rear end panel

complete,
1.5
IMPORTANT:
The cutting position given in the procedure cannot be
altered, it is determined according to the positions of
the linings and stiffeners. It may be cut symmetrically
depending on the side in question.
NOTE:
positions for partial replacement.
NOTE:
It is advisable to make some additional plug welds at
points hidden from view and covered by mastic.
44-32
vnx.su

Rear bumper cross member mounting
44
A
N

rear impact.
the part concerned.
NOTE:
The part supplied by the Parts Store is black and does
not need painting when fitted.
REMOVAL
Part supplied with:

Bumper cross member
Shock absorbers
Absorber closure panel.
Removal is by way of the mounting bolts (A) (two on

each side).
REFITTING
Refitting is carried out in the reverse order to removal.
44-33
vnx.su
TOP OF BODY
145
Cab roof
45
The replacement of this part is a basic operation.

NOTE:
the part concerned.
with in their respective chapters (refer to contents).
The number of plug welds is not specified for joint B.
A gap of approximately 70 mm must be left between
each weld.
M.J.Pro type setting adhesive (part number:
77 11 172 676) must be used for the areas to be
bonded.

1
2
3
4
5
6
Cab roof
Cab roof front cross member
Rear roof
Cab roof rear cross member
Cab side
Windscreen pillar lining
0.7
0.8
0.7
0.8
0.9
1
X8
45-1
vnx.su
TOP OF BODY
Cab roof
45
X
12
X12
NOTE:
To remove cab roof (1), it is necessary to slightly lift
rear roof (3) away from cross member (4), taking care
not to mark these parts.
45-2
vnx.su
TOP OF BODY
Roof
45
The replacement of this part is a basic operation.
NOTE:
the part concerned.
1
2
3
4
5
6
7
8
9
10
11
12

The number of plug welds is not specified for joints B,
F, I and G. A gap of approximately 70 mm must be left
between each weld.
M.J. type setting adhesive (part number:
77 11 172 676) must be used for the areas to be
bonded.
Cab roof
Rear section of roof
Roof rack mounting bridge pieces
Roof centre cross member
45-3
vnx.su
Roof
Roof front cross member
Cab side
A-pillar lining
Cab C-pillar lining
Rear side panel, front section
Centre cross member bracket
A
B
0.7
0.8
0.9
1
0.8
1.2
0.8
0.8
1.2
0.8
0.8
0.8
TOP OF BODY
Roof
45
A
B
X4
X4
X4
45-4
vnx.su
TOP OF BODY
Roof
45-5
vnx.su
45
A
B
TOP OF BODY
Roof
X4
NOTE:
This operation must be performed on each cross
member.
45-6
vnx.su
45
A
B
TOP OF BODY
Rear roof
45

with replacement of the roof rear cross member for a
rear collision.
complete,
part concerned.
NOTE:
For the long version (longer rear roof), the method is
the same as for the basic vehicle.
on replacement part
on the vehicle:

1
2
3
4
Rear roof
Rear drip moulding lining
0.7
0.8
0.8
0.8
45-7
vnx.su
A
C
TOP OF BODY
Rear roof
45
NOTE:
method.
You should:
the welds,
after welding, apply a bead of glue in the flange to
ensure leaktightness.
Use M.J.P type adhesive (part number:
77 11 172 676)
X11
45-8
vnx.su
A
C
TOP OF BODY
45
A
D
Replacement of these parts is an operation associated

with replacement of the rear roof.
In the method described below you will only find the
positioning dimensions for the roof rack mounting
bridge pieces.
IMPORTANT:
It is advisable to use the roof rack as a positioning
template where possible.
Parts delivered separately.
NOTE:
The two cab roof bridging pieces are used as starting
points for positioning the other bridging pieces.
Transverse positioning must observe the centre-tocentre distance (see plan view below).
The gap (A) must be the same on each side to ensure
perfect centring.
X1: 81 mm
45-9
vnx.su
TOP OF BODY
* Long version (L2)
NOTE:
All the dimensions are given from the front holes (A) of
the bridging piece ( 8.2 mm).
45-10
vnx.su
45
A
D
TOP OF BODY
Cab roof front cross member
of the cab roof.
Below, for information, is a view of the part in its
correct position on the body.
45-11
vnx.su
45
A
E
TOP OF BODY
to the replacement of the roof.
45-12
vnx.su
45
A
F
TOP OF BODY
Rear cab roof centre cross member
to the replacement of the roof.
Below, for information, is a view of the various cross
members in position on the body.
45-13
vnx.su
45 G
A
TOP OF BODY
Rear roof cross member bracket
45

replacement of a roof centre cross member or
additional to replacement of the rear roof drip moulding
lining.
Below, for information, is a view of the various cross
members in position on the body.

1 Roof cross member bracket
2 Rear roof drip moulding lining
0.8
0.8
X6
45-14
vnx.su
TOP OF BODY
Roof rear cross member
of the rear roof.
Rain channel
Striker stiffener
Stop mounting bridge piece
Welded nuts
Hinge reinforcements (tailgate version)
45-15
vnx.su
45
AI
TOP OF BODY
Rear roof rear cross member lining
of the rear roof.
Rain channel
Striker stiffener
Stop mounting bridge piece
Welded nuts
Hinge reinforcements (tailgate version)
45-16
vnx.su
45
SIDE OPENING 147

ELEMENTS
Front side door
Replacement of this part is a basic operation for a side
impact, or in addition to replacement of the front wing
in the event of hinge replacement.
ADJUSTMENT ZONES

There is no special feature in the door adjustment
procedure.
Below you will find only information concerning the
adjustment points.
REMINDER:
Information on additional parts or stripping of parts is
dealt with in the relevant sections.
All clearances are given in section 40.
Window surround
Rear mounting bracket
Panel stiffener
Rear stiffener plate
Impact bar
Impact stiffener
Impact reinforcement bracket
Reinforcement extender
Shock absorber
47-1
vnx.su
47
SIDE OPENING ELEMENTS

Front side door
I. FITTING THE DOOR
47
II. SETTINGS
REMINDER:
This operation can be carried out single-handed using
the door support tool.
Part number:
SUP01
otherwise, two people will be required to put the door
in place.
Fit all the parts to the door
IMPORTANT:
The door hinges are delivered complete with adhesive
zinc pads (example A) on each bearing face.
These pads perform an anti-corrosion function, and if
damaged during repair operations, should always be
replaced.
Otherwise, before final fitting, ensure there is a perfect
seal between the interfaces using filler mastic (refer to
Section 94).
All door gap adjustments (areas 1 to 5, see

introduction) are performed using the hinge
mounting bolts (B) and (C).
REMINDER:
Front to back adjustment (OX) of the door is performed
using only the hinge mounting bolts (C) on the A-pillar.
Access to these bolts requires removal of the front
wing.
Check the adjustments and tighten in position.
Hinge bolt
47-2
vnx.su
2.8

Front side door
47
II. SETTINGS (continued)

Special notes for original hinges
Striker plate bolts (D) prevent scraping and are used

for closure firmness adjustment.
During manufacture, a washer is welded to the upper
hole of the hinge (door support side) to guide the door
into a fixed position.
During this operation it is possible to adjust the

flushness of the rear edge of the door.
Check the adjustment and tighten in position.
If the door requires adjustment after replacement, it will

be necessary to unweld this washer or to enlarge the
hole (12 maxi).

Striker plate bolts
REMINDER:
Anti-corrosion protection is vital for all operations
which expose the bare metal of the bodywork.
Protect against corrosion by applying the following
products:
Pre-treatment primer
Reactive solvent
77 01 423 933
77 01 423 955
NOTE:
After-Sales hinges are supplied without the welded
washer.
47-3
vnx.su
2.8

Front side door
PASSIVE SAFETY
IMPORTANT:
On completion of the operation, check the presence of
the door-retaining device (E).
REMINDER:
The function of this part is essential in the event of a
frontal impact.
The door-retention device keeps the door in its
longitudinal plane, thereby absorbing impact energy
efficiently.
Door-retention device bolts
47-4
vnx.su
2.1
47

Front side door panel
side impact.
47
A
B
REMINDER:
with in the appropriate sections.
complete,
partial, using cuts A and B,
partial lower, using cut C.
NOTE:
For partial replacements, in the procedure you will only
find special notes concerning the cuts.
Shock absorber
Reinforcement
NOTE:
It is necessary to use a structural adhesive on the
periphery (crimping zone), type MTC 514
(part number: 77 11 172 674).
For zones (A), a setting adhesive is essential, type
M.J.Pro (part number: 77 11 172 676).

1 Door panel
2 Door box section
3 Door stiffener
0.8
1.2
1.5
47-5
vnx.su

47
A
B
or
NOTE:
For the window surround, the number of spot welds is
not specified in the procedure.
A gap of approximately 70 mm must be left between
the welds.
It is preferable to use resistance spot welding as used
in original manufacture, if your equipment can do this.
47-6
vnx.su

47
A
B
on replacement part
on the vehicle
X5
NOTE:
Partial replacement is performed by overlapping the
panels, the number of plug welds is not specified,
a gap of 60 mm must be left between the welds.
47-7
vnx.su

47-8
vnx.su
47
A
B

Front side door panel stiffener
47
A
C
Replacement of this part is in addition to replacement

of a front side door panel.
The method of replacement does not pose any
particular problems, below you will only find
information on the products.
Shock absorber
Reinforcement
NOTE:
For refitting, use 4.8 mm rivets and a side member
with 7.5 mm head.
47-9
vnx.su

Fuel filler flap
with replacement of a cab C-pillar.
47
A
D
Removal of the filler flap with mounting

the part concerned.
Part supplied on its own (pre-primed).
REMOVAL
Removal is by way of the mounting bolts (A).
REFITTING
Ensure sealing of the mounting bolts and the anticorrosion protection using a filler mastic (see
Section 94).
47-10
vnx.su

Fuel filler flap
47
A
D
Removal of the filler flap only
Remove the filler flap in the direction of the arrows 3

and 4.
REMOVAL
REFITTING
Unclip the retaining spring in the direction of the
arrows 1 and 2.
If replacing the filler flap, it will be necessary to lightly

grease the retaining spring to prevent abrasion and
ease movement.
REPAIR
The filler flap is made of NORYL GTX, for paint
products refer to Section 95.
47-11
vnx.su
SIDE OPENING 247

ELEMENTS
Sliding side door
Replacing this door after a side impact is a basic operation.
Only the door adjustment operations, and not the removal and refitting
methods, are described in the following procedure.
REMINDER
The information on the additional parts will be dealt with in the appropriate
sections.
WARNING:
For safety reasons, only open and close the door when the vehicle is
stationary.
Closing during braking risks derailing the slides and dislodging the
door. Opening during acceleration may deform the side panel at the
stop.
ADJUSTMENT ZONES
47-12
vnx.su
47
A
E

Sliding side door
47
A
E
I. PRE-ASSEMBLY PREPARATION
On the sliding side door:
On the vehicle:
Fit all the components to the door.
Remove:
the door frame rubber seal (A),
the central striker plate (B),
the male centring devices (C).
Do not remove the outer protective strip, in order to

preserve access to the lower slide mounting nut
(square slot 1).
Position the lower arm (D), the upper arm (E) and the
central slide (F) in their respective guide runners.
47-13
vnx.su

Sliding side door
47
A
E
II. FITTING THE DOOR
III. SETTINGS
REMINDER
This operation can be done by one person using the
door support tool.
Part number:
SUP01
If not using this tool, another operator will be required
to support the door.
NOTE:
when setting special points, linked to an incident
(e.g. rear flush-fitting), refer to the procedure for
more detailed instructions.
Even in a regular case, you should always check
the settings information. There may be more than
one way to repair a fault, but using the information
is quicker.
Engage the door in the central slide (F).

Position the lower arm (D) on the door.
Perform the following settings in this order:

Position the upper arm (E) on the door.
1 Height adjustment of the front section of the door
2 Height adjustment of the rear section of the door
3 Flush-fitting adjustment of the rear section of the
door
4 Flush-fitting adjustment of the top rear section of the
door
5 Flush-fitting adjustment of the lower rear section of
the door
6 Adjustment of front and rear centring
7 Flush-fitting adjustment of the top front section of the
door
8 Adjustment of the centring devices
Insert all the bolts without tightening them.

Remove the door mounting tool.
47-14
vnx.su

Sliding side door
1 Height adjustment of the front section of the
door
47
A
E
2 Height adjustment of the rear section of the door
IMPORTANT:
When tightening in position, the roller for the lower arm
must be perpendicular to the guiding runner to prevent
constriction. Always start with the lower nut and bolts
to prevent it pivoting.
REMINDER:
Adjustment is carried out without the door frame
rubber seal to prevent constriction when closing.
Ensure that the edges and the gaps in areas 4 and 6

are correctly aligned (see introduction) using the
bolts on the central slide (F).
This is a two-person job, as the bolts can only be
accessed from the inside of the vehicle.
Tighten in position.
NOTE:
The edges in zones 2 and 5 can be adjusted during
this operation, but this must be completed in
operation 6.

are correctly aligned (refer to the adjustment areas
diagram in the introduction) using the nut and bolts on
the lower arm (D).

Pre-tighten the two inner bolts, then tighten them from
the outside using the mounting nut on the arm.
Central carriage

Lower arm
2.1
47-15
vnx.su
2.1

Sliding side door
47
A
E
3 Flush-fitting adjustment of the rear section of

the door
Ensure flushness in area 5 (see introduction) using

the striker plate bolts (B).
IMPORTANT:
To make factory assembly easier, the striker plate is
riveted and thus immobile.
Fit:
the door frame rubber seal,
the striker plate B on the vehicle by finger tightening
the bolts without tightening them.
To allow adjustment of the striker plate, it will be

necessary to drill out the retaining rivets (L).
Close the door.
IMPORTANT:
The rivet nails will fall into the bottom of the pillar when
you perform this operation and may cause noise or
corrosion. To prevent this, either remove the inner trim
or inject the cavities.
Check and adjust flushness in the direction of the

arrows 1 and 1.
Striker
2.1
NOTE:
Adjustment in the direction of the arrows 2 and 2 will
prevent the lock scraping vertically.
47-16
vnx.su

Sliding side door
47
A
E
4 Flush-fitting adjustment of the top rear section of

the door
5 Flush-fitting adjustment of the bottom rear

section of the door
Check flushness in area 4 (see introduction) using

the adjustable stop (J).
There are no specific adjustments for this part of the

door, adjustment is done as part of operations 3 and 4.
Check that there are two stops (K) on the lower runner.
47-17
vnx.su

Sliding side door
6 Adjustment of front and rear centring
47
A
E
IMPORTANT:
Before finally locking the slide in position, it is essential
to ensure that the roller (H) supporting the central slide
(F) is correctly mounted on the rail. This will prevent
horizontal scraping of the central lock when opening or
closing the door.
To do this, insert a screwdriver between the runner and
the slide and lever it upwards (arrow 1) to ensure that
the roller is in proper contact.
This is a two-person job, as someone must be present
to lock from the inside.
are correctly aligned (see introduction) using the
bolts on the central slide (F).
Central carriage
NOTE:
This operation completes the flushnesss adjustments
carried out earlier in steps 3, 4 and 5.
If you have carried out the previous instructions
properly, there should be no need for this stage.
Nonetheless, we advise you to check them.
47-18
vnx.su
2.1

Sliding side door
7 Flush-fitting adjustment of the top front section
of the door
47
A
E

Upper arm
0.8
REMINDER:
Anti-corrosion protection is essential for all operations
products:
Reactive solvent
Check flushness in area 3 (see introduction) using

the upper arm bolts (E).
NOTE:
You can counter-pierce the arm mounting holes by
8 mm to allow for a wider setting.
IMPORTANT:
The roller for the upper arm must be kept
perpendicular to the guiding runner to prevent any
constriction.
Roller too high
Risk of contact with the

upper mounting bolts on
the runner
Roller too low
Wear of the lower

section of the runner
Roller crooked
Wear of the O-ring
47-19
vnx.su
77 01 423 933
77 01 423 955

Sliding side door
47
A
E
8 Adjustment of the centring devices
Adjust flushness in zones 1, 2 and 3 (see

introduction) using the male centring device bolts (C).
REMINDER:
To make factory assembly easier, the male centring
device mounting pads are riveted and thus immobile
(as with the door striker plate).
To allow adjustment of the striker plate, it will be
necessary to drill out the retaining rivets L).
First adjust with the upper centring fitting, and then

with the lower fitting, following the same procedure.
Adjust following the arrows 1 and 1.
As a general rule, it will not be necessary to drill the

rivets, as the centring devices are positioned in the
factory to correspond to an optimal door adjusting
position.
Adjustment in the direction of the arrows 2 and 2 will

vertically position the male centring devices and
prevent them from scraping.
The following operation should therefore only be

carried out in case of a fault.
NOTE:
Adjustments cannot be made with the female centring
devices on the door.
IMPORTANT:
Fitting of the centring fittings must be optimal
(autocentring) as external beading may cause the door
to become unseated.
47-20
Remove the inner trim from the cab pillar to retrieve

the rivet heads that have fallen into the pillar lining and
thus prevent potential noises and corrosion.
Male centring devices
0.8
Female centring devices
0.8
vnx.su

Sliding side door panel
side impact.
47
A
F
PANEL VERSION

complete for sheet panels,
partial for glazed panels, using cuts A.
NOTE:
For partial replacements, in the procedure you will only
find special notes concerning the cuts.
NOTE:
periphery (crimping zone), type MTC 514
(part number: 77 11 172 674).
For the other zones use a setting adhesive type
MJPro (part number: 77 11 172 676).
1 Door panel
2 Door box section
0.8
0.8
47-21
vnx.su

Sliding side door panel
GLAZED VERSION
47-22
vnx.su
47
A
F
NON-SIDE OPENING
148ELEMENTS
Bonnet
48
The replacement of this part is a basic operation for a frontal collision.

NOTE:
There is nothing particularly difficult about removal and refitting; the procedure only describes adjustment
possibilities.
REMINDER:
The information on the additional parts will be dealt with in the appropriate sections. All clearances are given in
section 40.
IMPORTANT:
To access the lower mountings of the bonnet strut, the windscreen wiper motor mounting plate assembly must be
removed.

Bonnet strut bolts
2.8
IMPORTANT:
The bonnet struts are supplied with an adhesive zinc pad on each side.
These pads perform an anticorrosion function. If damaged during repair operations, they should always be replaced.
Otherwise, ensure there is a perfect seal between the interfaces using filler mastic (see Section 94).
48-1
vnx.su
NON-SIDE OPENING ELEMENTS

Bonnet
48
ADJUSTMENT ZONES
ADJUSTMENT
Position the bonnet on the vehicle (two persons are required for this operation).
Finger tighten all the attachments.
IMPORTANT:
The bonnet safety catch and plunger are to be fitted during the final adjustment operations so as not to create any
stress in the closed position during the first two adjustment phases.
48-2
vnx.su

Bonnet
ADJUSTMENT SEQUENCE:
48
IMPORTANT:
To adjust the gap between the bonnet and the wing,
the bonnet strut slot (C) can be drilled out to 12 mm
(if necessary).
2 Adjustment: Bonnet-Wing (lower section)
Ensure clearances and flushness in zone 2 (bolts A
and B).
Check the adjustment and tighten in position.
NOTE:
When adjusting the side gap between the bonnet and
wing, you can use the upper attachments of the front
wing.
1 Adjustment: Bonnet-Wing (upper section)

Ensure correct clearances and flushness in zone 1
(bolts A and B).
REMINDER:
In all cases, you should begin by adjusting the contact
surfaces at the strut.
48-3
vnx.su

Bonnet
Reactive solvent
3 Adjustment: Bonnet-Headlight-Radiator grille

Fit the mounting plate for the bonnet closure pin and
safety catch (bolts D).
It is possible to drill the out plate to 8 mm (if
necessary) to provide additional adjustment play.
Prevention of scraping is achieved by adjusting the

lock (E).
These adjustments must not alter the peripheral play
set previously.
NOTE:
Adjustment of flushness in zones 2 and 3 is performed
using the stops (F).
REMINDER:
Anti-corrosion protection is vital whenever paintwork is
removed during drilling operations.
products:
48-4
vnx.su
48
77 01 423 933
77 01 423 955

Tailgate
rear collision.
There are no specific features concerning the method
of adjusting this component.
Below you will only find information concerning
adjustment.
REMINDER:
Shock absorber
Tapped plate
48-5
vnx.su
48
A
B

Tailgate
I. FITTING THE TAILGATE
48
A
B
II. SETTINGS
Fitting the tailgate requires the assistance of a second

person.
Fit all the parts to the door
REMINDER:
The hinges are delivered with adhesive zinc pads on
each contact face.
These pads perform an anticorrosion function. If
damaged during repair operations, they should always
be replaced.
Otherwise, before final fitting, ensure there is a perfect
seal between the interfaces using filler mastic (see
Section 94).
All gap adjustments in zones 1 to 4 (see diagram in

introduction) are performed using the hinge
mounting bolts (A).
IMPORTANT:
No adjustment is possible using bolts (B).
To access the mounting nuts (A), it is necessary to
partially remove the head lining.
Check the adjustments.
48-6
Hinge bolt
2.8
Hinge nut
2.8
vnx.su

Tailgate
II. SETTINGS (continued)
48
A
B
During this operation it is possible to adjust the

flushness of the lower edge of the door.
Check the adjustment.
Striker plate bolts
Prevention of scraping and closure firmness

adjustment are set using the striker plate bolts (C).
To increase the play of the striker plate, it will be

necessary to trim the plastic studs (D) of the striker
plate mounting.
48-7
vnx.su
0.8

Tailgate
II. SIDE STOP ADJUSTMENT
Remove the lights.

Close the tailgate.
Ensure there is contact between stop (E) on the
vehicle and stop (F) on the tailgate.
Lock in position using bolt (G).
Refit the lights.
Stop bolt on vehicle
2.1
Stop bolt on tailgate
0.4
48-8
vnx.su
48
A
B

Rear loading door
48
A
C
The door consists of two symmetrical doors, the left-hand door closing over the right, these are removable structural
components.
Replacement of these parts is a basic operation for a rear collision.
In the following method, you will only find a description of the adjustment operations, information concerning the
additional parts is given in their respective sections.
This method corresponds to replacement of the two doors with hinges (most complicated scenario in terms of setting
and adjustment), and is applicable to both panel and glazed doors.
IMPORTANT:
Where the hinges are not to be replaced, in order to make adjustment easier, it is advisable not to remove them:
from the door during bodywork replacement,
from the vehicle during door replacement.
If only one of the doors is being replaced, the method is the same, but it will be necessary to verify equal distribution
of gaps and clearances between the two doors.
IMPORTANT:
For safety reasons, only open and close the door when the vehicle is stationary.
IMPORTANT:
The hinges are delivered with adhesive zinc pads on each contact face.
These pads perform an anticorrosion function. If damaged during repair operations, they should always be replaced.
Otherwise, ensure there is a perfect seal between the interfaces using filler mastic (see Section 94).
48-9
vnx.su

Rear loading door
48
I. PRE-ASSEMBLY PREPARATION
On the doors:
Fit all the necessary parts to the doors (except the hinges).
Do not fit the striker plate (B) or seal (A) of the right-hand door.
IMPORTANT:
Leave the two striker plate bolts on the movable plate to avoid dropping them into hollows in the door opening
control.
Left-hand door
Right-hand door
48-10
vnx.su
A
C

Rear loading door
48
A
C
On the vehicle:
II. FITTING THE DOORS
Remove:
the lights,
the upper wing panel extensions,
the rear floor threshold trim,
the door frame rubber seal (C),
the striker plate (D) and the lower centring devices
(D'),
the upper striker plate (E),
the door check strap (F).
This operation can be carried out single-handed using

the door support tool.
Part Number: SUP01
Otherwise two additional persons will be required to
support the door.
IMPORTANT:
Use the old marks on the vehicle or door where
possible.
Pre-tighten the door hinges (G) at the centre of the

slots.
In the case of new (replacement) parts, position the

bolts in the centre of the hinge holes.
Fit the bumper, which will be used as a reference for

height adjustment of the doors during the first
operation.
48-11
vnx.su

Rear loading door
III. ORDER OF ADJUSTMENT
48
A
C
Height adjustment and centring of the two doors in

zones 1, 2, 3, 5, 6, 7.
1
2
3
4
5
6
Height adjustment in zones 1, 2, 3, 5, 6, 7.

Transverse adjustment (centring) in zones 2, 4, 6.
Adjustment of lateral flushness in zones 5, 7.
Adjustment of right-hand door flushness in zone 2.
Adjustment of right-hand door flushness in zone 6.
Adjustment of left-hand door flushness in zones 2, 4,
6.
7 Adjustment of left-hand door flushness in zones 1, 2.
IMPORTANT:
Follow the adjustment method described below. There
may be several ways to correct a fault, but this method
is the most efficient.
For particular adjustments associated with an incident,
refer to the method to find detailed instructions on the
point in question.
ADJUSTMENT ZONES
NOTE:
This operation requires the presence of the bumper,
which is used as one of the starting reference points
for height adjustment.
Each hinge (body support side) has a horizontal slot,
which limits only transverse adjustment (OY).
When replacing a single door, use the second door
fitted in place as a starting reference point (adjustment
guide).
Adjust the two doors in the closed position, starting
with the right-hand side.
Ensure alignment and centring of the upper section
with respect to the roof using bolts (H and G).
Adjust the height gap with respect to the bumper and
vertical flushness with respect to the roof using bolts
(I).
48-12
vnx.su

Rear loading door
48
A
C
Adjustment of flushness in upper section of zones

5, 7.
Adjustment of flushness in lower central area

(right-hand door)
Adjust the depth clearance of the upper section of the

door with respect to the roof using the upper hinge
bolts (I), the door being in the closed position.
Ensure flushness in zone 4 using the bolts of the lock

and self-centring striker plate (D).
It is possible to countersink the striker plate to 8 mm
(if necessary) to obtain a wider adjustment range.
Slacken the lower hinges to release any stresses, then

retighten them without locking them in position, they
will be adjusted later in the procedure.
Fit:
the door frame seal,
the door seal,
the striker plate on the vehicle by finger-tightening
the bolts.
48-13
vnx.su

Rear loading door
48
A
C
Adjustment of flushness in upper central area

(right-hand door)
Close the door.

Check and adjust flushness.

and self-centring striker plate (E).
The engagement of the centring device (M) must be

perfectly accurate (autocentring) to prevent scraping.

Finger tighten the striker plate bolts.

Striker
0.8
Close the door.
Lock
0.8

REMINDER:
Anti-corrosion protection is vital for all operations
The engagement of the centring device must be


products:
Reactive solvent
77 01 423 933
77 01 423 955
48-14
Striker
0.8
Lock
0.8
vnx.su

Rear loading door
Adjustment of flushness in central area
48
A
C
Adjustment of flushness in lower area (left-hand

door)
Ensure flushness in zone 4 using the striker plate bolts

(K).

and self-centring striker plate (D).

Close the door.

Close the door.

Striker
2.1
Lock
0.8
The engagement of the centring device must be

48-15
Striker
0.8
Lock
0.8
vnx.su

Rear loading door panels
rear collision.
48
A
D
PANEL VERSION
Left-hand side

complete for sheet panels,
partial for glazed panels, using cuts A and B.
part concerned.
NOTE:
periphery (crimping zone), type MTC 514 (part
number: 77 11 172 674).
1 Door panel
2 Door box section
For the other zones, a setting adhesive is sufficient,

type M.J.Pro (part number: 77 11 172 676).
0.8
0.8
48-16
vnx.su

48
A
D
NOTE:
The method of replacing the panel is identical to that
for the left-hand side; only the bonding zones are
shown.
48-17
vnx.su

GLAZED VERSION
Right-hand side
NOTE:
For partial replacements, the procedure only contains
special notes concerning the cuts.
Left-hand side
48-18
vnx.su
48
A
D
SIDE OPENING ELEMENT

151 MECHANISMS
Front door lock
REMOVAL
Put up the sliding window.
Remove:
the door trim (Section 72-A),
the tamper-proof cover (A),

the three lock mounting bolts (B).
51-1
vnx.su
51
SIDE OPENING ELEMENT MECHANISMS

Front door lock
Disconnect the connector (1).
Release the lock.
REFITTING
Remove:
the lock barrel control linkage (C),
the exterior door handle linkage (D).
Refit the tamper proof cover.
51-2
vnx.su
51

Front door lock barrel
REMOVAL
Remove:
the tamper-proof cover (A),

the three lock mounting bolts (B).
51-3
vnx.su
51

51
Disconnect the connector (1).
the lock,
Remove:
the lock barrel control linkage (B),
the exterior door handle linkage (C),
the two nuts (M6 10 head) (D), then hold the lock
barrel support plate in position.
51-4
vnx.su

Release the exterior door handle (1) then (2).
Remove the circlips (E).

Release the lock barrel.
51-5
vnx.su
51

151 MECHANISMS
Door opening handle - exterior, front door
REMOVAL
Remove:
the tamper-proof cover (A).
51-6
vnx.su
51

Door opening handle - exterior, front door
Remove:
the exterior door handle linkage (B),
the mounting nuts (D).

Release the door handle (1) then (2).
51-7
vnx.su
51

Front door window riser
REMOVAL (manual window)
After removing the door trim (Section 72-A), lower the
window until it meets the stop bolt.
Unfasten the stop bolt.
51-8
vnx.su
51

Remove the two mounting bolts (A)

on the fixed upright.
Release the window from the slide
shaft, then put it at the bottom of the
door box section (protect it with
cloth).
Remove the four mounting bolts (B)
from the window riser.
Release the window riser

mechanism.
51-9
vnx.su
51

REMOVAL (electric window)
Remove the four mounting bolts (C) from the window
riser.
Disconnect the power supply connector.
The procedure is the same as for manual window

risers.
51-10
vnx.su
51
SIDE
151 OPENING ELEMENT MECHANISMS
Lock and interior door handle on the sliding side door
REMOVAL
After removing the door trim (Section 72-B),
remove:
the three mounting bolts (A) for the locking control,
the lock barrel control linkage (B).
51-11
vnx.su
51

Remove the exterior door handle cable (C).
51-12
vnx.su
51

Remove the three lock mounting bolts.

Release the locking assembly, cables, and interior door handle.
51-13
vnx.su
51

Exterior door handle on the sliding side door
REMOVAL
remove:
Release the interior door handle.
51-14
vnx.su
51

Exterior door handle on the sliding side door
Remove:
the sleeve stop (C) from the exterior door handle,
the two mounting nuts (D),
the door handle (1), then (2).
51-15
vnx.su
51

151 MECHANISMS
Sliding side door lock barrel
REMOVAL
remove:
Release the interior door handle.
51-16
vnx.su
51

Remove:
the exterior door handle cable (C),
the door handle (1), then (2).
51-17
vnx.su
51

Remove circlips (E).

51-18
vnx.su
51
SIDE151
OPENING ELEMENT MECHANISMS
Runners and slides on the sliding side door
This operation can be carried out by just one person

using the door support tool.
Part number: SUPO 1
If this tool is not used, another operator will be required
to support the door.
51-19
vnx.su
51

REMOVAL OF THE UPPER ARM AND RUNNER
SPECIAL NOTES
This operation can be carried out with the door closed, without using the
door support tool.
Remove the two mounting bolts (A) from the upper

arm (T30).
Slide it towards the back of the vehicle, separate the
lining from the upper runner carefully (according to the
fitting), then release the arm
Replace the seal on the guide roller if necessary.
51-20
vnx.su
51

Using the tool Car. 1597, unfasten:

the clips from the towing ring cover and grab handles
(B),
the linings from the upper runner (1) then (2).
the right side lining from the roof cross member (3)
then (4),
the central lining (5).
51-21
vnx.su
51

Remove:
the four mounting bolts (C),
the upper runner.
REMOVAL OF THE SLIDE AND CENTRE RUNNER
Remove the rear light.
With the door ajar, fit the holding tool to it
51-22
vnx.su
51

Remove:
the blanking covers, then the two mounting nuts (D)
from the slide,
the mounting bolts (E),

the runner end (F), then move the slide to the back of
the runner to release it.
51-23
vnx.su
51

Remove:
the blanking covers, then the two mounting nuts (G)
from the runner,
the runner.
REMOVAL OF THE SLIDE AND LOWER RUNNER
Fit the holding tool to the door.
Remove:
the door strip,
the mounting nut (H) from the lower slide,
51-24
vnx.su
51

the two mounting bolts (I) from the lower slide.
Carefully move the door, and then release the slide.

REFITTING
To adjust the sliding side door, see Section 47.
51-25
vnx.su
51
NON-SIDE OPENING ELEMENT

152 MECHANISMS
Exterior door handles on the loading doors
52
REMOVAL
Remove:
mounting bolt (A),
the inside opening handle.
Unclip the door lining with the unclipping tool.
Remove:
the door handle linkage (B),
the two mounting nuts (C) from the door handle.
Lift the handle (1) then release the exterior door
handle (2).
52-1
vnx.su
NON-SIDE OPENING ELEMENT MECHANISMS

Loading rear door lock
52
REMOVAL of the left hand rear door lock
the door handle and lock barrel linkages (C),

the lock.
Remove:
mounting bolt (A),
Using the unclipping tool, unclip the lining panel.
Remove:
the three lock mounting bolts (B),
52-2
vnx.su

Loading rear door lock
52
REMOVAL of the right hand rear door locks
Unclip cable sleeve stop (E) using a flat screwdriver.

Unclip cable sleeve stop (D) using a flat screwdriver.
Remove the three mounting bolts from the lower lock.
Remove the three mounting bolts from the upper lock.
Carefully release the lock to remove the cable stop

knob.
Carefully release the lock to remove the cable stop

knob.
52-3
vnx.su
NON-SIDE OPENING ELEMENT

152 MECHANISMS
Rear loading door lock barrel
REMOVAL
Remove:
mounting bolt (A),

exterior door handle (1), then (2).
the lock barrel support plate,
Using the unclipping tool, unclip the lining panel.
circlips (E).
Remove:
the exterior door handle linkage (C),
52-4
vnx.su
52

Interior door handles on the loading doors
REMOVAL of the control
Using the unclipping tool, unclip
the lining panel.
Remove:
the two sleeve stops (A),
the two cable stop knobs,
52-5
vnx.su
52

Interior door handles on the loading doors
REMOVAL of the control
mechanism
Remove:
the four mounting bolts (B)
from the interior opening
control mechanism, then
remove it.
52-6
vnx.su
52

Exterior door handle and lock on the bonnet
REMOVAL
52
Passenger compartment section
The lock (bolt A) must be removed to fit the cable.
Remove:
retaining clip (E),
the door handle as shown on the diagram (1).
Release the blanking cover from the scuttle panel,
then the assembly via the inside of the vehicle.
REFITTING
Unclip:
the sleeve for the three retaining clips (B),
the sleeve stop (C),
the cable stop knob (D).
52-7
vnx.su
154
WINDOWS
Windscreen
PREPARATION BEFORE CUTTING
54
SPECIAL NOTE FOR VEHICLES FITTED WITH A

DE-ICING WINDSCREEN
Before cutting the windscreen using a stranded wire,

the following must be removed:
the cowl vent grilles,
the windscreen pillar trims,
the sun visors.
IMPORTANT:
It is essential to replace the five retaining blocks (A) of
the windscreen each time it is removed.
Disconnect connector (B), which is attached to the

engine interconnection unit, then release de-icing
wiring harness (C).
REMOVAL
Remove side seals (1), then upper seals (2).

Using locally made shims about 3 cm thick, carefully
detach the head lining.
54-1
vnx.su
WINDOWS
Windscreen
54
IMPORTANT:
There is no specific dashboard protector for this vehicle.
Protect: (protective tape 77 11 171 708)

the upper section of the front wings (D),
the windscreen surround.
Using the cutting wire insertion tool, pierce the bead of adhesive at (E).
IMPORTANT:
The use of dashboard protector (F) Car. 1482 is recommended for protecting both ends of the dashboard when
cutting the windscreen using twisted wire.
Two people are required to carry out his operation.
54-2
vnx.su
WINDOWS
Windscreen
54
Cut the bead of adhesive:

(area 1) downwards to the lower left-hand corner,
(area 2) in the opposite direction to the lower right-hand corner,
(area 3) with a to and fro motion in the bottom corners, taking care not to damage de-icing
wiring harness (G).
54-3
vnx.su
WINDOWS
Windscreen
REFITTING
Refer to the Procedure for fitting
windows section for information
about surface preparation and
applying adhesive.
Clip the five retaining blocks (H) to
the aperture (there are five oblong
holes for this).
Fit upper trim piece (I) to the
windscreen.
Retain the setting and size of the

bead of adhesive.
Glue the window (this requires two
people).
Adjust the side aspects clearance.
54-4
vnx.su
54
WINDOWS
Windscreen
NOTE:
The windscreen has several marks printed on the lower section. These
allow the wiper blades to be fitted during refitting.
left-hand blade mark (J),
right-hand blade mark (K),
Mark (L) is used on right-hand drive vehicles.
54-5
vnx.su
54
WINDOWS
Front door window
54
REMOVAL
After removing the door lining,
the two mounting screws (C) of the fixed upright.
partially release the upper weatherstrip (A).

Remove:
the inner weatherstrips then the outer ones (B),
Unclip window winder fork (D).

Release the window from the shaft of the moving slide.
Fit the glass at the bottom of the inner door shell.
IMPORTANT:
Clip fork (D) back onto the moving slide shaft, before
adjusting it.
54-6
vnx.su
WINDOWS
Front door window
54
REFITTING
Slide the fixed upright downwards to release it from its

retaining clip (E).
Remove the fixed upright by sliding it upwards on the
inside of the door side.
Check that the two adhesive foam shims (F) are fitted
before refitting the fixed window, then carry out the
opposite procedure to removal.
Release the sliding window.
Release the fixed window.
54-7
vnx.su
WINDOWS
Moving window on the sliding side door
NOTE:
The sliding window is not sold separately.
54
Mark the bead of adhesive at (B), then cut it (area 2).
Only the window assembly with frame / fixed window /

sliding window / lock, is available from the replacement
parts shop.
With the marking tool (protected at the end), press

down on water discharge pipe (C) then cut out the
adhesive bead (area 3).
Cut out the rest of the adhesive bead, with a to and fro
motion.
REFITTING
Refer to the Procedure for fitting windows section
for information about surface preparation and applying
adhesive.

Before cutting the window with a stranded wire, the
following should be protected (protective tape
77 11 171 708):
the interior window frame,
the interior door groove,
the exterior window surround.
REMOVAL: two people required
Fit the three shims (D) to the door rabbet (there are
three holes for this).
Stick the two adhesive shims (E) to the door rabbet.
Attach adhesive bead (F) between the two water
discharge pipes.
Slide the window fully against shims (D).
Using the cutting wire insertion tool, pierce the

adhesive bead at (A) from inside the vehicle.
Cut through the bead of adhesive (area 1).
54-8
vnx.su
WINDOWS
Moving window on the sliding side door
Adjust the aspect clearance:

in the upper section of the door,
in the rear side section.

After having adjusted the aspect clearance, hold the
window in position using masking tape while the
adhesive dries.
54-9
vnx.su
54
154
WINDOWS
Rear wing panel window
PREPARATION BEFORE CUTTING using a

stranded wire
Remove:
the rear light,
the rear upper corner protector.
Protect: (protective tape 77 11 171 708):
the exterior window surround,
the sliding side door runner.

adhesive bead at (A) from inside the vehicle.
54-10
vnx.su
54
WINDOWS
Fit the two divisible shims (B) onto the wing panel.
Stick the two adhesive shims (C) to the wing panel flange.
Remember the position of join (D) of the adhesive bead.
Slide the window fully against shims (B).
54-11
vnx.su
54
WINDOWS
Cut through the adhesive bead (area 1), from bottom to top then in (area 2)
from the front to the rear of the vehicle.
Return to marking point (A).
Cut through the adhesive bead (area 3) from the front to the rear of the
vehicle, then in (area 4) from the bottom to the top.
REFITTING
Refer to the Procedure for fitting windows section for information about
surface preparation and applying adhesive.
54-12
vnx.su
54
WINDOWS
SPECIAL NOTE: version LH2 (long)
Fit the two shims (E) onto the wing panel.

Stick the five adhesive shims (F) to the wing panel flange.
Remember the position of join (G) of the adhesive bead.
Slide the window fully against shims (B).
54-13
vnx.su
54
WINDOWS

sliding side door runner (E).
rear upper corner protector (F).

After having adjusted the aspect clearance, keep the
window in position using masking tape while the
adhesive dries.
54-14
vnx.su
54
WINDOWS
Luggage compartment lid window
PREPARATION BEFORE CUTTING using a

stranded wire
Remove the windscreen wiper arms.
Protect (protective tape 77 11 171 708) the exterior
surround of the window.
Disconnect the de-icing connectors (A).

adhesive bead at (B) from inside the vehicle.
Cut through the bead of adhesive.
54-15
vnx.su
54
WINDOWS
REFITTING
Refer to the Procedure for fitting windows section for information about
surface preparation and applying adhesive.
Fit the three shims (C) to the door panel.

Stick the three adhesive shims (D) to the door panel flange.
Remember the position of join (E) of the adhesive bead.
Slide the window fully against shims (C).
54-16
vnx.su
54
WINDOWS

(F) right-hand luggage
compartment door box section,
(G) left-hand luggage
compartment door box section,
After having adjusted the aspect
clearance, keep the window in
position using masking tape while
the adhesive dries.
marks (H) enable the wiper

blades to be positioned.
54-17
vnx.su
54
WINDOWS
Tailgate window

Remove:
the windscreen wiper arms,
the de-icing wiring harness connectors,
the tailgate trim.
Protect (protective tape 77 11 171 708) the exterior
surround of the window.
REMOVAL
The stranded wire procedure requires two people.
NOTE:
There are no particular removal difficulties.
Using the wire inserting tool, pierce the adhesive bead
from inside the vehicle, then cut through it.
REFITTING
Refer to the Procedure for fitting windows section
for information about surface preparation and applying
adhesive.
54-18
vnx.su
54
WINDOWS
Tailgate window
Fit the three shims (A) to the door panel.

Stick the three adhesive shims (B) to the door panel flange.
Remember the position of join (C) of the adhesive bead.
Slide the window fully against shims (A).
After having adjusted the aspect clearance, keep the window in position
using masking tape while the adhesive dries.
Marks (D) enable the wiper blades to be positioned.
54-19
vnx.su
54
WINDOWS
Tailgate window
Trim
Trim mounting
Bodywork
Glass primer/painted panel
Adhesive compound
End seal
Tinting
Window
54-20
vnx.su
54
WINDOWS
Passenger Airbag Information
54
MINIMUM VEHICLE REPAIR TIME
Vehicle fitted with:
No airbag
One airbag
Two airbags
BIPAC +
30 minutes
1 hour 30 minutes
MONOPAC +
1 hour
2 hours
MONOPAC
1 hour
3 hours 30 minutes
All the times stated are for a temperature of 20 C with 50 % relative humidity.
It is not advisable to use ONE COMPONENT products at temperatures below 10 C.
IT IS IMPERATIVE THAT THESE OPERATION TIMES ARE ADHERED TO

TO GUARANTEE OPTIMUM SAFETY
IMPORTANT
Never mix the products when carrying out any adhesive bonding process.
Only use the products that are contained in the adhesive kit that has been selected.
54-21
vnx.su
WINDOWS
Product Descriptions
BIPAC + ADHESIVE KIT Part no.: 77 11 219 552
CONTENTS OF KIT
Two 225 ml cartridges (activator + PU).

One sachet (yellow) containing two cloths: one impregnated + one dry.
One 10 ml tube (green) of glass primer.
One 10 ml tube (red) of paint primer.
One mixer.
One pair of gloves.
One specific nozzle.
IMPORTANT
Take note of the product expiry date printed on the kit.
54-22
vnx.su
54
WINDOWS
MONOPAC + 2 ADHESIVE KIT Part no.: 77 11 218 570
Additional tube + one bottle nozzle, Part no.: 77 11 218 571
CONTENTS OF KIT
One 300 ml bottle.

One sachet (yellow) containing two cloths: one impregnated + one dry.
One 10 ml tube (green) of glass primer.
One 10 ml tube (red) of paint primer.
One pair of gloves.
One bottle nozzle.
IMPORTANT
54-23
vnx.su
54
WINDOWS
MONOPAC ADHESIVE KIT Part no.: 77 11 210 350
Additional cartridge + one nozzle: Part no.: 77 11 210 482
CONTENTS OF KIT
One 310 ml cartridge.

One 15 ml phial (yellow) of cleaner.
One 15 ml phial (green) of glass primer.
One 15 ml phial (red) of paint primer.
One pair of gloves.
Two applicators.
One specific nozzle.
IMPORTANT
54-24
vnx.su
54
WINDOWS
Procedure Chart
54
PREPARING THE WINDOW APERTURE
Original parts
Parts store replacement parts
Clean with heptane using a lint-free cloth
On the bare panel

primer wash
30 minutes for drying
Trim the mouldings level
Before painting
protect the area to be adhesive bonded using
masking tape
Red primer
on the entire window aperture (beading/paint)
drying time: 10 to 15 minutes
Red primer
54-25
vnx.su
WINDOWS
Procedure Chart
54
PREPARING THE WINDOW
New window
Window with residual moulding
Clean with heptane using a lint-free cloth
Trim the mouldings level
Wear protective gloves
Fit additional moulding and trim
Yellow primer
or impregnated cloth
Area without residual beading
Wiping is essential:
dry cloth or lint-free cloth
Red primer
on residual beading
Green primer
54-26
vnx.su
WINDOWS
Product Information
54
HEPTANE
PRIMER TUBES (red/green)
Part No.: 77 11 170 064
Take care when opening the tube:

keep the tube upright (impregnating pad at the top),
push on the pad, then screw down.
Very volatile solvent that facilitates optimum cleaning

of the area surrounding the adhesive-bonded area.
Evaporates very quickly.
After applying the primer, allow it to dry for 10 to

15 minutes before applying the adhesive.
IMPORTANT
If any of the product is spilt outside the adhesive
bonding area, it must be wiped away
immediately (risk of marking the glass).
54-27
vnx.su
WINDOWS
Equipment for applying adhesives
GUN FOR TWO-PART ADHESIVE
GUN FOR ONE-PART ADHESIVE
Part No.: 77 01 408 909
Part No.: 77 11 171 310
54
IMPORTANT
If the adhesive is in a ROUNDED TUBE package,
a retainer, Part no.: 77 11 211 726 MUST be fitted
to the gun. The cup is screwed onto the piston of
the gun.
54-28
vnx.su
WINDOWS
Adhesive moulding
54
The moulding must be applied evenly, preferably

starting at the bottom and in the centre.
APPLICATION
Finish by overlapping the two ends of the moulding by

50 mm.
After the old moulding has been cut away, the

remainder should be trimmed level as late as possible.
This ensures the moulding is as clean as possible (risk
of contamination is reduced).
The adhesive moulding will be triangular in shape
(application nozzle supplied with the kits).
If you do not have the special nozzles, ensure that you
observe the dimensions specified for the moulding.
Slide the two ends of the moulding together to merge

them.
VERY IMPORTANT
During any adhesive-bonding process, it is
essential that the window is installed
immediately after the adhesive has been applied
54-29
vnx.su
WINDOWS
Prohibited actions
54 M
CONTACT BETWEEN THE ADHESIVE

PRODUCT AND ANY OF THESE PRODUCTS
IS PROHIBITED:
THINNERS
GREASES
OILS
ALCOHOLS
CHROMATE/PHOSPHATE COATINGS
(before drying)
SILICONE PRODUCTS
SOAP AND SOAPY WATER
In the event of serious contamination (with
silicone type products), clean with distilled
water or acetone prior to any preparation work.
IMPORTANT
Never mix the products when carrying out any adhesive bonding process.
It is essential that:
only those products contained in the adhesive kit selected are used,
that protective clothing (gloves and goggles) is worn
54-30
vnx.su
EXTERIOR PROTECTION
155
Front bumper
NOTE:
First, you must remove:
the number plate,
the side repeaters,
the lens units.
55
the side bolt (B) (one on each side),

the bolts (C) (two on each side),
REMOVAL
Remove:
the three skid bolts (A),
the bolts (D) (three on each side),

the central bolt (E).
REFITTING
This operation requires two people.
55-1
vnx.su
EXTERIOR PROTECTION
Rear corner protector
REMOVAL
After removing the rear lights,
remove bolt (A).
Unfasten the two clips (B) and then remove the part so
that the coolant hose can be disconnected.
REFITTING
Check that the coolant hose is correctly positioned on
the jet before refitting.
55-2
vnx.su
55
EXTERIOR PROTECTION
Rear wing interior protector
REMOVAL
Remove:
bolts (A),
clips (B).
55-3
vnx.su
55
EXTERIOR PROTECTION
Front wing interior protector
55
Front wing interior protector, rear section
REMOVAL
Front wing interior protector, front section
Remove:
bolt (D),
clips (E).
Remove:
bolts (A),
bolt (B),
clips (C) and then remove the wheel arch screen.
55-4
vnx.su
EXTERIOR PROTECTION
155
Protective side strips
55
Cab pillar strip
REMOVAL
Front door strip
NOTE:
Removal is in three stages:
1 slide the moulding strip towards the rear of the
vehicle,
2 carefully move the moulding strip towards you,
3 keeping the moulding strip steady, slide it towards
the front of the vehicle.
IMPORTANT:
Indexing clips (A) cannot be removed without being
damaged, so always fit new ones after removal
(e.g. after a panel straightening operation).
Slide the strip towards the rear of the vehicle.
55-5
vnx.su
EXTERIOR PROTECTION
Protective side strips
Side panel strips
After removing the cab pillar strip,
slide the strip towards the front of the vehicle.

WARNING:
Indexing clips (A) cannot be removed without being
damaged, so always fit new ones after removal
(e.g. after a panel straightening operation).
55-6
vnx.su
55
EXTERIOR PROTECTION
Rear bumper
REMOVAL
Unclip the inner mountings.
Rear bumper, central section
Rear bumper, side section

After removing the rear lights,
Remove the three upper mounting bolts.
remove:
bolts (A),
55-7
vnx.su
55
EXTERIOR PROTECTION
Rear bumper
bolts (B),
bolt (C).
Unfasten clip (D).
55-8
vnx.su
55
EXTERIOR PROTECTION
Engine undertray
REMOVAL
Remove bolts (A) and then slide the skid towards the
REFITTING
Position retaining bracket (B) on the sub-frame and
continue refitting in the reverse order to removal.
55-9
vnx.su
55
EXTERIOR ACCESSORIES
156
Radiator grille
REMOVAL
Remove mounting bolts (A).
56-1
vnx.su
56
256
Scuttle panel
56
REMOVAL
Unfasten the clips (D), and then remove the scuttle

panel grille support as shown in the diagram (2).
Remove:
the wiper arms using tool El. 1294-01,
the two clips (A) and release the cover (1),
the seal (B),
the clips (C).
REFITTING
Check that the coolant hose is correctly positioned
before refitting.
Carefully release the grille so that you can remove the

wiper hose.
TIGHTENING TORQUE (in Nm)

Wiper arms
56-2
vnx.su
21
Door mirror
56
REMOVAL
the door mirror upper cover, to reach the bolt (B).

Carefully move the door mirror, and then disconnect
the connector.
REFITTING
Check that the connector is fitted on the door mirror
before refitting.
Remove:
the blanking cover, to reach the mounting bolt (A).
56-3
vnx.su
Door mirror glazing
56
REMOVAL
Door mirror lower glazing
Rear-view mirror upper glazing
Note:
the glass is made of a durable plastic.
Insert tool Car. 1363, use the edge of the door mirror
plastic casing as a support and push as shown above.
Insert an 80 mm mastic knife and push as shown

above.
Disconnect the various connectors.
Once the lower section has been released, insert tool

Car. 1363, then push gently as shown above to
release the upper glazing.
56-4
vnx.su
LOWER INTERIOR 157

ACCESSORIES
Dashboard
WARNING:
Pyrotechnic systems (airbags and pretensioners) must not be handled near
to a heat source or flame as they may be triggered.
57-1
vnx.su
57
LOWER INTERIOR ACCESSORIES

Dashboard
57
REMOVAL
Unclip the cover under the steering wheel to connect

Unclip the driver's front airbag module.
Disconnect the airbag connector.

IMPORTANT:
Before removing the airbag modules, lock the
compute using the diagnostic tool (for instructions,
refer to Section 88).
WARNING:
It is essential to mark the position of the rotary switch
and ensure that the wheels are straight when
removing it, so that the strip is centred.
Remove:
the steering wheel bolt,
the steering wheel.
57-2
vnx.su

Dashboard
57
the windscreen pillar trims.
Unclip the instrument panel visor.
Disconnect the antenna connector.
Remove the two mounting bolts (A) from the casing.

Undo the lower half cowling (1) then (2).
57-3
vnx.su

Dashboard
Disconnect the rotary switch connectors.
57
Remove:
the diagnostic socket (F),
the ignition switch connector (G).
Undo the screw (B) then release the rotary switch.
Remove:
the transponder ring (C),
the two dashboard mounting bolts (D),
the instrument panel, and then disconnect the
connectors,
disconnect the plate connectors (E) (depending on
version).
Disconnect the UCH (H) (it is located close to the

steering column).
57-4
vnx.su

Dashboard
57
Remove the dashboard mounting bolts (I).
Remove the dashboard mounting bolts (J).
Lock the steering wheel height adjustment control.
Disconnect the glove compartment light connector.
Remove the six mounting bolts from the passenger

airbag.
Unclip the central upper cover.

Remove the radio with tool MS. 1373.
Disconnect the connector, then release the airbag.
57-5
vnx.su

Dashboard
57
20372.1
Remove:
the central display,
Unclip the gaiter from the gear control lever.

Remove the four mounting bolts (L) from the central
console.
Disconnect the hazard warning lights connector.
Release the central console.
the dashboard mounting bolts (K).
Remove the mounting bolt (M).

Disconnect the connectors, then release the heater
control panel.
57-6
vnx.su

Dashboard
57
20383.1
Remove:
the mounting bolts (N),
the earth wire (O),
Unclip the ashtray supports.
Remove the four side mounting bolts (P).

the connector.
The remainder of the operations require two

people.
Partially release the dash board.
Disconnect the connectors from the speakers.
Remove the dashboard.
57-7
vnx.su

Dashboard
REFITTING
57
Special notes on the driver's airbag
Special notes on the rotary switch

Ensure that the wheels are straight.
Tighten the rotary switch mounting bolt.
Connect the connectors.
Connect the connector, the lock it.

Special notes on the steering wheel
IMPORTANT:
The steering wheel splines are made so that the wheel
can be fitted in one position only. The steering wheel
must fit back into the splines easily. Be careful not
to damage them.
Position the driver's front airbag module onto the

steering wheel and slide it downwards until it clicks into
place.
It is essential to replace the steering wheel bolt each

time it is removed and to tighten it to a torque of
4.4 daNm.
57-8
vnx.su

Dashboard
Special notes on the passenger airbag
57
Special features for vehicles fitted with a

tachograph
IMPORTANT:
fitting the airbag module.
safety lock.
Refer to the user's manual for vehicles fitted with a

tachograph for a description of how to reinitialise the
system.
It is essential to check the tightening torque of the

mounting bolts:
four bolts (O) = 2 Nm,
two bolts (P) = 8 Nm.
Check the module using the diagnostic tool. If
everything is correct, unlock the computer or see the
"Fault finding" section.
57-9
vnx.su
171
BODY INTERIOR TRIM

Windscreen pillar trim
REMOVAL
Partially remove the front door seal.

Unclip the windscreen pillar trim.
71-1
vnx.su
71
BODY INTERIOR TRIM

Cabin pillar trim
71
Carefully release trim (B), ensuring that it is not

damaged.
Remove:
the seat belt mounting for the front seats,
the side sliding door upper rail trim,
the frame seals for the front door and sliding side
door (partially).
Unclip the lining from the upper section (3), then the
lower section (4).
Unclip the two covers (A) to allow removal of the two

mounting bolts for the grab handle.
Unclip trim (1), then (2).
71-2
vnx.su
BODY INTERIOR TRIM

Front door sill lining
REMOVAL
Remove:
the front seats,
the seat mounting spacers,
the four mounting bolts (A), then remove the step.
71-3
vnx.su
71
BODY INTERIOR TRIM

Cabin head lining
71
Unclip the sun visor, then turn it towards the door.

Remove mountings (A).
REMOVAL
Remove:
the cabin pillar upper trims,
Using tool Car. 1597, remove:

the grab handle clips (B), then pull on the handle to
remove it,
the courtesy light.
Remove the head lining.
Unclip the side sections of the trim (1).

Remove the trim (2).
Unclip the central section of the trim (3).
71-4
vnx.su
BODY INTERIOR TRIM

Rear head lining
71
REMOVAL
Remove the cabin pillar upper trim.
Unclip the side sections of the trim (1).

Remove the trim (2).
Unclip the central section of the trim (3).
Remove:
the luggage compartment lid seal (A) partially,
latch cover (B),
the four clips (C),
the four grab handles (D),
the six covers for the luggage net fixings (E)
(see photo below).
71-5
vnx.su
BODY INTERIOR TRIM

Rear head lining
71
Remove the mounting pin, then the cover.
Using tool Car. 1363, remove:

the two courtesy lights (F),
the two clips (G), then remove the head lining
towards the rear of the vehicle (this operation
requires two people).
Unclip the mounting pins (E) (they spring out by a

centimetre), then remove the handles, pulling
upwards.
Remove:
the grab handle,
the upper rail trims of the sliding side door at (1), then
at (2).
71-6
vnx.su
BODY INTERIOR TRIM

Rear wing trim
Remove:
the cabin pillar trim,
the central lower trim,
REMOVAL
the mounting clips (C),
the trim panel.
Remove the 12 V connection (A), then disconnect the

connector.
Using unclipping pliers, remove:
the retaining clips (B),
the trim panel.
71-7
vnx.su
71
BODY INTERIOR TRIM

Rear sill trim
REMOVAL
Remove the sill trim mounting bolts (A), then remove

the sill trim.
71-8
vnx.su
71
BODY INTERIOR TRIM

Rear floor carpet
71
REMOVAL of the centre section luggage

compartment carpet
Remove:
the driver and passenger seats,
the two rear bench seats,
the two front seat mounting studs (A), then remove

the trim as shown above (1),
Remove:
the step mountings (C),
the eight bench seat mounting studs (D),
the four clips (E),
the carpet.
Rear section luggage compartment carpet
the mountings (B), then remove the trims (2).
Remove:
the sill trim mounting bolts (F),
the eight bench seat anchorage studs (G), then
remove the carpet.
Bench seat mounting studs
71-9
vnx.su
4.4
BODY INTERIOR TRIM

Front floor carpet
Partially remove the door seal.

Remove:
the three clips (D),
the two steering column mountings (E), then
disconnect the steering column,
the sealing gaiter (F),
the cabin carpet, taking care to release the cut-out
around the steering column.
71-10
vnx.su
71
BODY INTERIOR TRIM

Front floor carpet
REMOVAL
Partially remove the door seal.
Remove:
the front seats,
Remove the two clips (C).
71
Unclip the handbrake lever gaiter.

the battery compartment carpet (A),
the step mounting bolts (B), then remove the step.
Release the carpet from the lower trims at (1) then

from the handbrake lever.
71-11
vnx.su

TRIM
172
Front door lining
REMOVAL
Remove:
mounting bolt (A) then the inside opening handle,
mounting bolt (B) of the grab handle,
mounting bolts (C),
the window winder handle.
Unclip the panel.
72-1
vnx.su
72
SIDE OPENING ELEMENT TRIM

Front door lining
SPECIAL NOTES for models fitted with electric
windows
Remove the electric window control at (D).

Disconnect the connectors.
Unclip the panel.
REFITTING
The self-adhesive protective film must always be

replaced if it has been removed.
72-2
vnx.su
72
SIDE OPENING ELEMENT TRIM

Side sliding door trim
REMOVAL
Remove mounting bolt (A) then the inside opening handle.

Using tool (Car. 1597), remove:
interior locking button (B),
the five clips (C) (the female section remains affixed to the door box
section),
the door trim.
72-3
vnx.su
72
NON-SIDE OPENING173
ELEMENT TRIM
Bonnet trim
73
REMOVAL
Unclip retaining lugs (D), then remove the vent grille.

Remove:
the four mounting screws (A),
the five trim mounting screws (B).
NOTE:
change retaining clips (E) whenever the bonnet is
replaced.
Use unclipping pliers to remove clip (C).
73-1
vnx.su
NON-SIDE OPENING ELEMENT TRIM

Tailgate trim
REMOVAL
Using tool Car. 1597, unclip pull strap trim (A).
Disconnect the two heated rear screen harness

connectors (B).
Unclip the trim at (1), then at (2).
73-2
vnx.su
73
FRONT
175 SEAT FRAMES AND RUNNERS
Complete seat
REMOVAL
Disconnect connector (A) fitted to the seat height adjuster.
75-1
vnx.su
75
FRONT SEAT FRAMES

AND RUNNERS
275
Whole seat
75
Remove:
the seat belt mounting (B),
the three seat mounting bolts (C).
Protect the door sill lining, then release the seat (1)
(one centring pin holds the seat in the right-hand rear
section of the seat height adjuster).
Check for the presence of the metal clip (D) on the

right-hand rear section of the seat height adjuster.
REFITTING
IMPORTANT:
Before refitting the seat, inspect the condition of the
connectors on the seat frame and on the body.
Ensure that the spacers for the seat level adjustment

system are present (E).
75-2
Seat mounting nuts
4.4
The seat belt mounting on the seat
3.7
vnx.su
FRONT SEAT FRAMES

AND RUNNERS
375
Backrest frame
NOTE:
It is not necessary to remove the seat to remove the
seatback, it merely needs to be moved fully forwards.
75
Using a small flat screwdriver, remove the blanking

cover (A) on the adjustment handle, using the recess
provided for this purpose (B).
Remove the adjustment handle.
REMOVAL
Unclip the two mounting covers (C).

Unclip the two side covers at (1) then at (2).
75-3
vnx.su
FRONT SEAT FRAMES

AND RUNNERS
475
Backrest frame
Disconnect the supply connector for the heating layer

(if fitted to the vehicle).
75
Remove the rear, then the front, seatback cover

retaining strips.
Remove:
the four mounting bolts (D),
the seatback.
Simultaneously pull away the front and back of the

cover towards the upper section of the seatback.
Unclip the two head rest guide covers.
The cover is held by Velcro (E) at the front section of

the seatback.
NOTE:
It is not necessary to cut cover retaining clips (F) if
removing the cover and foam pad assembly.
75-4
vnx.su
FRONT SEAT FRAMES

AND RUNNERS
575
Backrest frame
75

Seatback frame mounting bolt
Remove the cover and foam pad.
REFITTING
For right-hand drive vehicles.
SPECIAL NOTE:
It will be necessary to cut the seatback tilt adjuster

shaft at (G) to be able to mount the cover (see drawing
opposite).
75-5
vnx.su
3.9
FRONT SEAT FRAMES

AND RUNNERS
675
Seat height adjuster and runners
75
REMOVAL
NOTE:
The runners may be removed without removing the
seat height adjuster.
the right hand cover at (1), then at (2).
Remove:
the seat belt mounting (A),
the left hand cover at (B),
Remove the eight mounting bolts (C) located at each

end of the runner.
75-6
vnx.su
FRONT SEAT FRAMES AND RUNNERS

Seat height adjuster and runners
Cut retaining clip (D).

Remove the connector (E).
Remove the seat.
75
Operate the adjustment control bar (F) until the three

runner mounting bolts (G) line up with the holes in
rail (H), then remove the bolts.
Slide the rail as far as it will go towards the front of the
seat, then remove bolts (I).
Remove the runners together with the adjustment
control bar.
REFITTING
75-7
Seat bolt on frame (C)
1.9
Runner bolt on seat (G)
1.9
vnx.su
FRONT SEAT FRAMES

AND RUNNERS
775
Seat height adjustment mechanism
75
REMOVAL
Remove the eight mounting bolts (A) located at each

end of the runner.
Cut retaining clip (B).
Remove:
the sleeve stop (D),
the control cable (E).
Mark the centre of retaining pin (F) using a centring

punch. Use a drill to grind off the matt section of the
retaining pin, then remove it.
Remove the connector (C).

Remove the stop and the pin (G).
Remove the seat.
Disconnect the adjustment mechanism.
75-8
vnx.su
FRONT SEAT FRAMES AND RUNNERS

Seat height adjustment mechanism
REFITTING
The replacement parts store will supply specific After
Sales retaining pins.
Ensure that the two plastic washers (H) are in place.
75-9
vnx.su
75
FRONT SEAT FRAMES

AND RUNNERS
875
Complete rear bench
REMOVAL
75
the seat belt mounting bolt (B) for the bench seat.
Disconnect the harness connector under the seat.
Protect the door sill lining, then release the bench
seat (1) (one centring pin (C) holds the seat at the
rear).
Remove:
the four mounting screws (A),
75-10
vnx.su
FRONT SEAT FRAMES

AND RUNNERS
975
Complete rear bench
REFITTING
75
IMPORTANT:
Before refitting the seat, inspect the condition of the
connectors on the seat frame and on the body.
Front bench seat mounting
4.4
The seat belt mounting on the bench seat
3.7
Check for the presence of the metal clip (D) on the

lower left-hand rear section of the frame.
Ensure that the spacers for the seat level adjustment

system (E) are present at each mounting point.
75-11
vnx.su
REAR SEAT FRAMES

176 AND RUNNERS
Complete rear bench
REMOVAL
76
Slide the bench seat towards the rear of the vehicle

(3).
This operation requires two people.
Lift the rear part of the bench seat (4).

Slide the seat towards the front of the vehicle (5), then
remove it.
Unscrew the two sliding bolts (A), then release the

seat belt clips.
Unscrew the two bench seat mounting bolts (1), then
(2).
76-1
vnx.su
REAR SEAT FRAMES AND RUNNERS

Complete rear bench
REFITTING
IMPORTANT:
Before refitting, check the tightness of the seat
anchorage bolts.
Tightening torque: 4.4 daNm.
NOTE:
The removal method is identical for the two rear bench
seats.
76-2
vnx.su
76

Lock and locking control of the second-row bench seatback
76
REMOVING the lock
REMOVING the control catch
NOTE:
it is not necessary to remove the bench seat to carry
out this operation.
The lock must be removed prior to carrying out this

operation.
Lower the seatback.

Remove the retaining strips around the lock
mechanism.
Remove the two lock mounting bolts (A).

Remove the lock (1) and unclip the control cable.
Remove the three mounting bolts (B) of the catch;

On each side of the seat, remove:
the two bolts (C) and the seatback stop spacers,
the two mounting bolts (D) of the seatback.
Lower the seatback and remove the retaining strip (E)

from the seatback cover.
76-3
vnx.su

76
REFITTING

cover to half-way.
NOTE:
To fit the new lock mechanism, remove pin (H);
remove the reduction gearing (G).
Remove the three retaining strips (F).
IMPORTANT
Ensure that the control cable is correctly routed (I).
Cut the five control cable retaining clips, then remove
the cable.
Replace the retaining clips.
76-4
vnx.su


Lock mechanism mounting bolt
1.9
Control catch mounting bolt
0.2
Seatback mounting bolt
3.7
Seatback stop bolt
1.9
76-5
vnx.su
76
REAR SEAT FRAMES276

AND RUNNERS
Rear bench seat lower latches
76
Slide the seat towards the front of the vehicle (5), then
remove it.
SPECIAL NOTE:
The two rear bench seats (first and second row)
have the same locking system.
REMOVAL
Hold spring (B) in position, then remove mounting bolt

(C).
Unscrew the two sliding bolts (A), then remove the
seat belt clips.
Remove the lock mechanism.
Unscrew the two bench seat mounting bolts (1), then

(2).
REFITTING
IMPORTANT:
Take care to observe the correct direction of fitting of
spring (B).
Lock mechanism mounting bolt (C)
Slide the bench seat towards the rear of the vehicle

(3).
Lift the rear part of the bench seat (4).
76-6
vnx.su
0.6
REAR SEAT FRAMES376

AND RUNNERS
Rear bench seat lower latches
Ensure that the lower guides are in place.

The indexing lug (D) clips into the hole in the frame
(E).
76-7
vnx.su
76

Second-row rear bench seat lower latches
REMOVAL: This operation requires two people
Lower the bench seatback.
Remove:
the bench seat,
the mounting bolts (A).
Remove the entire mechanism.
REFITTING (assembly sequence):

Exterior locking mechanism (B).
Lower locking mechanism (C).
Lock mechanism mounting bolt (A)
1.9
76-8
vnx.su
76
FRONT SEAT
TRIM
177
Seatback trim
77
REMOVAL

Remove the seatback.
Unclip the two head rest guide covers.
The cover is held by Velcro (A) at the front section of

the seatback.
Cut the retaining clips (B).
Remove the cover.
Remove the rear, then the front, seatback cover

retaining strips.
Remove the foam pad.
77-1
vnx.su
FRONT SEAT TRIM

Seat cushion trim
77
REMOVAL
Remove:
the seat,
the seatback.
the front section clips.

Release:
the cover,
the foam pad.
Remove lower seat cushion cover retaining strips.
REFITTING
SPECIAL INSTRUCTIONS: on vehicles equipped
with a heater pad, it will be necessary to cut the seat
cushion at (A), to enable the heater pad electrical
harness to be removed.
Cut:
the side section clips,
77-2
vnx.su
178
REAR SEAT TRIM

Front row seatback trim
REMOVAL of the 1/3 seatback

Unclip the two head restraint guide covers.
78

cover towards the upper section of the seatback, the
cover is held in place by Velcro (C) at the front section
of the seatback.
Cut the retaining clips at (D).
Remove the 1/3 seatback cover.
REMOVAL of the 2/3 seatback
Release:
the retaining strips (A) of the cover,
the cover and foam pad (B).
Remove:
the seat belt mounting bolt (E), beneath the bench
seat,
the two bolts (F) of the upper cover,
the cover.
If only the cover is being removed:

Remove the cover retaining strips (A).
78-1
vnx.su
REAR SEAT TRIM

Front row seatback trim
Release:
the front and rear seatback cover retaining strips (G),
the retaining strip (H) (see photo below).
78
The cover is held in place by Velcro at (I).

Cut the retaining clips at (J).
Remove the cover.

78-2
vnx.su
REAR SEAT TRIM

Second row seatback trim
78
REMOVAL
the two seatback mounting bolts (E).
Remove:
the seat belt mounting bolt (A), beneath the bench
seat,
the two bolts (B) of the upper cover,
the cover.
Lower the back of the bench seat, then release:

the retaining strip (F) along the join,
Unclip the six head restraint guide covers.
the seatback cover retaining strip (G).
Remove:
the three mounting bolts (C) of the catch, then
the two bolts and spacers (D) of the seatback stop,
78-3
vnx.su
REAR SEAT TRIM

Second row seatback trim

cover to half-way.
Release:
the three retaining strips (H),
the cover, held in place by Velcro, at (I).

Cut the retaining clips at (J).
Release:
the cover,
the foam pad.
78-4
vnx.su
78
REAR SEAT TRIM

Bench seat cushion trim
78
REMOVAL
Remove the seat.
the cover retaining straps.

Remove the cover and foam cushion pad together.
Release the seat cover retaining strips beneath the
bench seat frame.
Cut the retaining clips at the rear.

Release the two sliding bolts (A), on each side of the
bench seat.
Release:
the seat cover retaining strips, on the rear section,
78-5
vnx.su
REAR SEAT TRIM

IMPORTANT: take care not to damage the

mounting lugs when cutting the clips.
78
the centre section clips.

Remove the cover.
REFITTING
IMPORTANT: Check the number and positioning of
the clips under the bench seat foam pads is correct.
Cut:
the side section clips,
Front row left-hand bench seat cushion.
78-6
vnx.su
REAR SEAT TRIM

Front row right-hand bench seat cushion.
78
Second row right-hand bench seat cushion.
Second row left-hand bench seat cushion.
78-7
vnx.su
ANTI-CORROSION194
PROTECTION
Sealing mastic for removable assemblies
The purpose of this section is to recommend a product for SEALING THE DETACHABLE BODYWORK
ASSEMBLIES (bolt-on, screw-on, etc.).
When sealing, it is essential to use IXEL sealing mastic part number 77 11 170 230.
94-1
vnx.su
94
ANTI-CORROSION PROTECTION
ASSEMBLIES CONCERNED:
Sealing the tailgate hinge leaves to be carried out
each time the tailgate is removed.
Sealing the Parts Department door bolt-on hinges.
94
The malleable mastic is supplied in a preformed 6L

300 mm roll which is applied to the mounting between
the two components to be assembled.
Generally, when a bodywork component is removed or

replaced, the removable assemblies (hinges, hinge
leaves) should be sealed using mastic, in accordance
with the original fitting.
After pressure has been applied, this product seals the

assembly and makes it weather-tight.
NOTE:
Before applying this product, both mating faces must
be cleaned using a surface cleaner.
94-2
vnx.su
ANTI-CORROSION PROTECTION
94
Sealing the bolt-on door hinges fitted when fitting a replacement door from the Parts Department.
Apply a mastic bead between the plate and the bodywork at the two hinge mounting bolts (C).
Reminder of the paintwork operations on a door following its replacement:
Paint the special After-Sales bolt-on hinges and door frames in accordance with the After-Sales paint range.
Fit hinges with mastic operations in between the plate and the bodywork.
Fit the door on the vehicle and on the hinge pins.
Adjust the door on the vehicle and tighten hinge bolts (C).
Touch up the paint around the hinges and bolt heads (C) if the paintwork was damaged when these were adjusted.
Paint the door panel and its pillars with the door fitted according to the After-Sales paint operations.
94-3
vnx.su
OPERATIONS FOR PAINT APPLICATION

ON PLASTIC
195
Painting NORYL GTX wings
Operations for painting on Noryl GTX
Degrease.
Sand with a very fine buffer pad (grey pad), soaked in antistatic thinner.
Degrease with antistatic thinner.
Wipe carefully.
Apply MAXIMA HS polyurethane dual component finish (following supplier's technical information).
Bake for 35 to 40 minutes at 60 C.
Polish P800.
Degrease with surface cleaner.
Apply paint (following supplier's technical information):
the base coats,
the top coat and lacquer (without flexibiliser*).
Bake for 35 minutes at 60 C.
* WARNING: these paint operations are only applicable to NORYL GTX wings.
95-2
vnx.su
95
HEATING
161
General information
AIR DISTRIBUTION: description of the air distributors in the passenger compartment.
1
2
3
4
5
6
7
8
Left-hand side air vent

Left-hand side window demisting
Windscreen demisting
Central air vents
Control panel
Right-hand side window demisting
Right-hand side air vent
Footwell heater outlets for front passengers
61-1
vnx.su
61
HEATING
General information
1 Air distribution unit

2 Heater radiator
3 Heater hoses
1
2
3
4
Fan assembly
Recirculation motor
Power module
Ventilation motor
61-2
vnx.su
61
HEATING
Operating principle
CONTROL PANEL
A
B
B1
C
D
Air temperature adjustment,

Air recirculation operation,
Passenger compartment air recirculation operating indicator light (on
some vehicles),
Adjustment of the amount of air delivered to the passenger
compartment,
Distribution of air in the passenger compartment.
Recirculation can:
isolate the passenger compartment from the external atmosphere (e.g.
when driving in polluted areas, etc.),
reach the desired passenger compartment temperature quickly.
Prolonged use of the air recirculation mode may cause the windows to mist
up or lead to odours, as the air is not renewed.
We therefore recommend that you return to normal mode (external air)
as soon as you have passed through the polluted areas, by pressing
button (B).
61-3
vnx.su
61
HEATING
Operating principle
Air temperature adjustment

Move the control (A).
To the right: Maximum possible temperature.
To the left: Minimum possible temperature.
compartment.
Move control (C).
The passenger compartment is ventilated by blown air. The ventilation fan
determines the amount of air supplied, but vehicle speed does affect it
slightly.
The further the control is moved to the right, the greater the quantity of air
blown.
NOTE:
To fully close the air inlet and turn off this function, turn control (C) to 0.
61-4
vnx.su
61
HEATING
Operating principle
Air recirculation control

Press control (B); the operation indicator light (B1) lights up.
When this function is switched on, the air from the passenger compartment is
recirculated and no external air is admitted.
61-5
vnx.su
61
HEATING
Passenger compartment filter
REMOVAL
Open the bonnet.
Remove the filter.
REFITTING
61-6
vnx.su
61
HEATING
Control panel
REMOVAL
61
Remove the control panel and its support - bolt (D).

Unclip:
gear lever gaiter (A) and unscrew the four bolts (B)
on the console,
the central console to access the hazard warning

lights switch connector (C).
61-7
vnx.su
HEATING
Control panel
REMOVAL
61
the two mounting bolts (F) securing the control panel

to its support.
Disconnect connectors (A), (B) and (C).
Remove:
air temperature control wire (D),
air distribution control wire (E),
Remove lower mounting (I) and remove the control
panel.
REFITTING
61-8
vnx.su
HEATING
Control cables
TEMPERATURE ADJUSTMENT DIAL CONTROL
WIRE
Remove wire (B).
REMOVAL
Temperature adjustment dial control wire on the
control unit side.
Remove the control panel (see the Control panel
section).
REFITTING
Temperature adjustment dial control wire on the
distribution unit side.
Remove:
the right-hand side covers,
the two clips (A).
61-9
vnx.su
61
HEATING
Control cables
AIR MIXING FLAP CONTROL WIRE
REMOVAL
Air mixing flap control wire on the control unit
side.
Remove the control panel (see the Control panel
section).
Air mixing flap control wire on the distribution unit
side.
Remove:
the two clips (A),
the right-hand side cover.
Remove wire (C).
REFITTING
61-10
vnx.su
61
HEATING
Air distribution unit
REMOVAL - REFITTING
Air distribution unit (A) can be accessed after removing the dashboard and
the passenger compartment reinforcement beam.
Follow the removal - refitting instructions in Section 62: Removal - refitting
the evaporator unit.
IMPORTANT:
Before reconnecting the driver's and passenger front airbag modules, the
procedure for checking the correct operation of the system must be
performed:
Switch on the ignition and check that the indicator light comes on for three
seconds and then goes out permanently.
Refer to Section 88 if the light fails to operate in this way.
61-11
vnx.su
61
HEATING
Air distribution unit
ADJUSTMENT AND DISTRIBUTION OF THE
HEATING POWER
There are two ways of varying the heating power:
air flow,
the air temperature.
The driver can adjust the air flow by using the control
panel instruments.
The air temperature is adjusted using the various
settings of the mixing flap. In the air distribution unit,
the air is diverted depending on the position of the
mixing flap, passes through to the heating radiator and
is then mixed with cold air to obtain the air temperature
requested by the user.
Air is supplied and distributed to the passenger
compartment through:
a five-mode air distributor,
four vents,
two front footwell ducts,
a windscreen demisting/de-icing vent,
two front side window demisting/de-icing vents.
61-12
vnx.su
61
HEATING
Radiator
61
REMOVAL
Place a container underneath the radiator and drain it.
Engine compartment side
Unscrew the two clips (A) on the radiator coolant

circuit hoses.
Place hose clamps over each coolant hose in front of

the heater matrix bleed screws.
Remove the two coolant hoses.
Unscrew the two radiator mounting bolts (B) and then

remove the radiator.
The dashboard does not need to be removed

before removing the radiator.
Remove the central console (see the Control panel
section).
Disconnect the hazard lights switch.
Unclip the three clips (A) on the left-hand side cover
with the air duct.
REFITTING
Replace the two radiator hose seals and replace the
two clamps correctly.
61-13
vnx.su
HEATING
Air inlet unit
REMOVAL
Disconnect:
the battery,
the air inlet unit connector.
Remove the four air inlet unit mountings.
Remove the coolant recovery hose.
Remove the air inlet unit.
REFITTING
61-14
vnx.su
61
HEATING
Fan assembly
REMOVAL
Open the bonnet.
Unscrew bolts (A) and remove the heating ventilation
motor from its housing.
Remove the unit and turn it gently. This will enable you
to disconnect supply connector (B).
REFITTING
61-15
vnx.su
61
AIR CONDITIONING
Power module
REFITTING
The power module controls the speed of the fan

assembly depending on the requirements determined
by the automatic control.
It can be accessed without removing the fan assembly.
REMOVAL
Disconnect connectors, (A) and (B).
Unscrew the fan assembly trim bolt.
Remove:
the wiring harness,
the power module mounting bolt,
the power module.
61-16
vnx.su
61
HEATING
Independent heater unit
61
Disconnect connector (C) from the metering pump.

Heater unit mounting bolts 0.8
The heater unit is located under the vehicle on the
right-hand side.
REMOVAL
Put the vehicle on a 2-post lift (5 tonnes minimum).
Place a hose clamp on each pipe (A) of the coolant
circuit, on the boiler side.
Remove the two clamps (B) on the coolant hoses
(heater inlet/outlet connections).
Disconnect heater connections (D).

Remove:
supply hose (1) from the metering pump,
boiler mounting bolt (E).
61-17
vnx.su
HEATING
Independent heating duct
Remove the two other mounting bolts (F) while
supporting it.
Removal of the heater from its bracket

Unscrew bolt (1) then turn the unit over.
61-18
vnx.su
61
HEATING
Unscrew bolt (2) and remove the heater from its mounting by releasing
lugs (3).
61-19
vnx.su
61
HEATING
Metering pump
REMOVAL
Place the vehicle on a lift.
Disconnect connectors (A) on the metering pump.
Remove:
fuel supply pipes (B) and (C),
the metering pump with or without its mounting.

REFITTING
IMPORTANT:
When refitting, fix the metering pump in the same
position.
61-20
vnx.su
61
F9Q engine
HEATING
Fuel supply pipe
61
REMOVAL
To remove the fuel supply pipe from the heater, you must first drain and remove the fuel tank (see the procedure in
Section 13 of the Workshop Repair Manual).
Unclip the supply quick-release union on the metering pump.
Drain the fuel tank and remove it.
Unclip supply quick-release union (1) on the pump-gauge assembly.
REFITTING
Refit in the reverse order to removal.
61-21
vnx.su
HEATING
Coolant supply pipe
REMOVAL
To remove the coolant supply pipes from the heater
unit, you must:
disconnect the battery.
fit a hose clamp on each side of the coolant supply
pipe.
pierce rivet (A) on the vehicles concerned.
unscrew the two coolant supply pipe mounting bolts
(B).
loosen clamps (B) and remove the supply pipe
housing.
REFITTING
Top up the coolant and bleed the main circuit.
61-22
vnx.su
61
HEATING
61
the two front seat anchoring points (C), then remove

the trim as shown above (1).
IMPORTANT:
It is not permitted to handle the pyrotechnic systems
(airbags and pretensioners) near a source of heat or
flame as there is a risk of triggering.
IMPORTANT:
Before removing a seat, lock the computer using the
diagnostic tool. When this function is activated, all
the trigger lines are disabled and the airbag indicator
light on the instrument panel comes on.
REMOVAL
Remove the front bench seat (see Section 75:
Complete seat).
NOTE:
This operation does not require the removal of the
driver's seat.
Remove mounting (D), then pull back the trim (2).
The procedure for removing the bench seat is identical

to the procedure for removing a single seat.
Remove the central console (see Section 61: Control
panel).
Right-hand side
Remove:
bench seat (A),
mounting bolts (B), then release the step,
61-23
vnx.su
HEATING
Partially release the door seal on the door on the righthand side.
61
REFITTING
Remove the two clips (3) then partially remove the

carpet and fold it back.
Unclip the electrical wiring harness clip.
Remove the air duct.
When refitting the seat and the front bench seat,

ensure that seat and front bench seat height
adjustment spacers (C) are replaced.
IMPORTANT:
Before refitting the seat, check visually the condition
of the connectors on the seat frame and on the body.
TIGHTENING TORQUES (in Nm)
61-24
Front seat mounting nuts
44
Seat belt mounting
37
vnx.su
AIR CONDITIONING
162
General information
62-1
vnx.su
62
AIR CONDITIONING
General information
A
B
C
D
E
F
Passenger compartment
Engine compartment
External air
To air mixing unit
Bulkhead
External or recirculated air
1
2
3
4
5
6
7
8
9
10
11
12
Compressor
Condenser
Dehydration canister
Pressure sensor
Pressure relief valve
Evaporator
Climate control fan
Engine cooling fan
Engine radiator
High pressure fluid
Low pressure vapour
High pressure vapour
62-2
vnx.su
62
AIR CONDITIONING
Consumables
F9Q ENGINE
Compressor:
DELPHI HARRISON V5
Oil for DELPHI HARRISON compressor:
PLANETELF PAG 488 220 cm3 + 15
Refrigerant:
R134a: 700 + 25
62-3
vnx.su
62
AIR CONDITIONING
Operating principle
CONTROL PANEL
A
B
B1
C
D
D1
E
Air temperature adjustment,

Air recirculation selection,
Passenger compartment air recirculation operating indicator light (on
some vehicles),
compartment,
Air conditioning selection,
Air conditioning operation indicator light
(the air is taken from outside the vehicle and is recirculated
continuously),
Distribution of air in the passenger compartment.
Recirculation can:
isolate the passenger compartment from the external atmosphere
(e.g. when driving in polluted areas, etc.),
reach the desired passenger compartment temperature quickly.
Prolonged use of the air recirculation mode may cause the windows to mist
up or lead to odours, as the air is not renewed.
We therefore recommend that you return to normal mode (external air) as
soon as you have passed through the polluted areas, by pressing
button (B).
62-4
vnx.su
62
AIR CONDITIONING
Operating principle
AIR CONDITIONING
Air conditioning controls.
Control (D) switches the air conditioning system on and off.
Use the air conditioning to:
lower the temperature inside the passenger compartment, especially on hot
days when driving or after parking the vehicle in direct sunlight,
reduce the volume of air blown into the passenger compartment
(for demisting).
NOTE: the air conditioning can be used in any conditions, but it does not
operate when the external temperature is low.
Indicator light D1 off
The air conditioning is not operating.
The heating and ventilation system is identical to a vehicle without air
conditioning.
Indicator light D1 on
The air conditioning is operating normally.
The air is taken from outside the vehicle and is recirculated continuously.
62-5
vnx.su
62
AIR CONDITIONING
Operating principle
In very hot weather, or when the vehicle has been parked in direct sunlight,
open the doors for a few minutes to let the hot air out before driving off.
Use the isolating the passenger compartment function to lower the
temperature to the desired level more quickly. Switch the recirculation mode
off once the desired temperature level has been reached.
Keep the windows closed when using the air conditioning to ensure that the
function works efficiently.
No cool air production
Check that the controls are working correctly and that the fuses are in good
condition. If not, turn off the heating and ventilation function (indicator light
D1 goes out).
Do not open the circuit as the refrigerant can harm the eyes and skin.
62-6
vnx.su
62
AIR CONDITIONING
Particle filter
REMOVAL
Open the bonnet.
Remove the filter.
REFITTING
62-7
vnx.su
62
AIR CONDITIONING
Condenser
62
REMOVAL
REFITTING
Check that the condenser is correctly secured.
Drain the refrigerant circuit using the filling equipment.
Remove:
the lens units,
the mudflap mountings on the bumper,
the inner protection bolts on the wing fixed to the
bumper only,
front bumper (two-man job)
(see the information on the exterior protection in
section 55).
Refit the bumper (two-man job).

Fill up the refrigerant circuit using the filling equipment.
When replacing the condenser, add 30 ml of
recommended oil to the compressor.
NOTE: remember to reconnect the pressure sensor.
Disconnect the pressure sensor.

Remove the hose unions on the condenser.
Unclip the condenser from the radiator at (A) and (B)
then gently raise the condenser upwards.
Take the condenser out from underneath.
62-8
vnx.su
AIR CONDITIONING
Dehydration canister
REMOVAL
Remove:
the right-hand side lens unit,
the mounting bolt (A) on the hose retaining bracket,
the mounting bolt (B) on the low pressure hose on the
body,
the mounting bolts (C) on the two hoses on the
dehydration canister,
the canister with the seal.

REFITTING
Oil the hose seals with the recommended oil.
When changing the dehydration canister, add 15 ml of
62-9
vnx.su
62
AIR CONDITIONING
Compressor
REMOVAL
62
Remove the three mountings (B) on the compressor.

Remove the accessories belt (see Section 07 for
information on the accessories belt tension).
NOTE: all removed belts must be replaced.
Remove:
the air conditioning hoses.
Disconnect the compressor connector (A).
REFITTING
If you need to fit a new compressor, remember that
they come pre-filled with oil.
IMPORTANT: Please follow carefully all the
instructions relating to adding oil when working on air
conditioning circuit components.
Proceed in the reverse order to removal (see
Section 07 Accessories belt tension).
Tighten the refrigerant hose mounting bolts on the
compressor to 3 daNm.
62-10
vnx.su
AIR CONDITIONING
Pressure relief valve
SPECIAL FEATURE:
Loosen nut (A).
Trafic is fitted with a calibrated choke pressure relief

valve.
Unscrew bolt (B).
62
Take out the high pressure hose and finish unscrewing

the nut.
Remove the pressure relief valve with a pair of long
flat-nose pliers.
A evaporator side
B driver's side
REMOVAL
REFITTING
Remove the air inlet unit (see Section 61 Heating for

information on the air inlet unit and the fan
assembly).

When changing the condenser, add 10 ml of
62-11
vnx.su
AIR CONDITIONING
Evaporator unit
REMOVING THE DASHBOARD
IMPORTANT: it is forbidden to handle the pyrotechnic systems

(air bags and pretensioners) near a source of heat or flame as there is
a risk of triggering.
62-12
vnx.su
62
AIR CONDITIONING
Evaporator unit
REMOVAL
62
Unclip the steering wheel air bag cushion.

Disconnect the air bag connector.
IMPORTANT: you must mark the position of the
rotary switch with the wheels straight at the
removal stage. This will ensure that the strip
length can be correctly positioned in the centre.
Remove:
the steering wheel.
Unclip the cover under the steering wheel.

IMPORTANT: use the diagnostic tool to lock the
computer before removing the air bags (see
Section 88 for instructions).
62-13
vnx.su
AIR CONDITIONING
Evaporator unit
Disconnect the antenna connector.
62
Remove the two mounting bolts (A).

Unclip the instrument panel visor.
62-14
vnx.su
AIR CONDITIONING
Evaporator unit
62
Remove:
Undo the screw (B) then release the rotary switch.
Remove:
the instrument panel.
the plate (E) and disconnect the connectors
(according to the version).

steering column).
62-15
vnx.su
AIR CONDITIONING
Evaporator unit
62
Remove the mounting bolts (I).
Remove the mounting bolts (J).
Remove the six mounting bolts from the passenger air

bag.

Remove the audio equipment.
Disconnect the connector, then release the air bag.
62-16
vnx.su
AIR CONDITIONING
Evaporator unit
Remove:
62

Remove the four mounting screws (L).
the mounting bolts (K).

control panel.
62-17
vnx.su
AIR CONDITIONING
Evaporator unit
Remove:
the earth wire (O),
62

the connector.
The remaining operations require two people.

Partially release the dash board.
62-18
vnx.su
AIR CONDITIONING
Evaporator unit
62
In the engine compartment
Remove the two side covers with their heating duct.
Remove the air inlet unit (see Section 61 for

information on fan assembly heating) to enable you
to remove the two air conditioning hoses where they
meet the bulkhead (remember to plug the holes).
Place a container underneath the radiator and drain it.

Unscrew the two clamps (A) on the refrigerant hoses
and then remove the hoses.
Fit a hose clamp on each refrigerant hose on the

radiator in front of the heater matrix bleed screws.
62-19
vnx.su
AIR CONDITIONING
Evaporator unit
Remove the electric wiring harness and the relay plate (mountings linked to
the reinforcer beam).
Disconnect the evaporator sensor.
Remove:
the two mounting bolts (B) on the steering column,
the bolts (D) and (E) on the air distribution unit,
the mounting bolts (F) and (G) on the reinforcer beam,
Tip the reinforcer beam to remove the air distribution unit.
NOTE: check that the coolant channel of the evaporator is sound.
62-20
vnx.su
62
AIR CONDITIONING
Evaporator unit
EVAPORATOR UNIT REMOVAL
Remove the seals (A) and (B).
Open the unit (C) and (D).
EVAPORATOR UNIT REFITTING

IMPORTANT: It is essential to fit the electrical wiring
harness correctly to avoid any possible damage.
62-21
vnx.su
62
AIR CONDITIONING
Evaporator unit
DASHBOARD REFITTING
62
Special notes on the driver's air bag

Connect the connector, the lock it.

Place the cushion on the steering wheel and slide it
downwards until it clicks.

IMPORTANT: the splines on the steering wheel have
foolproofing devices. The steering wheel must fit
back into the splines easily. Be careful not to
damage them.

4.4 daNm.
62-22
vnx.su
AIR CONDITIONING
Evaporator unit
Special notes on the passenger air bag
IMPORTANT:
fitting the air bag module.
safety lock.

mounting bolts:
four bolts (O) = 2 daNm,
two bolts (P) = 8 daNm.
"Fault finding" section.
Special features for vehicles fitted with a
tachograph
tachograph for a description of how to reboot the
system.
Fill up with refrigerant using the filling equipment.
62-23
vnx.su
62
AIR CONDITIONING
Connecting pipes
HIGH PRESSURE HOSE BETWEEN THE
COMPRESSOR AND THE CONDENSER
REMOVAL
Drain refrigerant circuit R134a using the filling
equipment.
Remove:
the assembly,
the lens units,
the bumper,
the hose.
Fit the plugs into the ports.
REFITTING
When changing a hose, add 10 ml of oil or when a
hose splits (rapid leak), add 100 ml.
62-24
vnx.su
62
AIR CONDITIONING
Connecting pipes
HIGH PRESSURE HOSE BETWEEN THE CONDENSER AND THE EVAPORATOR
REMOVAL
Drain refrigerant circuit R134a using the filling equipment.
Remove:
the fan assembly,
the mounting bolt on the evaporator where it meets the bulkhead,
the lens units.
Unclip the central retaining clip on the connecting hose.
Remove:
the engine undertray (front and centre sections),
the mounting bolt on the condenser.
Unscrew the front section and tip it up.
Remove the connecting hose.
REFITTING
NOTE: divide the hose into two sections with the threaded union (A) to remove the pressure relief valve.
When changing a hose, add 10 ml of oil or when a hose splits (rapid leak), add 100 ml.
62-25
vnx.su
62
AIR CONDITIONING
Connecting pipes
LOW PRESSURE HOSE BETWEEN THE EVAPORATOR AND THE DEHYDRATION CANISTER
REMOVAL
Remove:
the assembly,
the lens units,
the mounting bolt on the evaporator where it meets the bulkhead,
the mounting bolt on the dehydration canister,
the retaining bracket bolt on the bumper.
Unclip the retaining clip on the retaining bracket located by the shock absorber.
Remove the hose.
REFITTING
62-26
vnx.su
62
AIR CONDITIONING
Connecting pipes
LOW PRESSURE HOSE BETWEEN THE DEHYDRATION CANISTER AND THE COMPRESSOR
REMOVAL
Remove:
the lens units,
the mounting bolt on the dehydration canister,
the engine undertray (front and centre sections),
the mounting bolt on the compressor.
Unclip the retaining clip on the retaining bracket located by the shock absorber.
Remove the hose.
REFITTING
62-27
vnx.su
62
AIR CONDITIONING
Pressure sensor
PRESSURE SENSOR
62
The injection computer controls the engine cooling

fans depending on the high pressure in the refrigerant
circuit and the vehicle speed.
You do not need to drain the refrigerant circuit to
remove the pressure sensor.
An automatic shut-off valve isolates the circuit from the
environment when the switch is removed.
The pressure sensor fitted at the condenser inlet

protects the refrigerant circuit.
Low pressure cut-off: 3 bar
High pressure cut-off: 30 bar
It keeps the injection computer informed of the
refrigerant circuit pressure.
62-28
vnx.su
AIR CONDITIONING
Power module
The power module controls the speed of the blower

depending on the requirements determined by the
automatic control.
It can be accessed without removing the fan assembly.
REMOVAL
Disconnect the connectors, (A) and (B).
Unscrew the fan assembly trim bolt (C).
Remove:
the wiring harness,
the power module mounting bolt,
the power module.
REFITTING
62-29
vnx.su
62
AIR CONDITIONING
Recirculation motor
The recirculation motor positions the air inlet flap

accrording to the requirements determined by the
automatic control.
Remove the air inlet unit assembly before removing
the recirculation motor.
REMOVAL
Disconnect:
the main supply connector (A),
the connector located on the power module (B).
Remove:
the lower trim on the fan assembly,
the recirculation motor mounting bolts (C),
the recirculation motor.
REFITTING
62-30
vnx.su
62
AIR CONDITIONING
Evaporator sensor
The evaporator sensor provides information about the

temperature at the evaporator outlet.
It is a negative temperature coefficient (NTC)
thermistor.
REMOVAL
Slide your hand under the dashboard on the
passenger side.
Disconnect the sensor connector.
Turn the sensor a quarter turn to remove it.
REFITTING
62-31
vnx.su
62
AIR CONDITIONING
External temperature sensor
62
The temperature sensor is located in the right-hand

side door mirror.
NOTE: the lower reflective glass is made of tough

plastic.
REMOVAL
Unclip the temperature sensor and cut the wires (3) to

approximately four centimetres.
Use a mastic knife (1) to remove the inner reflective

glass in the door mirror, then use tool Car. 1363 (2), to
complete the operation.
REFITTING
Rejoin the two temperature sensor wires using heatshrink sleeves.
Fix the glass in place again with double sided tape.
NOTE: The external temperature sensor resistance
should be approximately 2500 at 20 C.
62-32
vnx.su
161
Program No.: 0001
Vdiag No.: 04
HEATING
61

This document presents the general fault finding procedure applicable to the auxiliary heating function on
PRIMASTAR vehicles with petrol and diesel combi engines and bus versions.
To perform fault finding on this system, it is essential to have the following items available:
The Workshop Repair Manual for the vehicle concerned,
The wiring diagram of the function for the vehicle concerned,
The tools listed under Special tooling required.

Look in the Fault finding documents corresponding to the system identified.
Take note of information contained in the introductory sections.
Read the faults stored in the computer memory and use the "Interpretation of faults" section of the documents.
REMINDER:
specified checks for dealing with each fault are therefore only to be performed if the fault declared by the
diagnostic tool can be identified in the document by its type. The way in which the fault is stored should be
considered when using the diagnostic tool after switching the ignition off and on again.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the notes box.
When these conditions are not satisfied, use the fault finding procedure to check the circuit of the faulty part, since
the fault is no longer present on the vehicle. Perform the same operation when a fault is declared as stored by the
diagnostic tool but is only interpreted in the documentation as a present fault.
procedure) and apply the associated fault finding procedure according to the results.
Use the fault finding procedure for each Customer complaint if the problem persists.
SPECIAL TOOLING REQUIRED:
diagnostic tool,
multimeter.
61-1
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF001
PRESENT
OR
STORED
NOTES
PRE-HEATER PLUG
CO : Open circuit
Application condition for a fault finding strategy for a stored fault only one fault
can be recalled at a time:
the spark plug has been ignited and with no other fault declared present.
Remove the blower cover and disconnect connector B2 from the control unit.
Check the condition of the connector and replace it if necessary.
Check the insulation, continuity and absence of interference resistance of the
connections:
Connector B2 track 9
+ Heater plug
Earth spark plug
If the fault persists, change the pre-heater plug.
AFTER REPAIR
Apply the procedures to confirm that the repair is successful.

Clear the stored faults and check that no other fault appears.
61-2
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF002
PRESENT
OR
STORED
NOTES
FUEL METERING PUMP

CO : Open circuit
the metering pump has been switched on and no other fault is declared present.
Check the condition of the 8-track connector and replace it if necessary.

connections:
8-track connector track 4
Track 2 connector ST2 of the

metering pump
Track 1 connector ST2 of the
metering pump
Measure the resistance at the metering pump terminals, if it is not approximately
10 replace the metering pump.
If the fault persists, replace the metering pump.
AFTER REPAIR

61-3
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF003
PRESENT
OR
STORED
NOTES

CO : Open circuit
the boiler has been ignited and with no other fault has been declared present.
connections:
Temperature sensor
Temperature sensor
Measure the resistance at the sensor terminals. If it is not 12 K 5% at 20C,
replace the internal wiring of the boiler.
If the fault persists, replace the heater.
AFTER REPAIR

61-4
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF004
PRESENT
OR
STORED
NOTES
COMBUSTION AIR FAN

CO : Open circuit
DEF : Blocked
connections:
Earth combustion air fan

+ Combustion air fan
Using a multimeter, check that the winding of the ventilation fan is not cut.
Replace the heater if necessary.
AFTER REPAIR

61-5
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF005
PRESENT
OR
STORED
NOTES
OVERHEATING SWITCH
CO : Open circuit
Application condition for a fault finding strategy for a stored fault: only one fault
connections:
Overheating switch
Overheating switch
Measure the resistance at the terminals of the switch. If it is not 12 K 5% at 20C,
replace the internal wiring of the boiler (the overheating switch is not separated from
the internal wiring).
AFTER REPAIR

61-6
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF006
PRESENT
OR
STORED
NOTES
FLAME DETECTOR
CO : Open circuit
connections:
Flame detector
Flame detector
Measure the resistance at the terminals of the flame detector. If it is not 1200 K
5% at 50C, replace the internal wiring of the boiler (the flame detector is not
separate from the internal wiring).
AFTER REPAIR

61-7
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
DF008
PRESENT
OR
STORED
NOTES
HEATER STOPS OPERATING

1.DEF
2.DEF
: Excess voltage
: Not enough voltage
Check the voltage between tracks 1 and 2 of the 8-track connector, it should be
between: 10.2 V < X < 16 V.
connections:
+ Battery
Battery earth
If the fault persists, check the vehicle battery and charge circuit.
AFTER REPAIR

61-8
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
DF010
PRESENT
OR
STORED
NOTES
START UP TIME EXCEEDED

1.DEF
two unsucessful attempts have been made to ignite the heater in 180 seconds and
no other fault is declared present.
Check the air inlet and exhaust ducts.

Check the heater diesel fuel supply pipes and ensure that they contain no air
bubbles, and check the condition of the metering pump filter.
Measure the resistance at the metering pump terminals, if it is not approximately
10 5% replace the metering pump.
Check the condition of the spark plug.
Replace if necessary.
Replace the heater if the fault persists.
AFTER REPAIR

61-9
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF011
PRESENT
OR
STORED
NOTES
COLD BLOWER TIME EXCEEDED

1.DEF : If the flame detector > 70C the fan is triggered for 4 minutes
Check the exhaust gas and combustion air pipes.

connections:
Flame detector
Flame detector
Measure the resistance at the terminals of the flame detector. If it is not
1200 K 5% at 50C, replace the internal wiring of the boiler (the flame detector is
not separate from the internal wiring).
Replace the heater if the fault persists.
AFTER REPAIR

61-10
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF012
PRESENT
OR
STORED
NOTES
CONTROL UNIT
1.DEF : Unidentified electrical fault
Replace the control unit.
AFTER REPAIR

61-11
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61

DF013
DF014
DF015
PRESENT
OR
STORED
NOTES
MINIMUM FLAME EXTINGUISHER OUTPUT

AVERAGE FLAME EXTINCTION OUTPUT MAXIMUM
FLAME EXTINGUISHER OUTPUT
Check the exhaust gas and combustion air pipes.

Check the diesel supply pipes to the heater for air bubbles.
Check the condition of connector B2 in the control unit and replace it if necessary.
connections:
+ Heater plug
Earth spark plug
If the fault persists, replace the spark plug.
AFTER REPAIR

61-12
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61

DF016
DF017
DF018
PRESENT
OR
STORED
OVERHEATING DETECTION: LOW PROBABILITY

OVERHEATING DETECTION: LIKELY
OVERHEATING DETECTION: CONFIRMED
NOTES
Special features
likely: difference in temperature of 15C between the sensor and the
overheating switch
confirmed: temperature at the sensor or switch > 125C
low probability: material temperature threshold exceeded, sensor or
switch > 130C.
Check the circulation of coolant through the system.

Ensure that it is thoroughly degassed.
connections:
Temperature sensor
Temperature sensor
Overheating switch
Overheating switch
Measure the resistance at the sensor terminals. If it is not 12 K 5% at 20C,
Measure the resistance at the switch terminals. If it is not 12 K 5% at 20C,
AFTER REPAIR

61-13
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF019
PRESENT
OR
STORED
BLOCK: TOO MANY SUCCESSIVE START UPS

Priority in dealing with a number of faults:

If more than one of faults DF019 and DF001, DF002 are stored, deal with faults DF001
Pre-heater plug and DF002 Metering pump first.
NOTES
ten unsucessful attempts have been made to ignite the heater and no other fault is
declared present.
Clear incorrect start up counter using the delete command RZ002.
AFTER REPAIR

61-14
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
DF020
PRESENT
OR
STORED
NOTES
BLOCK: SUCCESSIVE OVERHEATING

the heater has overheated ten times and no other fault is declared present.
Delete overheating meter using the clear control RZ001.
AFTER REPAIR

61-15
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
NOTES
The values indicated in this conformity check are given as examples.
Condition for performing check: engine temperature below 81C and external
temperature below 5C.
Order
Function
+ After ignition feed

present
Parameter or state
Check or action
ET001: + After ignition

present
Display
and notes
Fault finding
YES
If there is a fault, refer to

the fault finding procedure
for state ET001
YES
2
Engine running
ET007: Engine running
NO if control AC002 is
active, light the heater
ET002: Combustion air

fan
3
Heater ventilation
PR014: Heater fan
voltage
LIT
Flame detected
System blocked
Heater output
0 at 7 V
ET003: Flame detected
ET004: System blocked
ET005: Heater output
61-16
vnx.su

for state ET007

procedure for fault DF004
Combustion air fan
YES

Flame detector
NO

procedure for faults
DF019 Block due to
successive starting, and
DF020 Block due to
successive overheating
MIN
OR
AVERAGE

for state ET005
HEATING
Program No.: 0001

Vdiag No.: 04
61
NOTES
Order
10
The values indicated in this conformity check are given as examples.
Condition for performing check: engine temperature below 81C and external
temperature below 5C
Function
Parameter or state
Check or action
Display
and notes
Fault finding
Overheats if the
temperature is above
125C
If there is a fault, apply

the fault finding
Overheating switch
Overheating switch
PR008: Overheating
switch value measured
Coolant
temperature sensor
PR010: Coolant
temperature sensor value
measured
X = engine
temperature 5 C

the fault finding
Coolant temperature
sensor circuit
PR013: Flame detector

value measured
X = heater
temperature 20C

Flame detector
10.2 V < X < 16 V

refer to the fault finding
procedure for parameter
PR108
None

the fault finding
Pre-heating plug
X = frequency in Hz
5%
If there is a fault apply the

fault finding procedure
for fault DF002 Fuel
metering pump
11
Flame detector
12
Computer supply
voltage
PR108: Computer supply

voltage
13
Spark plug feed

instruction
PR016: Pre-heater feed

instruction
14
Fuel pump control

frequency
PR017: Fuel pump control

frequency
61-17
vnx.su
Program No.: 0001

Vdiag No.: 04
HEATING
61
FAULT FINDING - INTERPRETATION OF CONTROLS
HEATER CONTROL
AC002
AC003
NOTES
AC002 : Ignite the heater

AC003 : Switch off the heater
Important : During boiler control phase, it is essential that the engine is running
to avoid any overheating due to non-circulation of coolant.
The boiler can be activated or deactivated using the control menu on the fault finding
tool. If it is not activated, check the following:
there is fuel in the tank,
that the fuses are intact
that the combustion air and exhaust pipes are not plugged.
Check the connection and the condition of the intermediary 5-track connector
between the vehicle wiring and the heater and replace if necessary.
Check the insulation, continuity and absence of interference resistance on the
connections between:
+ Battery
Earth
Diagnostic socket HK7
61-18
vnx.su
Track A 5-track connector

Track D 5 track connector
Track E 5-track connector
Track B 5-track connector
HEATING
Program No.: 0001

Vdiag No.: 04
61
FAULT FINDING - INTERPRETATION OF STATES
+ AFTER IGNITION PRESENT

ET001
NOTES
None.
If the state is INACTIVE check that the battery charge is above 10.2 V, if not repair
the vehicle charge circuit.
Check the connection and condition of the intermediate 8-track connector
located on the heater mounting.
+ battery
Earth
Track 1 8-track connector

Track 7 8 track connector
Replace the heater control unit if the fault persists.
61-19
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
HEATER OUTPUT
ET005
NOTES
OFF
None
State normal if engine off.

The heater state is OFF if the external air temperature is above 5C.
The heater state is also OFF if the engine temperature is above 82C.
MIN
The state of the heater is MINIMUM OUTPUT when the engine temperature is
between 77C and 82C (and is increasing) and the external air temperature is
below 5C.
The state of the heater is MINIMUM OUTPUT when the engine temperature is
between 82C and 73C (and is decreasing) and the external air temperature is
below 5C.
AVERAGE
The heater state is MEDIUM OUTPUT when the outside temperature is below 5C
and the coolant temperature is below 73C, it operates at this level of output until the
coolant temperature reaches 77C.
61-20
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
ENGINE RUNNING
ET007
NOTES
PRIMASTAR
None.

connection between:
Inertia sensor
Track 1 independent heating relay
With the engine running, check that there is a 12 V supply to track 1 and track 3
of the relay and an earth from the oil pressure switch on track 2 of the relay.
Repair if necessary (see the vehicle wiring diagram).
Track 5 independent heating relay
Track C ST1 5-track connector
Track 2 ST3 bimetallic strip connector
Track C ST1 5-track

connector
Track 1 ST3 bimetallic strip
connector
If the continuity is poor between tracks 1 and 2 of the ST3 connector, replace the
bimetallic strip with a shunt and test the continuity between tracks 1 and 2.
Replace the bimetal strip if necessary.
61-21
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
FAULT FINDING - INTERPRETATION OF PARAMETERS

PR108
NOTES
None.
+ Battery
Earth

Track D 5-track connector
Track D 5-track connector
61-22
vnx.su

Program No.: 0001

Vdiag No.: 04
HEATING
61
DIAGNOSTICS - CUSTOMER COMPLAINTS
NO DIALOGUE WITH THE COMPUTER
CHART 1
NO HEATING OR INADEQUATE HEATING
CHART 2
61-23
vnx.su
HEATING
Program No.: 0001

Vdiag No.: 04
61
No dialogue with the computer
CHART 1
NOTES
None.

Check:
the connection between the diagnostic tool and the diagnostic socket (wiring in
good condition),
the engine fuses.
Check for the presence of + 12 V before ignition on track 16, for + 12 V after
ignition on track 1 and for an earth on tracks 4 and 5 of the diagnostic socket.
Connector ST1 track A
Connector ST1 track E
Connector ST1 track D
Connector ST1 track B
61-24
vnx.su
V battery (fuse box)

+ After ignition (fuse box)
Earth
Track 7 of the diagnostic socket
(line K)
HEATING
Program No.: 0001

Vdiag No.: 04
61
CHART 2
No heating or inadequate heating
NOTES
Only refer to this customer complaint after a complete check with the diagnostic tool.
Is the air flow correct?
NO
Carry out the fault finding procedure for

climate control.
NO
Carry out the fault finding procedure for

climate control.
NO
Are the heater matrix pipes on the

bulkhead hot?
YES
Is the air distribution correct?
YES
With the engine warm, turn the heating on
full.
Is the air supplied hot?
YES
YES
YES
NO
Check that the heater works properly with

the AC002 engine running command.
Does the heater heat up correctly (see
parameter PR010: Coolant temperature
sensor)?
Check that the

heater matrix is not
blocked, clean or
replace it if
necessary.
NO
Replace the heater.
End of fault finding.
AFTER REPAIR
Check that the system is operating correctly.
61-25
vnx.su
116
STARTING - CHARGING
Alternator
OPERATION - FAULT FINDING
16
The customer complains of a charging fault but the

warning light is operating correctly.
These vehicles are equipped with alternators with

internal ventilation and integral regulator. There is also
a warning light on the instrument panel which has the
following functions:
the warning light comes on when the ignition is
switched on,
the light goes out when the engine starts,
if the warning light comes on while the engine is
running it shows there is a charging fault.
If the regulated voltage is less than 13.5 V, check the

alternator. The fault could be caused by:
damaged diode,
broken wire,
charred or worn tracks.
Checking the tension
Connect a voltmeter to the battery terminals and read
the battery voltage.
FAULT FINDING
The warning light does not come on when the
ignition is switched on
Start the engine and increase the engine speed until

the voltmeter needle registers a stable regulated
voltage.
Check:
that all electrical connections are sound;
whether the bulb is blown (to do this, connect the
circuit to earth; the bulb should light up).
This voltage should be between 13.5 V and 14.8 V.

Switch on as many power consumers as possible; the
regulated voltage should be between 13.5 V and
14.8 V.
The warning light comes on when the engine is

running
WARNING:
In the event of arc welding work on the vehicle, it is
essential to disconnect the battery and the
regulator.
This indicates a charging fault which could be caused

by:
broken alternator drive belt or charging circuit,
damage inside the alternator (rotor, stator, diodes or
brushes),
regulator fault,
overvoltage.
16-1
vnx.su
STARTING - CHARGING
Alternator
16
IDENTIFICATION
Vehicle
Engine
Alternator
Current
XL0B
XL0C
F9Q 760
Valo SG 10B 050

Valo SG 12B 017
125 A
CHECKING
After 15 minutes warming up at a voltage of 13.5 volts.
Rpm
125 Amps
800
64
2000
81
4000
118
6000
123
16-2
vnx.su
STARTING - CHARGING
Alternator
16
FAULT FINDING
Diagnostic tools make it possible to check the alternator by measuring the voltage and the output current, with or
without electrical power consumers.
NOTE:
The station ampermetric clamp is inductive (range of measurement: 0 to 1000 A). It is placed in position without
disconnecting the battery, which allows computer memories and adjustment programs to be saved.
Fit the ampermetric clamp directly to the alternator output, with the arrow on the clamp pointing towards the
alternator (the station will detect an incorrect position).
Measurement is carried out in three stages:
measurement of the battery voltage, ignition off,
measurement of the regulated voltage and the output current, without consumers,
measurement of the regulated voltage and output current, with a maximum number of consumers.
On completion of the test, the values found will lead to the following diagnostic messages, where appropriate:
battery voltage, no load < 12.3 V = battery discharged.
Without consumers:
regulated voltage > 14.8 V regulator faulty,
(regulated voltage, no load < 13.2 V) or (charging current < 2 A) charging fault.
With consumers:
regulated voltage > 14.8 V regulator faulty,
regulated voltage < 12.7 V it is necessary to check the alternator output against its specification:
Engine
Current (amps)
Minimum current the alternator must supply
with all power consumers switched on
(3000 rpm)
F9Q
80
If the measured output is too low, check:

alternator wear (brushes, etc.),
the battery connections,
the engine earth strap,
the alternator is functioning correctly,
the belt tension.
If the measured output is correct but the regulated voltage is too low, the alternator is not faulty.
The cause of the problem can be attributed to one of the following sources:
the vehicle has too many electrical power consumers,
the battery is flat.
16-3
vnx.su
STARTING - CHARGING
Alternator
REMOVAL
16
Remove:
the alternator mounting bolts, then remove the
alternator with the help of a screwdriver.

Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift.
NOTE:
the alternator, from above the vehicle.
Remove:
the engine undertray and the left-hand side
protection.
the radiator air deflector,
the accessories belt (see Section 07 Accessories
belt tension),
the pulley.
Disconnect the electrical connections of the alternator
and those of the air conditioning compressor (if fitted).
16-4
vnx.su
STARTING - CHARGING
Alternator
REFITTING
To facilitate the installation of the alternator, compress
the rings (A).
Refer to Section 07 Accessories belt tension for the

tensioning procedure.
16-5
vnx.su
16
STARTING - CHARGING
Starter
16
IDENTIFICATION
Vehicle
Engine
Starter
XL0B
XL0C
F9Q 760
Valo D7 R44
16-6
vnx.su
STARTING - CHARGING
Starter
REMOVAL
16
the turbocharger air outlet pipe,

the expansion box,
stays (1) and (2), then the catalytic converter (3),

Lifting equipment for the correct positions of the
lifting jack and axle stands) or on a lift.
NOTE:
the starter electrical connections,

the starter mountings,
the starter motor.
REFITTING
Remove:
Check for the presence of the centring dowel when

refitting.
16-7
vnx.su
BATTERY
180
Special notes
LOCATION
80
The battery is located under the front left-hand seat.
NOTE:
It is not necessary to undo bolts (B) completely to
remove the cover.
REMOVAL
Disconnect the battery starting with the negative

terminal.
Move the front left-hand seat back as far as possible.
Undo the mounting clamp (C) to remove the battery.
Remove:
the floor carpet (clips A),
REFITTING
the cover (bolt B),
When the battery is refitted, or whenever it has been

disconnected, it will be necessary to do some simple
programming which does not require a diagnostic tool:
setting the clock
entering the four-digit radio code.
Special feature for vehicles fitted with a
tachograph:
Refer to the user manual for instructions on how to
reinitialise the system.
80-1
vnx.su
BATTERY
Special notes
80
A - CHECKING
It is vital:
Check and ensure that:
to ensure that there are no sulphur deposits on the

terminals,
to clean and grease the terminals if necessary,
check that the nuts are correctly tightened on the

terminals. Poor contact could cause starting faults or
charging faults which could cause sparks, and could
cause the battery to explode,
to check the electrolyte level.
the battery tray and cover are not cracked or split,
the top of the battery is clean,
the terminals are in good condition.
Batteries with sets of removable plugs:
remove the cover by hand or by using a tool (stiff

spatula),
check that the electrolyte level in all components is

above the dividers (approximately 1.5 centimetres),
if necessary, use demineralised water to top up the

level.
IMPORTANT:
If the electrolyte overflows, both the battery and its tray
must be rinsed with clean water to prevent oxidisation.
NOTE:
Some types of battery have translucent bodies which
allow the level of the electrolyte to be seen.
Never add electrolyte, acid or other products.
80-2
vnx.su
BATTERY
Special notes
80
B - PRECAUTIONS
2) DANGER = RISK OF EXPLOSION
It should be remembered that a battery:
When a battery is charging (either in a vehicle or

elsewhere), oxygen and hydrogen are produced. Gas
production is at a maximum when the battery is
completely charged and the quantity of gas produced
is proportional to the strength of the charging current.
contains sulphuric acid, which is a dangerous

product,
produces oxygen and hydrogen during charging. The

mixture of these two gases is a detonating gas,
hence the risk of explosion.
1) DANGER = ACID
The sulphuric acid solution is a highly aggressive, toxic
and corrosive product. It attacks skin, clothing,
concrete and corrodes most metals.
It is also very important, when handling a battery, to
take the following precautions:
protect your eyes with goggles,
wear acid-proof gloves and clothing.
The oxygen and the hydrogen mix in the open air, on

the surface of the plates and form a detonating
mixture. This mixture is highly explosive.
The smallest of sparks, a cigarette or a recently
extinguished match are sufficient to cause an
explosion. The explosion is strong enough to shatter
the battery and spray the acid into the surrounding
atmosphere. People nearby are at risk (shattered
casing parts, acid splashes). Acid splashes are
harmful to the eyes, face and hands. They also
damage clothing.
Protection against the danger of explosion, which
can be caused by incorrect battery handling, must be
taken very seriously. Avoid all risks of sparks.
If acid splashes on to your clothing, rinse all

contaminated areas thoroughly in water. If your
eyes are affected, consult a doctor.
Check that the consumers are switched off, before

disconnecting or reconnecting a battery.
When a battery is being charged in a room, switch off

the charger before connecting or disconnecting the
battery.
Do not put any metallic items onto the battery to

avoid a short circuit across the terminals.
Never place a naked flame, a welding torch, hot air

gun, a cigarette or a lighted match near to a battery.
80-3
vnx.su
HEADLIGHT
Headlight unit
80
REMOVAL
Disconnect the connectors from the headlight unit.
Remove:
the indicator light,
the radiator grille mounting bolts (A),
REFITTING
It is essential to adjust the lens units every time they
are removed:
the lens unit mounting bolts (B).
Take off the lens unit and release the lower mounting
clip (C).
80-4
vnx.su
position the vehicle on level ground, without applying

the handbrake,
ensure that the vehicle is empty with a full tank if
possible,
set the adjustment control to 0,
turn screw (D) to adjust the height,
turn screw (E) to adjust the direction.
HEADLIGHT
Bulbs
REPLACING BULBS
Main beam headlight, dipped beam headlight bulb
The bulb can be replaced once the plastic cover has
been removed (1).
NOTE:
When replacing main beam headlight or dipped beam
headlight bulbs, use only approved H4 bulbs.
Indicator light bulb

Use approved PY 21W bulbs.
Side light bulbs
Use W5W type bulbs.
80-5
vnx.su
80
HEADLIGHT
Beam adjustment
80
HEADLIGHT ADJUSTMENT CONTROL

Connection
Unclip the control unit support using a small

screwdriver at (2).
Disconnect the connector, then release the control
from the support plate.
Wheel position
Control output voltage

(in volts)
11
8.5
3.5
1.1
Track
80-6
vnx.su
Description
A1
+ After ignition
B1
Earth
B2
Dipped headlights signal
B3
Control output
HEADLIGHT
Beam adjustment
ACTUATORS
ACTUATOR
REMOVAL
CONNECTION
80
Disconnect the connector from the remote adjustment

actuator.
Turn the actuator an eighth of a turn towards the
vehicle wing to release the lens unit.
Then disconnect the ball joint from the parabola, tilting
the actuator slightly.
NOTE:
The headlight does not have to be removed to remove
the actuator.
REFITTING
Keep the parabola towards the rear of the lens unit,
pulling on the bulb base.
Click the ball joint into the headlight clip.
Position the actuator on the lens unit.
Track
Turn the actuator through an eighth of a turn towards

the inside then insert it into the lens unit.
Description
Earth
Reconnect the connector and fit the sealed cover.
Control
Adjust the headlights.
Supply (dipped headlights)
ADJUSTMENT PROCEDURE
Position the vehicle on level ground, without applying

the handbrake.
Ensure that the vehicle is empty with a full tank if
possible.
Set the adjustment control to 0.
Screw (D) to adjust the height.
Screw (E) to adjust the direction.
80-7
vnx.su
HEADLIGHT
Front fog lights
REMOVAL
Undo the two mounting bolts.
Take out the fog light and its support.
Release the fog light from its support (one bolt).
REFITTING
There are no specific points, however remember to
adjust the fog light using screw (A).
80-8
vnx.su
80
REAR AND INTERIOR

181 LIGHTS
Rear lights
The rear lights are made up of two sections: an upper
section (side light, stop light and indicator) and a lower
section (reversing light and fog light).
81
REMOVAL OF LIGHTS (upper section)

Remove the mounting bolts (1).
Connection
Track
1A
2A
3A
4A
5A
6A
1B
2B
3B
4B
5B
6B
Rotate the light to release it from its pins (3).
Description
Side light supply
Reversing light supply (input)
Earth
Fog light supply (input)
Indicator
Brake lights
Not in use
Reversing light supply (output)
Earth
Fog light supply (output)
Not in use
Not in use
NOTE:
The fog light and reversing light supply passes through
the upper light plate.
81-1
vnx.su
REAR AND INTERIOR LIGHTS

Rear lights
81
REMOVAL OF LIGHTS (lower section)

Remove the mounting bolts (4).
Release the light unit.
Connection
Track
1
2
3
Description
Fog light supply
Reversing light supply
Earth
NOTE:
The fog light and reversing light supply passes through
the upper light plate.
81-2
vnx.su

Brake lights
The high-mounted brake light position varies
according to version (hinged rear doors or tailgate).
(tailgate version)
Remove the mounting bolt (4).
REMOVAL OF THE THIRD BRAKE LIGHT

(Version with hinged doors)
Remove the mounting bolt (3).
81-3
vnx.su
81

Number plate lighting
The bulb is accessed in the same way for both hinged

door and tailgate versions of the vehicle.
REMOVAL
Undo the screws (1) on the lens to access the bulb.
Bulb type: W 5W
81-4
vnx.su
81

Fuse box
FUSE SYMBOLS
81-5
vnx.su
81

Fuse box
81
Allocation of fuses (depending on equipment level)

No.
Symbol
Rating
Description
F1
--
Spare
F2
15A
F3
--
Spare
F4
--
Spare
F5
--
Spare
F6
--
Spare
F7
25A
F8
--
F9
15A
Front fog lights
F10
30A
Central door locking
F11
15A
Front and rear interior lights
F12
10A
Instrument panel - Diagnostic socket - Immobiliser
F13
30A
Heated rear screen
F14
25A
Rear screen wiper - Rear screen washer - Reversing light switch - Air
conditioning clutch relay - Windscreen heating control - Air conditioning control
panel - Windscreen heating timer
F15
25A
Windscreen wiper
F16
15A
Stop - Instrument panel - Diagnostic socket - Headlight beam adjustment

control - Heated rear screen control - Glove compartment light - Door locking
control - Cigarette lighter - Air conditioning - Air bag - Daytime running lights
F17
5A
Anti-lock Braking System and Electronic Stability Program
F18
--
Spare
F19
25A
Electric windows
F20
25A
Electric windows
Consumer cut-out - Radio - Central door locking control - Convertible exterior

temperature dial and radio display - Central Communication Unit - Navigation
computer - Electric rear-view mirror control - Ultrasound alarm sensor - Alarm
siren - Car phone communication interface
Air conditioning
Spare
81-6
vnx.su

Fuse box
No.
Symbol
Rating
81
Description
F21
20A
Heated seats
F22
--
Spare
F23
--
Spare
F24
15A
Radio - Cigarette lighter - Rear screen relay - Windscreen heater relay - + after
ignition feed relay - Central Communication Unit - Daytime running lights -Car
phone communication interface
F25
25A
Heating
F26
15A
Accessories socket
F27
10A
Left-hand main beam headlight
F28
10A
Right-hand main beam headlight
F29
10A
Left-hand dipped headlight
F30
10A
Right-hand dipped headlight
F31
10A
Left-hand side light - Instrument lighting
F32
10A
Right-hand side light
F33
10A
Rear fog light
F34
15A
Audible alarm (beeper)
F35
10A
Heated door mirrors
F36
5A
Heated windscreen activation
F37
--
Spare
F38
--
Spare
F39
--
Spare
81-7
vnx.su

Relay plate
LOCATION
The relay plate (1) is located in the passenger
compartment on the drivers side.
81-8
vnx.su
81

Relay plate
RELAY PLATE
Allocation (depending on equipment level)

Track
Description
REL A
REL B
REL C
REL D
REL E
REL F
REL G
REL H
Relay: heated rear window

Timer rear screen wiper
Relay: rear screen wiper
Relay: + after ignition feed
Relay: air conditioning cut-out
Relay: heated windscreen
Relay: rear fog light
Relay: dipped beam headlight for daytime
running lights (depending on country)
Relay: side lights for daytime running
lights (depending on country)
Relay: main relay for daytime running
lights (depending on country)
Relay: electronic thermostat
REL I
REL J
REL K
81-9
vnx.su
81

Relay/fuse box
All types

No.
Rating
F01
F02
F03
F04
F05
F06
FA
FB
FC
FD
R12
R13
70A
60A
60A
60A
60A
50A
50A
40A
Description
Fuse: pre-heating and thermoplungers
Fuse: supply (depending on the engine)
Fuse: fan assembly (depending on the engine)
Fuse: instrument panel
Fuse: Anti-lock Braking System
Fuse: air conditioning
Relay: heated windscreen
Relay: heated windscreen relay
81-10
vnx.su
81

Relay/fuse box
F4R engine

No.
Rating
F02
F03
F1
F2
F4
R2
R4
R6
R8
R9
R10
50A
50A
30A
25A
15A
Description
Fuse: supply
Fuse: fan assembly
Fuse: + before ignition
Fuse: heating device
Fuse: + after ignition injection
Relay: injection locking
Relay: fuel pump
Relay: air conditioning compressor clutch
Relay: independent heater
Relay: fan assembly (with air conditioning)
Relay: fan assembly relay (without air conditioning) or second speed fan (with air
conditioning)
81-11
vnx.su
81

Relay/fuse box
81
F9Q engine, with thermoplungers

No.
Rating
F01
F02
F03
F2
F3
F4
R1
R2
R4
R6
R7
R8
R9
70A
60A
60A
30A
15A
15A
R10
Description
Fuse: pre-heating fan and thermoplungers
Fuse: supply
Fuse: fan assembly
Fuse: pre-heating and diesel injection
Fuse: air conditioning compressor clutch
Fuse: + after ignition feed
Relay: additional heating 2 or 3 (thermoplungers)
Relay: diesel injection central electric unit supply
Relay: diesel reheating
Relay: Additional heating 1 (thermoplungers)
Relay: Additional heating 2 or 3 (thermoplungers)
Relay: fan assembly relay (without air conditioning) or two speed fan assembly (with air
conditioning)
Relay: single speed fan assembly (with air conditioning)
81-12
vnx.su

Relay/fuse box
F9Q engine, without thermoplungers

No.
Rating
F01
F02
F03
F1
F2
F4
R1
R2
R3
R4
R5
R6
R9
R10
70A
60A
60A
25A
30A
15A
Description
Fuse: pre-heating
Fuse: supply
Fuse: fan assembly
Fuse: independent heating
Fuse: pre-heating and diesel injection
Fuse: + after ignition feed
Relay: independent heating
Relay: diesel injection central electric unit supply
Relay: fuel pump
Relay: diesel reheating
Relay: two speed fan assembly
Relay: fan assembly
Relay: single speed fan assembly
81-13
vnx.su
81
IMMOBILISER
182
Coded key immobiliser system
SPECIAL NOTES
GENERAL INFORMATION
The security code no longer exists but has been

replaced by an After-Sales code allocated to the
vehicle for life during manufacture.
there is no number marked on the key,
at the time of delivery, the vehicle does not have a
label showing the code.
Spare keys are supplied uncoded, without a number
and without metal insert.
This system can have up to four keys. The remote
control function and the battery have no effect on the
immobiliser.
In the event of a key being stolen or lost or at the
customer's request, one or more of the vehicle's keys
can be deallocated. They can be reallocated to the
same vehicle if necessary.
IMPORTANT:
With this system, it is not possible to replace several
components (UCH and keys or UCH and injection
computer) at the same time. These parts are sold
uncoded.
The engine immobiliser is controlled by a random

rolling code key recognition system (encrypted).
The immobiliser is activated a few seconds after the
ignition is switched off. This may be indicated by the
flashing of the red warning light located on the
instrument panel.
During manufacture, a 12-character hexadecimal code
is allocated to the vehicle to make the engine
immobiliser operational.
This After-Sales code will be necessary to:
add keys,
replace one or more keys,
deallocate one or more keys (e.g. if lost or stolen),
replace a UCH.
It is effectively not possible to code these

components when replacing them, if none of them
has the vehicle's original code in its memory (see
allocation table).
82
There is no way of erasing the code programmed into

the system components. The programmed code
cannot be erased.
82-1
vnx.su
IMMOBILISER
SYSTEM DESCRIPTION
a coded chip (B) to control the engine immobiliser

and the locking and unlocking of doors by radio
frequency.
With this system, the engine immobiliser is activated a

few seconds after the ignition is switched off (shown by
the red engine immobiliser warning light flashing).
NOTE:
The immobiliser chip is now integrated in the remote
control printed circuit.
The system comprises:
82
two key heads fitted with either:

a coded chip without remote control to control the
engine immobliser (A),
82-2
vnx.su
IMMOBILISER
an aerial ring (D) located around the ignition switch,

fitted with a chip to transmit the key codes to the
UCH.
82
CONNECTION
NOTE:
This aerial ring is not coded.
Track
Description
REMOVAL - REFITTING
Not used
Remove the half-cowlings from under the steering

wheel, release the ring from the ignition switch and
disconnect its connector.
Earth
+ Before ignition
Output signal
82-3
vnx.su
IMMOBILISER
a UCH.
For the engine immobiliser function, the UCH carries
out the following functions:
decodes the key signal,
communicates with the injection computer,
controls the red warning light on the instrument
panel,
communicates with the diagnostic tool.
The UCH (1) is located under the instrument panel.
For notes on removal, refer to Section 87.
a red engine immobiliser indicator light located on the

instrument panel used to signal:
activation of the engine immobiliser,
non-recognition of the key,
a fault in the system,
programming of a key.
82-4
vnx.su
82
IMMOBILISER
82
OPENING A KEY HEAD (WITHOUT REMOTE

CONTROL)
OPENING A KEY HEAD (WITH REMOTE

CONTROL)
Place the key head on a table with the metal insert

facing downwards.
Use a small screwdriver as a lever as shown below in

(C).
Use a small screwdriver as a lever as shown below,

ensuring that the end of the screwdriver is placed on
lower section (E) of the key head. This allows you to
slide the upper section off the lower section.
82-5
vnx.su
IMMOBILISER
OPERATION
When the immobiliser system is operational, the
engine immobiliser indicator light flashes slowly:
(once per second).
After the ignition is switched on, the key code is

transmitted to the UCH.
If the code is recognised by the UCH, the UCH and

the injection computer send coded signals to each
other via the multiplex network and turn off the
immobiliser indicator light.
If the signals transmitted by the UCH and the

injection computer match, the UCH authorises the
engine to start and the injection is unlocked.
SPECIAL CASES:
The injection computer has no reference code in its

memory: the code which is transmitted is stored.
The system remains locked if the key code and the

UCH code do not match. The engine immobiliser red
indicator light flashes (quickly). The vehicle cannot
be started.
IMPORTANT:
When the vehicle battery has a low charge, the drop in
voltage caused by operating the starter could
reactivate the immobiliser. If the voltage is too low, the
engine cannot be started, even by pushing the vehicle.
82-6
vnx.su
82
IMMOBILISER
82
REPLACEMENT AND CONFIGURATION

New parts are not coded. Once fitted on the vehicle, they must be programmed with a code to become operational.
To perform this procedure, it is essential that some parts on the vehicle are already correctly coded (with the vehicle
code). Refer to the allocation table.
IMPORTANT:
If a part is programmed with a code, the part is then allocated to the vehicle and it is not possible for the code to be
erased or for the part to be programmed with a second code. The programmed code cannot be erased.
ALLOCATION TABLE
AFTER-SALES
OPERATION
STATE OF COMPONENTS
REPAIR CODE
NEEDED
UCH
Key
Injection
computer
Programming the
UCH
Blank
Coded
Coded
YES
Key allocation or
cancellation
Coded
Blank*
YES
Programming the
injection
computer
Coded
Coded
NO
* A key allocated to a vehicle must be blank or already programmed to this vehicle.

NOTE:
The key can be programmed to a vehicle but is not operational (unallocated).
REMINDER:
Only keys used in this procedure will work.
82-7
vnx.su
IMMOBILISER
82
A new UCH is not programmed with a code. You must therefore program a code into a new UCH fitted to a vehicle to
make the UCH operational.
At least one of the vehicle's old keys and the After-Sales code are required to carry out this procedure, and the
injection computer must be correctly coded (refer to the allocation table).
IMPORTANT:
If a code is programmed into the UCH, the UCH is allocated to the vehicle. It is impossible to erase the code or
program in another one.
IMPORTANT:
The keys submitted during this procedure will only work if:
they have already been coded on this vehicle, or
they are new (uncoded).
UCH PROGRAMMING PROCEDURE
SPECIAL CASES
Using the diagnostic tool:
If the screen displays:
Establish dialogue with the Engine immobiliser

system.
In the Command: Specific command menu, select

and confirm the SC027: Program UCH line.
The tool displays Remove the key from the ignition

switch,
The tool displays Please enter the After-Sales

code. With the ignition off, enter the secret AfterSales code (12 hexadecimal digits) and press
confirm.
If the code format is correct, the tool displays Insert

a key which has already been programmed to the
vehicle and the programming procedure starts.
The tool displays UCH programming completed,

please start key programming procedure, the
UCH is coded. You must now enter key programming
mode to allocate the other keys (maximum of four).
Several seconds may elapse before this message
appears.
The After-Sales code entered does not

correspond with the key inserted. Check that you
have entered the correct code and that you have
presented a key: the code does not correspond to
the key or the key does not belong to the vehicle.
The UCH is not blank. Please start the key

programming procedure: The UCH has already
been programmed for this vehicle.
Check the After-Sales code: the code entered is

incorrect. Check, then try entering the data again,
UCH programming failure, key cannot be used on

this vehicle: the key code does not correspond (the
key belongs to a vehicle from a different range).
The key inserted is blank. Please present another

key which has already been programmed to this
vehicle: the key is blank, present a key which has
already been coded on this vehicle.
IMPORTANT:
The maximum delay time between each operation is
5 minutes, otherwise the procedure is cancelled.
82-8
vnx.su
IMMOBILISER
KEY PROGRAMMING PROCEDURE
IMPORTANT:
If none of the keys are available, it will be necessary to
carry out a reallocation procedure for all keys.
Establish dialogue with the Engine immobiliser

system.
In the Command: Specific command menu, select

and confirm the SC028: Program cards/keys line.
The tool displays Remove the key from the ignition

switch,
The tool displays Please enter the After-Sales

code. With the ignition off, enter the secret AfterSales code (12 hexadecimal digits) and press
confirm.
IMPORTANT:
The maximum delay time between each operation is
5 minutes, otherwise the procedure is cancelled and
the tool displays the message Procedure
interrupted: warning, the keys allocated to the
vehicle are the ones allocated before starting the
procedure. The keys submitted before interruption
of the procedure are no longer blank and can only
be assigned to this vehicle. This message also
appears where dialogue with the UCH is lost or the
battery power supply fails.
NOTE:
If only the UCH is replaced, there is no operation to
perform on the injection computer, as it retains the
same immobiliser code.
SPECIAL CASES
The tool displays Warning, keys not inserted will

no longer be operational. Restart the procedure
to reallocate them: programming is in progress.
The tool displays Insert the key in the ignition
switch and turn on the ignition, then press Enter:
switch on the ignition with a key from the vehicle or a
blank key. The screen displays 1 key programmed,
then press Enter, then Remove the key from the
ignition switch.
The tool asks: Would you like to program another

key?
To assign additional keys, switch on the ignition for a

few seconds with the other vehicle keys to be
programmed (four maximum), then press enter. The
screen displays 2, 3 or 4 keys programmed then
remove the key from the immobiliser switch.
The UCH is blank. Run the UCH programming

procedure: the UCH is blank. It is impossible to
allocate keys to an uncoded UCH.
Check the After-Sales code: the code entered is

incorrect. Check, then try entering the data again.
If the key does not correspond to the vehicle UCH,

the tool will display procedure cancelled: warning,
the keys assigned to the vehicle are the ones
assigned before the procedure was started. The
keys submitted before interruption of the
procedure are no longer blank and can only be
allocated to this vehicle.
IMPORTANT:
These must be old keys belonging to the vehicle or
new, uncoded keys
82
The tool displays Writing data to memory, the UCH

is coded and the keys are programmed. Several
seconds will elapse before this message appears, in
order to exit the reallocation mode.
82-9
vnx.su
IMMOBILISER
CODING THE INJECTION COMPUTER
The injection computer is supplied uncoded. It
therefore has to be programmed with the engine
immobiliser code when it is installed to allow the
vehicle to be started.
Simply switch on the ignition for a few seconds without
starting the engine. Switch the ignition off, the
immobiliser will be activated after a few seconds
(engine immobiliser red indicator light flashes).
IMPORTANT:
With this engine immobiliser, the vehicle keeps
its immobiliser code for life.
In addition, this system does not have a security
code.
Consequently, it is forbidden to carry out tests
with injection computers borrowed from stores
and subsequently returned.
The programmed code cannot be erased.
82-10
vnx.su
82
182
Program No.: 3.7 and above
Vdiag No.: 04
IMMOBILISER
82
This document presents the general fault finding procedure applicable to all computers for the Immobiliser
function on PRIMASTAR vehicles with all engine types.
The following are thus required for fault finding on this system:
The electrical circuit diagram of the function for the vehicle concerned,
The tools listed under Special tooling required.
GENERAL APPROACH TO DIAGNOSTIC:

Include information contained in the introductory sections.
Read the faults stored in the computer memory and use the Fault interpretation section of the documents.
REMINDER: each fault is interpreted for a given type of storage (fault present, fault stored, fault present or stored).
The specified checks for dealing with each fault are therefore only to be performed if the fault declared by the
diagnostic tool can be identified in the document by its type of storage. The way in which the fault is stored should be
considered when using the diagnostic tool after switching the ignition off and on again.
If a fault is interpreted when it is declared as stored, the conditions for applying fault finding appear in the Notes box.
procedure) and apply the relevant fault finding procedures according to the results.
Use the fault finding procedure for each Customer complaint if the fault persists.
Consult II diagnostic tool,
Electrical bornier El. 1622,
Multimeter.
82-1
vnx.su

Vdiag No.: 04
IMMOBILISER
82
OPERATING CHARACTERISTIC
The immobliser system is based on the recognition of a key by the inductive connection between the transponder
built into the key and the transponder loop aerial every time starting is requested.
The key is authenticated when the transponder aerial detects the correct code, when the vehicle is in the protected
state (immobiliser active).
Every time the ignition is switched off, the immobiliser is automatically activated after a timed period of 10 seconds.
OPERATION
In this mode, transponder authentication is initiated by the transponder aerial detecting the key (+ After ignition).
When the user introduces their key into the ignition switch and switches on the ignition, the UCH (Passenger
Compartment ECU) requests the number of the key via the transponder aerial.
In response to this request, the key gives its unique n to the UCH.
If the UCH recognizes this response, (which means that the key is among those programmed into the UCH) the
UCH then sends back a message (challenge).
The key deciphers the message. If the message is recognized, the key sends back its response.
The UCH compares the response with the value stored in its memory.
If this response is recognized by the UCH, then the authentication is successful.
All data exchanged between the key and the UCH is coded.
Once the authentication of the key is successful, the UCH then authorizes the operation of the engine management
(immobiliser code exchanged with the injection computer).
Key recognition in normal operation
IMMOBILISER WARNING LIGHT
vehicle protected (without After Ignition)
warning light flashes at 1 Hz
key recognized, injection unprotected
warning light comes on for 3 seconds, then goes out
key recognized, injection protected or blank
after 3 seconds, warning light remains lit
key not recognized
warning light flashes at 4 Hz
82-2
vnx.su

Vdiag No.: 04
IMMOBILISER
82
TRANSPONDER AND RADIO-FREQUENCY KEY PROGRAMMING

All programming procedures carried out in After-Sales must be followed after the vehicle's After-Sales code has
been entered on the diagnostic tool.
There is no number marked on the keys.
At the time of delivery, the vehicle does not have a label showing the code.
Spare keys are supplied uncoded, without a number and without metal insert.
The system can have up to four keys.
The remote control and battery have no effect on the immobiliser, only the transponder enables the immobiliser
function.
In the event of a key being stolen or lost or at the customer's request, one or more of the vehicle's keys can
be de-allocated. These can be reallocated to the same vehicle if necessary.
WARNING
It is impossible to replace two components (UCH and keys) at the same time because it will not be possible
to code these components if none of them has the vehicle's original code in its memory.
There are three types of part on the vehicle
parts without codes

Transponder aerial
This is the only component which can be transferred to another vehicle without any precautions.
parts with codes

Injection computer:
The injection receives codes from the UCH.
Programming takes place as soon as the key is introduced, without any action on the part of the operator or
the NISSAN agent. Programming a code into this part means it cannot be used on any other vehicle.
parts which are coded using an After-Sales procedure

UCH and keys
Just fitting or introducing new or blank parts to a vehicle is not sufficient to program a code. As long as the
After-Sales programming procedure has not been carried out, these parts remain blank.
On the other hand, once the programming procedure has been carried out, these parts are coded and
therefore cannot be used on any other vehicle.
82-3
vnx.su

Vdiag No.: 04
IMMOBILISER
82
PROGRAMMING PROCEDURE
Programming of the UCH
The UCH programming procedure is carried out using the diagnostic tool.
Establish dialogue with the Engine immobiliser system.
In the Command menu, select Specific command,
start command SC027: UCH programming.
The tool displays Remove the key from the immobiliser switch.
The tool displays Please enter the After-Sales code:
with the ignition off, enter the secret After-Sales code (12 hexadecimal characters) and press enter.
If the code format is correct, the tool displays Insert a key which has already been programmed on the vehicle,
and the programming procedure starts.
The tool displays UCH programming completed, please start key programming procedure. The UCH is coded.
You must now enter key programming mode to allocate the other keys (maximum of four). Several seconds may
elapse before this message appears.
WARNING
The maximum time delay between operations is 5 minutes, otherwise the procedure is cancelled.
Once the UCH is coded, it is impossible to clear or program it with a new code.
SPECIAL CASE
The After-Sales code entered does not correspond with the key presented. Check that you have entered
the correct code and that you have presented a key from the vehicle.
The wrong code has been read or the UCH has previously been coded on another vehicle. See ET110 UCH. Check
the code then try entering the data again.
The UCH is not blank; please start the key programming procedure.
The UCH has already been coded on this vehicle.
Check the After-Sales code: the format of the code entered is incorrect. Check, then try entering the data again.
UCH programming failed; key cannot be used with this vehicle.
The code introduced by this key does not correspond with the vehicle present.
The key inserted is blank. Please present another key already programmed on the vehicle.
The key is blank, introduce a key which has already been coded on this vehicle.
The injection code does not correspond with the key code. Make sure that the multiplex network is not
faulty, that the injection is operating and that the injection is not blank.
The injection code is absent or does not correspond with the code entered.
check the connection between the injection computer and the UCH.
check that the computer is the correct one for the vehicle.
82-4
vnx.su

Vdiag No.: 04
IMMOBILISER
82

IMPORTANT: in the event that not all the keys are available, it will be necessary to carry out a reprogramming
procedure later with all the keys.
Establish dialogue with the Engine immobiliser system.
In the Command menu, select Specific command, start command SC028: card/key programming.
The tool displays Remove the key from the ignition switch.
The tool displays Please enter the After-Sales code:
with the ignition off, enter the secret After-Sales code (12 hexadecimal characters) and press enter.
The tool displays Warning: keys not presented will no longer be active, start the procedure again to
reprogram them: Programming starts.
The tool displays Insert the key in the ignition switch and switch on the ignition, then press enter.
Switch on the ignition with a new key or an old key from the vehicle. The screen displays 1 key programmed press
enter, then remove the key from the immobiliser switch.
The tool asks: Would you like to program another key?
To allocate additional keys, switch on the ignition for a few seconds with the other vehicle keys to be programmed
(four maximum), then press enter. The screen displays 2, 3 or 4 keys programmed then Remove the key from
the ignition switch.
WARNING
These must be the old keys belonging to the vehicle or new non-coded keys.
The tool displays Writing data to memory, the UCH is coded and the keys are programmed. Several seconds will
elapse before this message appears.
WARNING: the maximum time delay between each operation is 5 minutes, otherwise the procedure will be
cancelled and the tool will display the message Procedure interrupted: warning, the keys allocated to the
vehicle are the ones allocated before starting the procedure. The keys presented before the procedure
was interrupted are no longer blank and cannot be allocated to this vehicle, this message also appears if
communication with the UCH is lost or the battery is cut off.
NOTE: there is no operation to perform on the injection computer when the UCH only is replaced, it retains the
same immobiliser code.
82-5
vnx.su

Vdiag No.: 04
IMMOBILISER
82
SPECIAL CASE
The UCH is blank, please start the UCH programming procedure. The UCH is blank. It is impossible to allocate
keys to an uncoded UCH.
Check the After-Sales code: the format of the code entered is incorrect, check, then try entering the data again.
If the key does not correspond to the vehicle UCH, the tool will display Procedure cancelled: warning, the keys
allocated to the vehicle are the ones allocated before the procedure was started. The keys submitted before
interruption of the procedure are no longer blank and can only be allocated to this vehicle.
CODING THE INJECTION COMPUTER
The injection computer is delivered uncoded. It will therefore have to be programmed with the code of the engine
immobiliser system when fitted, to enable the vehicle to start.
Simply switch on the ignition for a few seconds without starting the engine. Switch the ignition off, the immobiliser will
be activated after a few seconds (engine immobiliser indicator light flashes).
WARNING
With this engine immobiliser, the vehicle keeps its immobiliser code for life.
In addition, this system does not have a security code.
Consequently, it is forbidden to carry out tests with injection computers borrowed from the stores which
must be returned.
The programmed code cannot be cleared.
82-6
vnx.su

Vdiag No.: 04
IMMOBILISER
UCH track allocation: all options (N3)

P202 Connector (15-track)
BROWN
Track
Allocation
Front courtesy light
Rear courtesy light
RH direction indicator
LH direction indicator
Door unlocking
Locking of the doors and luggage compartment
+ lighting
+ locking of opening elements
Opening elements unlocking

GREEN
Track
Allocation
+ direction indicator
Windscreen wiper feed
+ windscreen wiper
Windscreen wiper park position
Timed feed
Earth
82-7
vnx.su
82

Vdiag No.: 04
IMMOBILISER
UCH track allocation: all options (N3)

P201 (40-track)
Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Track
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
BROWN
Allocation
+ battery
Immobiliser warning light
Heated rear screen relay
Heated rear screen switch
Not used
RH direction indicator control
LH direction indicator control
Multiplex connection H
Not used
Multiplex connection L
Not used
Opening element locking warning light
Opening element unlocking switch
Opening element locking switch
Ultrasound alarm sensor
Alarm feed
Bonnet switch
Not used
GREEN
Allocation
Hazard warning lights indicator light
Transponder signal
Rear door rabbet switches
Windscreen wiper and washer switch
Timed windscreen wiper control
Side lights control
Front door rabbet switches
Not used
Not used
Not used
Not used
Not used
+ After ignition
Not used
Not used
Hazard warning lights switch
Airbag connection
Not used
Not used
Diagnostic line
82-8
vnx.su
82

Vdiag No.: 04
DF039
PRESENT
OR
STORED
NOTES
IMMOBILISER
UCH INTERNAL ELECTRICAL FAULT
The fault is declared present when the ignition is switched off.
Replace the UCH.
AFTER REPAIR
Follow the instructions to confirm repair.

82-9
vnx.su
82

Vdiag No.: 04
DF067
PRESENT
OR
STORED
NOTES
1.DEF
IMMOBILISER
82
AERIAL DECODER LINK

1.DEF
2.DEF
: Invalid key code

: No communication from the ring or the transponder key
Conditions for applying the fault finding to stored faults.:

The fault is declared present when the ignition is switched on (+ after ignition).
Check parameter PR065 Number of transponder keys programmed.

Check State ET104: Valid key code, if key code valid, status NO.
Carry out reprogramming of the keys using the diagnostic tool.
Replace the key if necessary.
2.DEF
Check the connection and the condition of the transponder aerial connector.
Check the connection and condition of the 40-track UCH connector.
Check the insulation, continuity and absence of resistance of the connection:
UCH 40-track connector track 22
Track 4 transponder ring
AFTER REPAIR

82-10
vnx.su

Vdiag No.: 04
DF069
PRESENT
OR
STORED
NOTES
CC.0
IMMOBILISER
82
DECODER AERIAL LINK


Check the connection and the condition of the transponder aerial connector.
Check the connection and condition of the UCH 40-track connector.
Disconnect the connector of the transponder aerial and ensure that the transponder
aerial is correctly supplied with + 12 V on track 3.
Check the continuity and insulation of the connection between:
fuse box F12
Track 3: transponder aerial
CC.1
Check the transponder aerial connectors.

Check the UCH connectors.
earth
Track 2 transponder aerial
Track 4 transponder ring
AFTER REPAIR

82-11
vnx.su

Vdiag No.: 04
DF105
PRESENT
OR
STORED
NOTES
CC.0
IMMOBILISER
IMMOBILISER WARNING LIGHT CIRCUIT

Check the connection and the condition of the instrument panel connector.
Check the continuity and insulation against earth of connection:
instrument panel
CC.1
Check the connection and the condition of the instrument panel connector.
Check the continuity and insulation from + 12 V of the connection:
instrument panel
AFTER REPAIR
82

82-12
vnx.su

Vdiag No.: 04
NOTES
IMMOBILISER
Diagnostics - Conformity check
82
Only perform this conformity check after a complete check with the diagnostic tool. The
values indicated in this conformity check are given as examples.
Test conditions: Engine stopped, ignition on
Parameter or State
Check or action
Display
and notes
Order
Function
After ignition
ET154: + 12 V after
ignition present
Immobiliser
ET103: Key code

received
Status YES when ignition

switched on
If there is a fault:
procedure State ET103
ET104: Valid key code
Status YES when ignition

switched on
ET153: Immobiliser
active
NO
ET167: Immobiliser
warning light
OFF
apply fault finding
procedure Immobiliser
warning light fault DF105
ET178: Blank UCH
NO
If UCH blank or injection

blank, status YES, see
programming
procedure
Programming:
YES
82-13
vnx.su
Fault finding
refer to fault finding State
ET154

Vdiag No.: 04
IMMOBILISER
Diagnostics - Conformity check
82
STATUS TEST
By checking specific States, it is possible to determine the fault on a vehicle by means of the various pieces of
information provided.
ET154: + 12 V after ignition present
ET103: Key code received
ET104: Key code valid
ET153: Immobiliser active
If ET154 State YES

ET103 State YES
ET104 State YES
ET153 State YES
Check the injection with the tool and see if the injection computer is not
locked.
Check for problems on the multiplex network.
If ET154 State YES

ET103 State YES
ET104 State NO
ET153 State YES
The coded key does not belong to the vehicle.

If the key belongs to the vehicle, then carry out reallocation of the keys.
If the key still does not work, replace the key.
If ET154 State YES

ET103 State NO
ET104 State NO
ET153 State NO
The key is out of service or does not correspond with the type of vehicle.
82-14
vnx.su

Vdiag No.: 04
IMMOBILISER
82
KEY CODE RECEIVED

ET103
NOTES
Check that no fault is present or stored.

The state will be displayed YES when the ignition is switched on (+ after ignition) with
a valid key.
If the State remains NO, try with another key belonging to the vehicle before carrying
out any work.
ET103 NO: ignition on and key belonging to the vehicle.
Check that State ET154 + 12 V after ignition present is active with the ignition on.
Deal with State ET154 if it is INACTIVE with the ignition on.
Remove any metal objects from the key-ring and try again.
Switch on the ignition with the key from another vehicle, exchanging the key inserts.
If the KEY CODE RECEIVED status changes to YES, replace the vehicle key.
If the KEY CODE RECEIVED status remains NO, replace the transponder aerial.
If the fault persists, replace the UCH.
AFTER REPAIR
Repeat the fault finding procedure on the system.

82-15
vnx.su

Vdiag No.: 04
IMMOBILISER
82
VALID KEY CODE

ET104
NOTES
The state will be displayed YES when the ignition is switched on (+ after ignition) with
a key from the vehicle.
If the State remains NO, try with another key belonging to the vehicle before carrying
out any work.
ET104: NO despite presence of ignition and a key belonging to the vehicle
Check that State ET154 + 12 V after igntion present is active with the ignition on.
Carry out reallocation of the keys with the After-Sales code.
If the fault persists, replace the whole set of vehicle keys.
AFTER REPAIR

82-16
vnx.su

Vdiag No.: 04
IMMOBILISER
82
IMMOBILISER ACTIVE
ET153
NOTES
The immobiliser active State should change to inactive when the + after ignition is
switched on.
The immobiliser State should be active when the key is absent from the ignition switch.
ET153 ACTIVE despite the presence of a key in the ignition switch and + after ignition
Check there is no fault before dealing with this State.

Check that State ET154 + 12 V after ignition present is indeed ACTIVE with the ignition on.
Deal with State ET154 if it is INACTIVE with the ignition on.
Check State ET103 Key code received and State ET104 Key code valid with the ignition on.
If State ET103 and ET104 are YES, perform a fault finding check on the injection computer.
If State ET103 is NO, deal with this State first.
If State ET103 is YES and State ET104 is NO, deal with ET104 first.
Check the injection with the diagnostic tool and check that the computer is not locked.
Check the multiplex network.
AFTER REPAIR

82-17
vnx.su

Vdiag No.: 04
IMMOBILISER
82
+ 12 V AFTER IGNITION PRESENT

ET154
NOTES
None.
ET154 INACTIVE, ignition on
Check the passenger compartment fuse.

Use a multimeter to check the presence of + 12 V at the fuse holder with the ignition on.
Use a multimeter to check the presence of + 12 V on track 1 of the UCH 40-track connector with the ignition on.
If the voltage is present, replace the UCH.
If the voltage is absent, check the continuity and insulation against earth between track 1 of the UCH 40-track
connector and the 10A fuse in the passenger compartment fuse box.
ET154 ACTIVE, ignition off
Use a multimeter to check the absence of + 12 V at the passenger compartment fuse holder with the ignition
off.
If the voltage is absent, replace the UCH.
AFTER REPAIR

82-18
vnx.su

Vdiag No.: 04
IMMOBILISER
82
These customer complaints should only be investigated after a complete check

has been run using the diagnostic tool.
NOTES
NO DIALOGUE WITH THE UCH
CHART 1
THE VEHICLE WILL NOT START
CHART 2
AFTER REPAIR

82-19
vnx.su

Vdiag No.: 04
IMMOBILISER
No dialogue with the UCH
CHART 1
NOTES
82
None.

Check:
- the connection between the diagnostic tool and the diagnostic socket (wiring in good condition),
the engine and passenger compartment fuses.
Check for the presence of + 12 volts before ignition on track 16, for + 12 volts after ignition on track 1 and
for an earth on tracks 4 and 5 of the diagnostic socket.
Connect the bornier and check the insulation, continuity and absence of unwanted resistance on the
following connections::
Fuse box
+ After ignition supply
UCH 15-track connector track B6
Earth
Track 7 of the diagnostic socket (line K)
AFTER REPAIR
Check the operation of the system.
82-20
vnx.su
IMMOBILISER

Vdiag No.: 04
82
The vehicle will not start
CHART 2
Consult the customer complaint before carrying out a complete check using the
diagnostic tool.
NOTES
Do the doors of the vehicle open?
Refer to the interconnection

unit section of the UCH fault
finding methods.
NO
YES
Battery test: switch on the lights and note the brightness of the courtesy light.
OK
Repair. The immobiliser diode goes out.
NO
YES
Turn the starter.
Nothing
happens.
The starter clicks but

the engine does not
turn over.
The starter
motor turns but
there is no
engagement
The engine turns

but does not
start.
Carry out a test

with the
diagnostic tool.
AFTER REPAIR
82-21
vnx.su
The engine turns

over progressively
more slowly and
does not start.
Check the battery

voltage. Check the
condition of the starter

Vdiag No.: 04
IMMOBILISER
82
CHART 2
CONTINUED 1
NOTES
diagnostic tool.
Is the diode PERMANENTLY lit?
The diode
flashes
NO
YES
Normally
Are the warning lights on the
instrument panel lit ?
YES
Has the injection warning light

gone out?
YES

Perform a fault finding check on
the UCH and the injection
system.
NO
The UCH has not

detected the after
ignition feed.
Perform a fault finding

check on the
instrument panel using
NO
Check the injection computer power

supply (fault: severity 2), or fault in
CAN.
Test the multiplex network. Perform

a fault finding check on the injection
system.
82-22
vnx.su
Rapidly
Carry out a test using

the diagnostic tool
and refer to the fault
finding procedure.
Carry out a test using the

diagnostic tool and refer to the
fault finding procedure.

Vdiag No.: 04
IMMOBILISER
82
CHART 2
CONTINUED 2
NOTES
diagnostic tool.
Check the battery voltage and the power supply to the + starter.
Check the fuse for the UCH power supply and replace if necessary.
Check the connection and condition of the connector of the starter relay located beneath the
engine compartment.
Check the insulation from + 12 V of the connection between the UCH and the starter relay.
Ensure the continuity and insulation of the connections between:

Ignition switch and starter relay.
Starter relay and starter motor.
If the problem has still not been solved, check that the starter operates correctly. Replace it if
necessary.
82-23
vnx.su

Vdiag No.: 04
IMMOBILISER
82
CHART 2
CONTINUED 3
NOTES
diagnostic tool.
Check the battery voltage and check the earth straps connecting the power train to the vehicle chassis.
Ensure that the engine is not seized or blocked.
AFTER REPAIR
82-24
vnx.su

Vdiag No.: 04
IMMOBILISER
82
CHART 2
CONTINUED 4
NOTES
diagnostic tool.
Check that the starter operates correctly.

Replace it if necessary.
If the problem has still not been solved, check the timing belt.
82-25
vnx.su
ALARM
182C
Program no.:
3.7 and higher
Vdiag No.: 04
82C
This document covers the generic fault finding procedures applicable to the alarm funciton on PRIMASTAR
vehicles fitted with any engine.
The following are thus required for carrying out a diagnostic on this system:
the Workshop Repair Manual for the vehicle concerned,
the tools listed in Special tooling required.

Take account of information contained in the introductory sections.
Read the faults stored in the computer memory and use the "Fault interpretation" section of the documents.
REMINDER:
specified checks for dealing with each fault are therefore only to be performed if the fault declared by the diagnostic
tool can be identified in the document by its type. The way in which the fault is stored should be considered when
using the diagnostic tool after switching the ignition off and on again.
Perform the conformity check (appearance of possible incorrect operations not yet declared by the system's self
diagnosis procedure) and apply the associated fault finding strategy according to results.
Use the diagnostic strategy for each Customer complaint if the problem persists.
diagnostic tool (CONSULT II),
bornier El. 1622,
multimeter.
82C-1
vnx.su
ALARM
Program no.:
3.7 and higher
Vdiag No.: 04
82C
COMPOSITION OF THE SYSTEM

The alarm system on PRIMASTAR consists of:
a perimeter monitoring system (3 zones)
Bonnet (1 contact)
Front doors (driver's and passenger's)
Rear doors and tailgate (or boot lid)
an interior space monitoring system
Ultrasonic module - driver's position monitor
an after ignition transponder key recognition system
ACTIVATING THE MONITORING SYSTEM

The entire system is active five seconds after the remote control unit button is pressed
Press the remote control
LOCKING
UNLOCKING
Effect on the locks
Operation of the
direction indicators
1 short press
Locking of opening
elements + alarm
2 flashes
1 long press
Locking of opening
elements + alarm
+ interior space
protection inhibited
2 flashes
2nd short press
Central locking of
opening elements
5 flashes
2nd long press
Central locking of
opening elements
+ interior space
5 flashes
1 short or long
press
Door unlocking
1 flash
Operation of horn
1 beep
1 beep
If a door is not closed correctly: the direction indicators will not flash twice when the vehicle is locked.
DEACTIVATING THE MONITORING SYSTEM
Unlock the vehicle using the radio frequency remote control.
Switch on the ignition using the transponder key.
82C-2
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
ALARM
82C
TRIGGERING AND STOPPING THE ALARM
The alarm and indicators are triggered if:

the bonnet and/or boot is (are) opened,
intrusion (interior space detection),
+ after ignition is switched on without the key having been recognised,
alarm wiring fault.
When the vehicle is locked with the interior space protection inhibited, manually opening one of the doors will cause
the alarm and the hazard warning lights to operate for 25 seconds.
When the vehicle is locked with the interior space protection activated, the ultrasonic sensors are active after
7 seconds.
If a hand is passed in front of the sensors, this will cause the alarm and the hazard warning lights to operate for
25 seconds.
The alarm and indicators stop if:

the vehicle is unlocked using the radio frequency remote control,
the transponder key is recognised when the ignition is switched on.
Driver warning that the alarm has been triggered:

If the alarm has been triggered, this will be indicated by the direction indicators not flashing when the driver unlocks
the vehicle.
82C-3
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
DF139
PRESENT
OR
STORED
NOTES
ALARM
182C
SUPPLY TO THE ALARM
Conditions for applying the fault finding procedure to the stored fault:
The fault is declared present with the alarm on stand by (alarm system triggered or
armed).
Check the connection and condition of the alarm connector.

+ Battery
Track 1 alarm siren
Replace the siren if necessary.
AFTER REPAIR
82C

82C-4
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
DF140
PRESENT
OR
STORED
NOTES
CC.0
ALARM
82C
SIREN CIRCUIT
the fault is declared present with the alarm on stand by (alarm system triggered or
armed).

Check the continuity and insulation against earth of connection:
Track 2 alarm siren
CC.1

Check for continuity and insulation against + 12 V on the following connection:
AFTER REPAIR

82C-5
vnx.su
Track 2 alarm siren
Program no.:
3.7 and higher
Vdiag No.: 04
DF141
PRESENT
OR
STORED
NOTES
CC.0
CC.1
ALARM
82C
ULTRASONIC SENSOR CIRCUIT

1.DEF : Sensor signal absent
armed).
Check the connection and condition of the ultrasonic sensors' connector.

Check for continuity and insulation against earth and + 12 V on the following
connection:
Track 1 ultrasonic alarm module
1.DEF
Check the connection and condition of the ultrasonic sensors' connector.

Ensure that + 12 V is present on track 15 of the ultrasonic module.
Ensure that there is an earth on track 1 of the ultrasonic module.
Replace the ultrasonic module if necessary.
AFTER REPAIR

82C-6
vnx.su
Track 1 ultrasonic module
Program no.:
3.7 and higher
Vdiag No.: 04
DF144
PRESENT
OR
STORED
NOTES
ALARM
SIREN
armed).

Check for continuity and insulation on the following connections:
Earth
Track 2 alarm siren

Track 3 alarm siren
Replace the siren if necessary.
AFTER REPAIR
82C

82C-7
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
NOTES
Order
Function
After ignition
ALARM
82C
Only check the conformity after having performed a complete check with the diagnostic
tool. The values indicated in this conformity check are given merely as examples.
Test conditions: ignition off.
Parameter or State
Check or Action
ET154:
Presence of
+ 12 V after
ignition
ET236:
Ultrasonic
sensor
ET057:
Bonnet open
Display and notes
Fault finding
YES
In the event of a fault: refer

to the fault finding procedure
for state ET154.
INACTIVE
ACTIVE when the
alarm is operating
except when interior
space protection
inhibited.
Alarm
YES if the bonnet is

open.
NO if the bonnet is
closed.
ET232:
Siren
INACTIVE
STAND BY
ACTIVE
82C-8
vnx.su
In the event of a fault: apply

the fault finding procedure for
fault DF141 Ultrasonic sensor
circuit.
In the event of a fault: refer

to the fault finding procedure
for state ET057.
In the event of a fault: apply
the fault finding procedure for
fault DF140 Siren circuit.
Program no.:
3.7 and higher
Vdiag No.: 04
ALARM
82C
BONNET OPEN
ET057
NOTES
None.
Check that the corresponding state is open for the open bonnet, or closed for the closed bonnet.
Check for continuity and insulation of the following connections:
Earth
Bonnet catch
Bonnet catch
Open the bonnet, then disconnect and close the lock.
Verify the continuity between the earth input track and the track on the UCH.
Pull the handle to open the lock and check that there is no longer continuity between the earth input track and
the UCH track.
In the event of a fault, replace the lock.
Check that the lock is fitted into the striker properly.
AFTER REPAIR
Repeat the diagnostic procedure on the system.

Clear the stored faults.
82C-9
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
ALARM
82C
REAR DOORS OPEN

ET122
NOTES
None.
Check that the corresponding state is open for open rear doors, or closed for closed rear doors.
Earth

Open the rear doors, then disconnect and close the lock.
the UCH track.
AFTER REPAIR

82C-10
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
ALARM
82C
FRONT DOORS
ET192
NOTES
None.
Check that the corresponding state is open for open front doors, or closed for closed front doors.
Earth

Open the front door, then disconnect and close the lock.
the UCH track.
AFTER REPAIR

82C-11
vnx.su
Program no.:
3.7 and higher
Vdiag No.: 04
ET301
ET302
ET303
ET304
NOTES
ALARM
82C
SOURCE FOR ALARM TRIGGERING FOR THE FIRST TIME

SOURCE FOR ALARM TRIGGERING FOR THE SECOND TIME
SOURCE FOR ALARM TRIGGERING FOR THE THIRD TIME
SOURCE FOR ALARM TRIGGERING FOR THE FOURTH TIME
None.
When the alarm is triggered a number of times, it is possible to check the triggering source for up to four
consecutive instances of the alarm being triggered.
The triggering source is divided into three zones for perimeter monitoring.
Zone 1: bonnet
Zone 2: front doors (driver's and passenger's)
Zone 3: rear doors and tailgate (or boot-lid)
Interior space monitoring (ultrasonic module)
After ignition transponder key recognition.
AFTER REPAIR

82C-12
vnx.su
INSTRUMENT
183 PANEL
Dashboard
WARNING: Handling the pyrotechnic systems (pretensioners or air

bags) near a source of heat or a flame is forbidden; there is a risk of
triggering.
83-1
vnx.su
83
INSTRUMENT PANEL
Dashboard
REMOVAL
Unclip the cover under the steering wheel to connect

Unclip the steering wheel air bag cushion.
83

IMPORTANT: before removing the air bags, lock
the computer using the diagnostic tool (for
instructions, see Section 88).
WARNING: it is essential to mark the position of

the rotary switch and ensure that the wheels are
straight when removing it, so that the strip is
centred.
Remove:
the steering wheel.
83-2
vnx.su
INSTRUMENT PANEL
Dashboard
83
Unclip the instrument panel glass.
Disconnect the aerial connector.
Remove the two mounting bolts (A) from the casing.

83-3
vnx.su
INSTRUMENT PANEL
Dashboard

Undo the bolt (B) then release the rotary switch.
Remove:
the instrument panel,
the plate (E) and disconnect the connectors
(according to the version).
83
Remove:

steering column).
83-4
vnx.su
INSTRUMENT PANEL
Dashboard
83
Remove the mounting bolts (I).
Remove the mounting bolts (J).
Remove the six mounting bolts from the passenger air

bag.

Remove the radio, using the tool (MS. 1373).
Disconnect the connector, then release the air bag.
83-5
vnx.su
INSTRUMENT PANEL
Dashboard
Remove:
83

Remove the four mounting screws (L).
the mounting bolts (K).

control panel.
83-6
vnx.su
INSTRUMENT PANEL
Dashboard
83
20383.1
Remove:
the earth wire (O),

the connector.
The remaining operations require two people.

Partially release the dashboard.
83-7
vnx.su
INSTRUMENT PANEL
Dashboard
REFITTING
83
Special notes on the driver's air bag

Connect the connector, then lock it.

Place the air bag on the steering wheel and slide it
downwards until it clicks.

foolproofing devices. The steering wheel must fit
back into the splines easily. Be careful not to
damage them.

4.4 daNm.
83-8
vnx.su
INSTRUMENT PANEL
Dashboard
Special notes on the passenger air bag
83
Special notes on vehicles fitted with a tachograph
IMPORTANT:
fitting the air bag module.
safety lock.

tachograph for a description of how to reboot the
system.

mounting bolts:
four bolts (O) = 2 N.m,
two bolts (P) = 8 N.m.
83-9
vnx.su
INSTRUMENT PANEL
Instrument panel
REMOVAL
Remove:
the instrument panel glass clipped onto the
dashboard,
the mounting bolts (A).
83-10
vnx.su
83
INSTRUMENT PANEL
Instrument panel
CONFIGURATION
When the instrument panel is replaced it is configured
automatically once the ignition is switched on. The
UCH sends the configuration stored in the memory of
the old instrument panel to the new instrument panel.
When the instrument panel is not configured, an
instrument panel not configured fault will appear on
the UCH.
apply the procedure using the diagnostic tool to
change the instrument panel configurations:
83
Clock with or without,

Speed signal ABS or gearbox sensor,
Engine type petrol or diesel,
Speed sensor index
-215/65 R16
-205/65 R16
-215/65 R16,
Chronotachograph with or without
When it is finished, the tool displays:
Are the configurations correct?
YES or NO
Test the multiplex network to check that it is in good

condition, then exit the fault finding,
Disconnect the battery (for at least 1 minute) then
reconnect it,
WITHOUT SWITCHING THE IGNITION BACK ON,
test the multiplex network again (ignore the
segments that are faulty due to the ignition being
switched off),
Establish a dialogue with the UCH,
In the Command, Specific command menu,
confirm CF 719 instrument panel type,
The tool displays Are you sure you want to
configure?
If there is an error in operations, confirm NO to restart

the procedure.
If the answer is YES, switch off and restart the ignition
twice to confirm the instrument panel configuration.
The tool displays: configuration complete.
YES or NO,
NO exit the procedure,

YES the tool displays:
Turn off the ignition, then press Enter,
83-11
vnx.su
INSTRUMENT PANEL
Instrument panel
RED CONNECTOR
Track
Description
1
2
3
4
5
6
not in use
not in use
not in use
not in use
Lighting dimmer
Assisted steering scroll button (according to
the version)
not in use
not in use
Service warning light
Multiplexing
Multiplexing
not in use
not in use
Anti-lock braking system indicator light
Electronic braking regulator indicator
light
7
8
9
10
11
12
13
14
15
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
GREY CONNECTOR
Track
1
2
3
4
5
6
7
Description
30
not in use
Right direction signal indicator light
Left direction signal indicator light
+ before ignition
Engine immobiliser indicator light
Seat belt indicator light
not in use
83-12
vnx.su
83
Dipped beam headlights indicator light

Main beam headlights indicator light
Air bag indicator light (depending on the
version)
Rear fog light indicator light
Fog light indicator light
not in use
Battery charge warning light
not in use
+ after ignition
not in use
Oil pressure warning light
not in use
not in use
Oil level sensor
Fuel sender signal
Vehicle speed signal
Earth
Fuel sender earth
Oil level sensor earth
Side lights indicator light
Hand brake indicator light
not in use
Brake fault warning light
INSTRUMENT PANEL
Instrument panel
GENERAL INFORMATION
The instrument panel contains the following functions:
needle gauge functions
vehicle speed
rev counter
coolant temperature,
fuel level
audible function (ignition on)
indicators
headlights on reminder when a door is opened
automatic locking when driving confirmation
limit speed exceeded (Saudi Arabia) (depending
on the version)
warning and indicator light function
display function
oil level reading
odometer
total mileage
trip mileage
driving assistance (according to the version)
fuel consumed
average consumption
current consumption
fuel range
distance travelled
average speed
clock (depending on the version).
83-13
vnx.su
83
INSTRUMENT PANEL
Instrument panel
OPERATION OF THE DISPLAY
Oil level reading

This function is displayed for approximately
30 seconds when the ignition is switched on or after
83
It is normal to find that the oil level is not always the

same: Various parameters are involved:
parking on a slope,
too short a wait after running the engine briefly
(especially when the oil is cold),
different oil temperatures.
Odometer
If the level is between the permitted maximum and
minimum, the display shows oil ok
Total mileage
The mileometer will be displayed approximately
30 seconds after the ignition is switched on (after the
oil level information). Pressing the "ADAC" or "reset"
button shortens this waiting time.
Trip mileage
13141a
If the "ADAC" or "reset" button is pressed during this

time, the display shows "oil ok" and the oil level as
represented by squares. These disappear as the oil
level drops and are replaced by dashes.
The trip meter is displayed instead of the total mileage

when the "ADAC" or "reset" button is pressed briefly.
It is reset by pressing the "reset" button. Resetting the
trip mileometer is different to resetting the driving
assistance function.
NOTE: different instrument panels are required for a
display in kilometres or miles.
13141b
If the oil level is at a minimum when the ignition is

switched on, the dashes and the word oil flash for
30 seconds. The service warning light comes on and
remains lit after the engine is started.
13141c
NOTE:
Under normal operating conditions, the oil level is
only measured if the ignition has been switched off
for over one minute; otherwise the old oil level value
is redisplayed.
however, when a fault is detected on the dipstick, the
display switches directly to the mileometer function
when the ignition is switched on.
83-14
vnx.su
INSTRUMENT PANEL
Instrument panel
On-board computer ("ADAC") (according to
version)
83
Current consumption (in l/100 km)
The various sequences of the on-board computer may

be displayed instead of the total mileages by
successively pressing the button on the end of the
wiper stalk (ADAC button).
It is reset by pressing the reset button.
13141f
The information from the on-board computer is

displayed after the trip meter as follows:
This is only displayed when the vehicle speed is above

approximately 18 mph (30 km/h). Below this, fixed
dashes appear on the display.
Fuel consumed (in l/100 km or mpg* ) since the last

reset.
In the accelerator pedal no load position, if the speed

is greater than 20 mph (30 km/h), the current
consumption is equal to 0.
NOTE: this function is not available on the UK version.
13141d
Estimated range with remaining fuel (in km or

miles*).
Average consumption (in l/100 km or mpg *) since

the last reset.
13141g
13141e
This is only displayed after the vehicle has travelled

approximately 400 m. Below this, fixed dashes appear
on the display.
This is only displayed after the vehicle has travelled

on the display.
This is the potential distance remaining calculated by
taking into account the distance travelled, the amount
of fuel remaining in the tank and the fuel consumed.
This takes into consideration the distance covered and

the fuel consumption since the last time the reset
button was pressed.
NOTE: the range remaining is not displayed when the

low fuel warning light is lit.
* UK version.
83-15
vnx.su
INSTRUMENT PANEL
Instrument panel
83
Distance travelled since the last reset (resetting the

ADAC).
13141h
Average speed since the last reset.
13141j
This is displayed after the vehicle has travelled

on the display.
This is obtained by dividing the distance travelled by
the time elapsed since the last time the reset button
was pressed.
The time base is inside the trip computer.
83-16
vnx.su
INSTRUMENT PANEL
Instrument panel
83
FAULT FINDING PROCEDURE
Press the "ADAC" button to proceed to the next test.
To access the fault finding procedure, press and hold

the "ADAC" button on the end of the wiper stalk, with
the ignition on but the engine off.
Viewing stored faults.
All the warning lights illuminate and the needles on

the four gauges move in steps.
The liquid crystal display test appears.
13141o
If the letter t is displayed, this means that an injection

signal fault has been stored for at least 4 seconds.
13141l
All the segments on the display should be lit up.
If the letter J is displayed, this means that a fault has

been detected on the fuel sender (disconnected for
more than 100 seconds). The resistance should be
between 5 and 350 .
If the letter d is displayed, this means that an injection
signal fault has been detected.

The amount of fuel remaining in the tank test
appears.
If the letter h is displayed, this means that an oil level

sensor fault has been detected. The resistance should
be between 6 and 20 .
If only fixed dashes are displayed, this means that no
faults have been detected.
Pressing the "reset" button exits the fault finding
procedure and clears the fault memory.
13141m
IMPORTANT:
The on-board computer shows a fault by displaying
flashing dashes.
If no information is received from the injection
computer via the multiplex network, the fuel gauge,
current consumption and fuel range functions do not
work.
If no information is received from the ABS computer
via the multiplex network, the mileometer and
mileage to next oil change functions will not work.
The value displayed should correspond to the amount

of fuel remaining in the tank in litres (even for the UK
version).
The fuel flow in litres / hour test appears (engine
running).
13141N
A value should be displayed when the engine is

running.
83-17
vnx.su
INSTRUMENT PANEL
Fuel level sensor
83
Checking
CONNECTION
Check that the resistance varies when the float is

moved.
Level
Resistance
( 10 )
Effective volume
( 5 l)
Tank full
20
70
Tank 3/4 full
87.5
54
Tank half full
155
38
Tank 1/4 full
222.5
23
Tank empty
290
NOTE: all the above values are given merely as a

guide.
Track
Description
A1
Fuel level information
A2
Not used
B1
- Fuel sender
B2
Not used
C1
+ Fuel pump
C2
- Fuel pump
NOTE: refer to Section 13 for the removal/refitting

method.
83-18
vnx.su
INSTRUMENT PANEL
Oil level sensor
83
OPERATION
CHECKING
The sensor consists of a wire with a high resistance

coefficient. A wire with a current passing through it
does not have the same thermal conductivity when it is
immersed in a liquid or in air.
The sensor resistance must be between 6 and 20 .
After a fixed time a voltage difference is obtained at the

sensor terminals depending on the depth of immersion
of the wire. This voltage difference is processed by the
instrument panel computer which then displays the
level and also controls the low oil level warning light
on the central display.
The sensor is deemed to be in open circuit at a value

higher than 20 .
The sensor is deemed to be in short circuit at a value

lower than 3 .
LOCATION
Example: F engine.
When the ignition is switched on, the central display

shows the message oil ok for approximately
30 seconds before switching to the mileometer
function.
NOTE: if a short circuit or an open circuit is detected
when the oil level is measured, the display will
immediately show the mileometer function.
If the battery voltage is less than 8 V, the level will not
be displayed.
83-19
vnx.su
INSTRUMENT
PANEL
183
Multiplex instrument panel
83
Integrated Self-test:
The PRIMASTAR instrument panel is equipped with an on-board self-test sequence. This makes it possible to
visually test the various indicators and warning lights controlled by the system inside the instrument panel.
Activation of all segments of the mileometer and trip computer display.
Activation of all the needle indicators.
Activation of all the warning lights controlled by the microprocessor.
Activation of the audible warning incorporated in the instrument panel.
For versions without on-board computer, fault finding mode is obtained by pressing the mileometer reset button
for 5 seconds when switching on the + after ignition.
For versions with trip computer, fault finding mode is obtained by pressing the trip computer sequence button
when switching on + after ignition.
IMPORTANT:
It is essential to carry out an instrument panel self-test to check that the indicators and warning lights are
operating correctly.
The computer-controlled warning lights covered by the self-test are: opening elements status / injection coolant
temperature criticality 2 / airbag / airbag off / de-icing / fuel level low / injection criticality 1 / preheating / pollution
control / automatic transmission fault / STOP / SERVICE / cruise control / tyre pressure monitor / ABS system /
ESP system / LPG.
The dual-coloured warning lights (amber and green) light up at the same time during the self-test; this creates
an abnormal warning light colour (speed limiter control warning light, LPG warning light).
Failure of any of the warning lights requires replacement of the instrument panel.
IMPORTANT:
Warning lights which are controlled via a wire link (conventional control by means of a wire connecting the
warning light to the computer) are not tested by the instrument panel.
To test these, use a diagnostic tool (CONSULT II) and use fault warning light test command mode for the
computer controlling the warning light to be checked.
83-1
vnx.su
INSTRUMENT PANEL
83
FAULT FINDING
Special notes:
The PRIMASTAR instrument panel manages part of its display by using information received from the
multiplex network. This information is listed by transmitting computer in each column and by receiving warning
light on each line in the table in appendix No. 1.
The indicators and warning lights which are not present on this instrument panel are to be dealt with using
FAULT FINDING CHARTS 5 to 26 (wiring fault finding information).
A multiplex network fault may be shown by several statuses:
1 The loss of a message from a computer, due to a break in the multiplex network between the node (junction
of the network of all the computers) and the transmitting computer, or a fault inside the transmitter computer.
This is indicated by the loss of several indicators and the lighting of several warning lights (see table in
appendix No. 2).
2 The loss of a large amount of instrument panel information crossing the multiplex network due to a break in
the network between the node and the instrument panel (receiver) or a fault inside the instrument panel
(FAULT FINDING CHART 4).
3 The loss of all the data crossing the multiplex network due to a short circuit in the network, which manifests
itself as a large number of defect modes in all the computers connected to the network.
For an electrical conformity check on the multiplex network, refer to the section concerned.
83-2
vnx.su
INSTRUMENT PANEL
83
Instrument panel configuration

When the instrument panel is replaced it is configured automatically once the ignition is switched on. The UCH
sends the configuration stored in the memory of the former instrument panel to the new instrument panel.
When the instrument panel is not configured, fault DF130 Instrument panel not configured will appear on the UCH.
1) In the event of replacement of the instrument panel and the UCH at the same time, it will be necessary to perform
fault finding with a diagnostic tool.
METHOD: Ignition off
Connect the diagnostic tool and establish dialogue with the UCH without switching on the ignition.
Configure the UCH (CF719).
Switch the ignition on and off to enter the new parameters.
2) If the instrument panel configuration is changed, it will be necessary to use a diagnostic tool.
METHOD: Ignition off
Disconnect the battery for at least 1 minute, then reconnect it.
Connect the diagnostic tool and establish dialogue with the UCH without switching on the ignition.
Configure the UCH (CF719).
Switch the ignition on and off to enter the new parameters.
83-3
vnx.su
INSTRUMENT PANEL
83
Instrument panel parameters which can be configured are:

Engine type: petrol or diesel
LPG present or absent
Traction control present or absent
Tyre pressure monitoring system present or absent
Clock present or absent
Speed signal generator (Anti-lock Braking System or gearbox sensor)
Type of airbag: wire or multiplex
Type of tyre
Export vehicle (Mercosur/S. America)
Instrument panel with chronotachograph
Configuration is carried out by a CONSULT II diagnostic tool. The tool is connected to the UCH on line K and
transmits the instrument panel configuration frame by means of the multiplex network.
To configure the instrument panel, access the configuration mode via the diagnostic tool.
IMPORTANT:
If the vehicle has ABS as well as a speed sensor on the gearbox connected to the engine wiring, configure the
instrument panel with a "speed signal generator: sensor on gearbox".
For the speed calibration, the factor must be selected according to the type of tyre fitted to the vehicle.
83-4
vnx.su
INSTRUMENT PANEL
Warning lights
Doors open
warning light no. 1
Coolant temperature + injection level 2 fault
warning light no. 2
Airbag
warning light no. 3
Airbag deactivated
warning light no. 4
Heated rear screen
warning light no. 5
Level 1 injection fault
warning light no. 6
Emission control
warning light no. 8
Stop
warning light no. 9
Service
warning light no. 10
Cruise control
Traction control system
Indicators
Vehicle speed
indicator no. 1
Rev counter
indicator no. 2
Coolant temperature
indicator no. 3
Trip computer test mode
indicator no. 4
Multiplex computer
Airbag
Airbag
UCH
UCH
Carminat navigation aid system
Carminat
Instrument panel
Instrument panel
83-5
vnx.su
83
INSTRUMENT PANEL
83
APPENDIX 1
Multiplex network fault finding
Signal generators/receivers used by the instrument panel:
Multiplex computers
F4R
engine
F9Q
engine
Airbag
UCH
Carminat
Instrument
panel
Warning lights:
Warning light no. 1
Warning light no. 2
1
1
Warning light no. 3
Warning light no. 4
Warning light no. 5
Warning light no. 6
Warning light no. 8
Warning light no. 11
Indicator no. 1
Indicator no. 2
Indicator no. 3
Indicator no. 4
Indicators
2
(1) Transmitting computer

(2) Receiving computer
IMPORTANT:
If there is a fault with an indicator on the instrument panel, the data should be considered as having been
transmitted correctly over the multiplex network because it is transmitted with several pieces of data in the
same message (signal).
Therefore, either the indicator on the instrument panel is faulty, or the message is wrong.
The message may be wrong due to incorrect interpretation by the transmitting computer (e.g. faulty
coolant temperature sensor) or a fault inside the transmitting computer.
Using the table in appendix 1, isolate the computer issuing the data and carry out a full diagnostic
check on it before carrying out any work on the instrument panel.
83-6
vnx.su
INSTRUMENT PANEL
Warning lights:
Status of opening elements
warning light no. 1
Coolant temperature + injection level 2 fault
warning light no. 2
Airbag
warning light no. 3
Airbag deactivated
warning light no. 4
Heated rear screen
warning light no. 5
Level 1 injection fault
warning light no. 6
Emission control
warning light no. 8
Stop
warning light no. 9
Service
Cruise control
Traction control system
Indicators
Vehicle speed
indicator no. 1
Rev counter
indicator no. 2
Coolant temperature
indicator no. 3
Trip computer test mode
indicator no. 4
Multiplex computer
Airbag
Airbag
UCH
UCH
Carminat navigation aid system
Carminat
Instrument panel
Instrument panel
83-7
vnx.su
83
INSTRUMENT PANEL
83
APPENDIX 2
Defect mode and lighting of warning lights when there is loss of communication with the transmitting
computer:
Transmitting computer
Fault finding chart
F4R
engine
F9Q
engine
Airbag
UCH
Warning lights:
Warning light no. 1
Warning light no. 2
2
1
Warning light no. 3
Warning light no. 4
Warning light no. 5
Warning light no. 6
Warning light no. 8
Warning light no. 9
Indicator no. 2
Indicator no. 3
Indicator no. 4
t-d-
t-d-
Indicators
(0) indicator not used

(1) warning light on
(2) warning light off
(3) on for 3 seconds + after ignition
(4) on for 5 seconds + after ignition
IMPORTANT:
Loss of a message is often shown by the failure of several indicators and some computers, which require
the missing data for their operation, go into defect mode.
Check the multiplex network using a diagnostic tool (CONSULT II) or or isolate the transmitting computer with
the help of appendix no. 2.
To do that, make a list of the faulty indicators on the instrument panel and refer to the column of the
corresponding fault finding chart.
Loss of the CAN link between the network node and the instrument panel is interpreted by all the indicators
and warning lights as defect mode operation (all columns in the table in appendix no. 2) see FAULT FINDING
CHART 4.
83-8
vnx.su
INSTRUMENT PANEL
83

Finding faults on warning lights and indicators controlled by the multiplex network:
COOLANT TEMPERATURE GAUGE AND/OR REV COUNTER AT ZERO
MESSAGE FROM: INJECTION COMPUTER
CHART 1
AIRBAG FAULT AND SERVICE WARNING LIGHT ON

MESSAGE FROM: AIRBAG COMPUTER
CHART 2
DOOR STATUS AND/OR DE-ICING INDICATOR DOES NOT LIGHT UP

MESSAGE FROM: UCH
CHART 3
WARNING LIGHTS: ESP, SERVICE, AIRBAG, AUTOMATIC TRANSMISSION (IF

FITTED), LPG (IF FITTED) DO NOT LIGHT UP WHEN THE IGNITION IS
SWITCHED ON AND THE COOLANT TEMPERATURE GAUGE AND REV
COUNTER REMAIN AT ZERO
CHART 4
83-9
vnx.su
INSTRUMENT PANEL
83

Fault finding on warning lights and indicators controlled by wire link:
SPEEDOMETER FAULTY OR INCONSISTENT
SIGNAL EMITTED BY THE SENSOR ON THE GEARBOX
CHART 5
SPEEDOMETER FAULTY OR INCONSISTENT

SIGNAL SUPPLIED BY THE ANTI-LOCK BRAKING SYSTEM
CHART 6
NO FUEL LEVEL INFORMATION ON NEEDLE GAUGE (TANK NOT EMPTY)

WITH RESERVE LIGHT ON
CHART 7
FUEL GAUGE NEEDLE REMAINS AT MAXIMUM, TANK NOT FULL
CHART 8
FUEL GAUGE STUCK IRRESPECTIVE OF THE LEVEL OF FUEL WITH NO

LIGHTING OF RESERVE WARNING LIGHT
CHART 9
OIL LEVEL INFORMATION ABSENT OR INCORRECT AND SERVICE WARNING

LIGHT ON
CHART 10
BATTERY CHARGE AND STOP WARNING LIGHTS REMAIN LIT
CHART 11
IMMOBILISER WARNING LIGHT REMAINS LIT
CHART 12
IMMOBILISER WARNING LIGHT REMAINS OFF
CHART 13
OIL PRESSURE AND BRAKE WARNING LIGHTS COME ON
CHART 14
ANTI-LOCK BRAKING SYSTEM WARNING LIGHT REMAINS LIT
CHART 15
83-10
vnx.su
INSTRUMENT PANEL
83

ANTI-LOCK BRAKING SYSTEM WARNING LIGHT REMAINS OFF
CHART 16
DIRECTION INDICATORS AND DIRECTION INDICATOR WARNING LIGHTS

REMAIN ON OR OFF
CHART 17
MAIN BEAM WARNING LIGHT REMAINS ON OR OFF
CHART 18
DIPPED BEAM WARNING LIGHT REMAINS ON OR OFF
CHART 19
FRONT FOG LIGHT WARNING LIGHT REMAINS ON OR OFF
CHART 20
REAR FOG LIGHT WARNING LIGHT REMAINS ON OR OFF
CHART 21
SEAT BELT NOT FASTENED WARNING LIGHT REMAINS OFF
CHART 22
BRAKE FAULT WARNING LIGHT REMAINS ON WITHOUT LIGHTING OF THE

STOP WARNING LIGHT
CHART 23
BRAKE FAULT AND STOP WARNING LIGHTS COME ON
CHART 24
SERVICE WARNING LIGHT REMAINS LIT
CHART 25
INSTRUMENT PANEL INOPERATIVE
CHART 26
TRIP COMPUTER AND THE TRIP METER RESET TO ZERO EACH TIME THE
IGNITION IS SWITCHED OFF
CHART 27
83-11
vnx.su
INSTRUMENT PANEL
83
Coolant temperature gauge and/or rev counter at zero

Message from: injection computer
CHART 1
First carry out fault finding on the multiplex

network with the diagnostic tool.
no
Result: multiplex network correct.
Refer to the
Multiplexing
section.
yes
Carry out a full fault finding check on the engine

injection.
yes
Check that the coolant temperature signal is

present and consistent.
(Warning: coolant temperature gauge position is
fixed between 80 and 105 C).
Injection fault:
no
Replace the instrument panel.
83-12
vnx.su
See engine
injection fault
finding.
INSTRUMENT PANEL
83
Airbag fault and service warning light on

Message from: airbag computer
CHART 2

no
Refer to the
Multiplexing
section.
yes
See airbag fault

finding.
yes
Carry out a full diagnostic check of the airbag

system.
Result: fault present.
no
83-13
vnx.su
INSTRUMENT PANEL
83
Door status and/or de-icing indicator does not light up

Message transmitted by: UCH
CHART 3

no
Refer to the
Multiplexing
section.
yes
See UCH fault

finding.
yes
Carry out a full fault finding sequence on the

UCH.
no
83-14
vnx.su
INSTRUMENT PANEL
83
CHART 4
The warning lights: ESP, SERVICE, airbag, automatic

transmission (if fitted), LPG (if fitted) do not light up when the
ignition is switched on and the coolant temperature gauge and rev
counter remain at zero

no
yes
Are the insulation and electrical condition of the

multiplex network correct?
no
Check the continuity of the multiplex network

between the node and the instrument panel
connector.
Are the instrument panel connectors in good
condition, especially the twisted pair cable
(multiplex bus), tracks 10 and 11 of the 15-track
connector?
yes
Refer to the
Multiplexing
section.
83-15
vnx.su
INSTRUMENT PANEL
83
CHART 5
Speedometer faulty or inconsistent; signal supplied by the

sensor on the gearbox
If the signal is inconsistent, check that the instrument panel speed

calibration parameters are correct before carrying out any work.
yes
Using a diagnostic tool, check

that the UCH is correctly
receiving the vehicle speed
information during a road test.
no
Use a diagnostic tool during a

road test to check whether the
injection computer is receiving
the vehicle speed signal
correctly.
no
yes
Check that the connectors on the

gearbox sensor are correctly
locked.
Check that the connectors

behind the instrument panel are
correctly locked.
Check that the speed sensor shaft

on the gearbox is in good condition
mechanically.
Check that the speedometer drive
gear is operating correctly.
83-16
vnx.su
INSTRUMENT PANEL
83
CHART 5
CONTINUED
Is there continuity between the

vehicle speed sensor connector
and track 13 on the instrument
panel 15-track connector?
no
(speed signal line)
(speed signal line)
yes
yes
Is the vehicle speed sensor

correctly fed with + after ignition?
Is there continuity between the

vehicle speed sensor connector
and track 13 on the instrument
panel 15-track connector?
no
yes
Replace the vehicle speed sensor.

Repair.
83-17
vnx.su
INSTRUMENT PANEL
83
Speedometer faulty or inconsistent

(signal supplied by the Anti-lock Braking System)
CHART 6
Using a diagnostic tool, check

that the UCH is correctly
receiving the vehicle speed
signal during a road test.
yes
no
Check the functioning of the Antilock Braking System and the

absence of faults using a
diagnostic tool (CONSULT II).
Check that the connectors on the
ABS unit and behind the
instrument panel are correctly
locked.
Is there continuity between

track 22 on the ABS computer
connector and track 13 on the
15-track instrument panel
connector?
no
Repair.
(speed signal line)
yes
Use a diagnostic tool during a road

test to check whether the electric
power steering computer is
receiving the vehicle speed signal
correctly.
no
The speed signal is not supplied by

the Anti-lock Braking System.
See the Anti-lock Braking System
fault finding.
yes
83-18
vnx.su
INSTRUMENT PANEL
83
No fuel level information on needle gauge (tank not empty) with

reserve light on
CHART 7
Check the condition of the fuel tank sender connector and the 30-track
and 15-track instrument panel connectors.
Check the resistance of the fuel tank sender at the disconnected fuel
tank connector.
A resistance of more than 350 is read by the instrument panel as an
open circuit.
Open circuit
Fuel tank sender correct
Replace the fuel tank
sender.
Disconnect the connectors at the instrument panel and

check the continuity of the fuel tank sender electrical
wiring between:
track 2 on the 15-track instrument panel connector

and track A1 of the fuel tank sender.

and track B1 of the fuel tank sender.
no
Is it correct?
yes
Replace the instrument

panel.
Repair.
83-19
vnx.su
INSTRUMENT PANEL
83
CHART 8
Fuel gauge needle remains at maximum (ignition on), tank not full
CONDITION
If the instrument panel detects a fault, it causes the oil warning light (h) to come on in
trip computer test mode 100 seconds after the ignition is switched on.
Check the condition of the fuel tank sender connector and the 30-track
and 15-track instrument panel connectors.
tank connector.
A resistance of less than 5 is read by the instrument panel as a short
circuit.
Short circuit
Fuel tank sender correct
Replace the fuel tank
sender.
Disconnect the connectors from the instrument panel

and check the insulation of the fuel tank sender unit
electric wiring harness between the earth and the
+ 12 V supply:

(which is connected to track A1 of the fuel tank
sender).
no

(which is connected to track B1 of the fuel tank
sender).
Is it correct?
yes

panel.
Repair.
83-20
vnx.su
INSTRUMENT PANEL
83
CHART 9
Fuel gauge stuck irrespective of the level of fuel without lighting

of reserve warning light
CONDITION
When testing the indicator with the fuel tank sender removed, it is necessary to switch
the ignition off and on again between each variation so that the instrument panel can
take a new measurement.
tank connector.
Compare the true level in the tank with the fuel tank sender resistance
value table.
Is there a lack of correlation?
no
yes

check the continuity of the fuel tank sender electrical
wiring between:
Check that the sender

unit slides correctly inside
the tank.

and track A1 of the fuel tank sender.

and track B1 of the fuel tank sender.
Check their insulation to earth and + 12 V.

Is it correct?
yes
no

panel.
Repair.
Fuel tank sender resistance value:

proportion:
reserve
full
resistance:
290
20
83-21
vnx.su
If the problem persists,

replace the fuel tank
sender.
INSTRUMENT PANEL
83
CHART 10
Oil level indication absent or incorrect

and SERVICE warning light on
CONDITION
The oil level indication will only be correct if the vehicle is on a flat surface; a
measurement should be retaken after switching the ignition off for at least one minute.
Check in trip computer test mode (if fitted) the presence of the letter (h).
(h) missing or no trip

computer
(h) present
Remove the oil level

sensor and check its
resistance at ambient
temperature, which
should be between 5 and
16 and check its
insulation to earth.
no
Is it correct?
yes
Replace the oil level sensor.

check the continuity and insulation of the oil level gauge
electrical wiring:
track 21 of the 30-track connector (which is connected

to track 1 of the fuel tank sender unit)
track 26 of the 30-track connector (which is connected

to track 2 of the oil level sender unit)
no
Is it correct?
yes

panel.
Repair.
83-22
vnx.su
INSTRUMENT PANEL
83
CHART 10
CONTINUED
Remove the oil level sensor and

check its resistance at ambient
temperature, which should be
between 3 and 20 and check
its insulation to earth.
Is it correct?
Disconnect the connectors at the

instrument panel and check the continuity
and insulation of the oil level gauge
electrical wiring:
yes
track 21 of the 30-track connector

(which is connected to track 1 of the oil
level sender unit)
track 26 of the 30-track connector

(which is connected to track 2 of the oil
level sender unit)
Is it correct?
no
Replace the oil level sensor.
yes
83-23
vnx.su
no
Repair.
INSTRUMENT PANEL
The battery charge and brake warning lights remain lit
CHART 11
Check the charging circuit and repair if

necessary.
no
End
Is the fault still present?
yes
Disconnect the alternator connector, then start

the engine.
no
Replace the
alternator.
no
Repair.
yes
Disconnect the connectors from the instrument

panel, then check the insulation to earth of the
alternator charging indicator light line, track 14
of the 30-track connector.
Is the line insulated?
yes
83-24
vnx.su
83
INSTRUMENT PANEL
The immobiliser warning light remains lit
CHART 12
Carry out the fault finding sequence on the UCH.

Check that the immobiliser warning light status
changes to inactive when the engine is running.
no
Refer to the UCH

fault finding.
no
Replace the UCH.
no
Repair.
Is this correct?
yes
Disconnect the UCH connector containing the

immobiliser warning light command line
(track A5 green connector).
Is the warning light still on?
yes
Disconnect the instrument panel connectors and

check the earth insulation of the immobiliser
warning light control line.
Is it correct?
yes
83-25
vnx.su
83
INSTRUMENT PANEL
83
The immobiliser warning light remains off
CHART 13
Check the condition of fuse F21.
Check the presence of + 12 V

on fuse F21.
Trigger the command and check the presence of an

intermittent + 12 V (1 Hz) between track 20 connector
PE3 of the UCH and fuse F21 of the passenger
compartment fuse box.
yes
Replace the UCH.
yes
Is the voltage absent?
no
If there is a voltage present, check the continuity and

insulation between track 20 of the PE3 connector of the
UCH and track 5 of the 30 track connector of the
instrument panel.
Is continuity ensured ?
no
Repair.
83-26
vnx.su
INSTRUMENT PANEL
83
The oil pressure and brake warning lights come on
CHART 14
The instrument panel only registers the oil pressure switch signal when the engine
speed is higher than 1600 rpm.
WARNING
Check the engine oil pressure with a pressure

gauge and repair if necessary.
no
End
no
Replace the oil

pressure
switch.
yes
Disconnect the pressure switch connector, then

start the engine.
Increase the engine speed to more than
1600 rpm.
yes
Disconnect the instrument panel connectors,

then check the earth insulation of the oil
pressure switch warning light line, track 18 on
the 30-track connector.
no
yes
83-27
vnx.su
Repair.
INSTRUMENT PANEL
83
The Anti-lock Braking System warning light remains lit
CHART 15
Is the vehicle fitted with an Anti-lock Braking

System?
Check that the faulty Anti-lock

Braking System warning lights
located in the engine
interconnection unit are
earthed.
no
yes
Carry out the fault finding procedure on the Antilock Braking System.
Refer to the Antilock Braking

System fault.
yes
Is there a fault?
no
Use a multimeter to test the presence of an earth on the ABS fault

warning light control line, + after ignition on.
track 12 on the 15-track connector (which is connected to track 20
of the Anti-lock Braking System connector)
no
Is the line earthed?
yes
Repair.
83-28
vnx.su
INSTRUMENT PANEL
83
The Anti-lock Braking System warning light remains off
CHART 16
yes
Refer to the Anti-lock

Braking System fault.
yes
Replace the Anti-lock

Braking System
computer.
Is there a fault?
no
Disconnect the Anti-lock Braking System

computer connector.
Does the warning light come on?
no
Use a multimeter to measure the insulation to earth on the Antilock Braking System fault warning light control line (track 20 of
the Anti-lock Braking System connector).
Is the line earthed?
no
83-29
vnx.su
yes
Repair.
INSTRUMENT PANEL
83
The direction indicators and direction indicator warning lights

remain on or off
CHART 17
The warning light

remains ...
On
Do the external direction

indicator lights stay on?
Off
Do the external direction

indicator lights stay off?
yes
no
no
See UCH fault

finding
Disconnect the instrument panel connectors

and check the continuity between the UCH
and the direction indicators warning light
control line:

and check the absence of voltage on the
direction indicators warning light control line:
right-hand direction indicator track 2 on
30-track connector
right-hand indicator track 2 30-track

connector towards track A2 black 15-track
connector of the UCH
left-hand direction indicator track 3 on

30-track connector
left-hand indicator track 3 30-track

connector towards track A2 black 15-track
connector of the UCH
Is it correct?
Is it correct?
no
yes
yes
Repair
Replace the instrument panel
83-30
vnx.su
no
Repair
INSTRUMENT PANEL
83
The main beam warning light remains on or off
CHART 18
The warning light

remains ...
On
Do the main beam

headlights stay on?
Off
Do the main beam

headlights stay off?
yes
no
no
See UCH fault
finding

main beam warning light control line:

and verify continuity between the UCH and
the main beam warning light control line:
track 9 on the 30-track connector
track 9 30-track connector towards track A5

black 15-track connector of the UCH
Is it correct?
Is it correct?
no
yes
yes
Repair
83-31
vnx.su
no
Repair
INSTRUMENT PANEL
83
The dipped beam warning light remains on or off
CHART 19
The warning light

remains ...
On
Do the dipped beam

headlights stay on?
Off
Do the dipped beam

headlights stay off?
yes
no
no
See UCH fault

finding
Disconnect the connectors from the

between the UCH and the command line of
dipped headlights warning light.

dipped beam warning light control line:
track 9 30-track connector towards track 11

black 40-track connector of the UCH
Is it correct?
Is it correct?
no
yes
yes
Repair
83-32
vnx.su
no
Repair
INSTRUMENT PANEL
83
The front fog light warning light remains on or off
CHART 20
The warning light

remains ...
On
Do the front fog lights

stay on?
Off
Do the front fog lights

stay off?
yes
no
no
See UCH fault

finding

and check the absence of voltage on the front
fog lights warning light control line:

and check the continuity between the UCH
and the front fog lights warning light control
line:
track 12 on the 30-track connector to

track A5 of the front fog light relay.
Is it correct?
Is it correct?
no
yes
yes
Repair
83-33
vnx.su
no
Repair
INSTRUMENT PANEL
83
The rear fog light warning light remains on or off
CHART 21
The warning light

remains ...
On
Does the rear fog light

stay on?
Off
Does the rear fog light

stay off?
yes
no
no
See UCH fault

finding

and check the absence of voltage on the rear
fog light warning light control line:
Disconnect the connectors from the

between the UCH and the command line of
rear fog light warning light.
track 11 on the 30-track connector to the

rear fog light fuse.
Is it correct?
Is it correct?
no
yes
yes
Repair
83-34
vnx.su
no
Repair
INSTRUMENT PANEL
The seat belt not fastened warning light remains lit
CHART 22
Disconnect the connector of the seat belt switch

in the seat belt catch which carries the warning
light control line.
no
Replace the seat belt

catch switch.
yes

check the earth insulation of the seat belt not
fastened warning light control line.
no
Is it correct?
yes
83-35
vnx.su
Repair.
83
INSTRUMENT PANEL
83
The brake fault warning light remains on without lighting of the

STOP warning light
CHART 23
Disconnect the handbrake switch connector.

no
Replace the handbrake

switch.
yes

check the earth insulation of the handbrake
warning light control line.
no
Is it correct?
yes
See CHART 23
83-36
vnx.su
Repair.
INSTRUMENT PANEL
Brake fault and STOP warning lights come on
CHART 24
Check the brake fluid level and top up if

necessary.
no
Check the hydraulic braking

system for any leaks.
no
Replace the brake fluid level

sensor.
yes
See the Anti-lock Braking

System fault finding.
no
Repair.
yes
Disconnect the brake fluid level sensor

connector, then start the engine.
yes
Is there a fault?
no
Disconnect the instrument panel connectors,

then check the earth insulation of the brake fault
warning light line track 30 of the 30-track
connector and Anti-lock Braking System
track 15 15-track connector.
yes
83-37
vnx.su
83
INSTRUMENT PANEL
83
The SERVICE warning light remains lit
CHART 25
Check in trip computer test mode the absence of

fault (h) oil level sensor.
(h) present
See CHART 15.
(h) missing or no trip computer
Use a diagnostic tool to check the presence of

any wiper fault on the UCH.
yes
Refer to the UCH fault.
no
Check that the ABS fault warning light is
operating correctly when + after ignition is
switched on.
yes
Is there a fault?
no
83-38
vnx.su
Repair.
INSTRUMENT PANEL
83
Instrument panel inoperative
CHART 26
Check the condition of the passenger

compartment fuses.
Check all feeds to the instrument panel:
yes
+ after ignition on track 16 of the 30-track

connector
no
earth on track 24 of the 30-track connector

Is it correct?
Repair.
83-39
vnx.su
INSTRUMENT PANEL
83
The trip computer and the trip meter reset to zero each time the
ignition is switched off
CHART 27
Check the condition of the passenger

compartment fuses.
Check all feeds to the instrument panel:
+ battery on track 4 of the 30-track connector
yes
earth on track 24 of the 30-track connector
no
Is it correct?
Repair.
83-40
vnx.su
INSTRUMENT
PANEL
183
Tachograph
83

This document presents the general fault finding procedure which applies to all vehicles fitted with a tachograph.
The following are required for carrying out fault finding on this system:
This section of the Workshop Repair Manual,
The wiring diagram for the function on the vehicle concerned.
the tools listed under Special tooling required.

Include information contained in the Introduction sections.
Interpretation of customer complaints.
83-41
vnx.su
INSTRUMENT PANEL
Tachograph
83
The tachograph system is used by the police to check vehicle speeds. The system is equipped with a fault
memory which memorizes any work done on the system with the exact date and time.
Only approved tachograph centres are authorized to repair, remove components or work on the fault
memory in the computer of the tachograph system.
Faults are displayed on the screen in the form of an alphanumeric code.
Disconnecting the battery will enter a fault in the memory, as will disconnecting the speed sensor.
If it is essential to work on the system, the vehicle must be taken to an approved centre soon afterwards to
check the conformity of the repair and to have the fault memory cleared.
The chronotachograph generates a speed signal on the 47F speed signal line in the same form as a speed
sensor on the gearbox.
The instrument panel still has to be configured for the type of tyre and this must be updated on the tachograph
by an approved garage.
The tachograph receives its speed signal from a special speed sensor on the gearbox.
This sensor is sealed on the gearbox and is fitted with an electronic system which links it to the tachograph.
When the ignition is switched on, a coded message is exchanged continuously between the sensor and the
tachograph module.
Also randomly from time to time when the ignition is off or the battery disconnected, due to the presence of a
battery inside the tachograph module.
It is strictly forbidden to disconnect the sensor or the sensor link from the tachograph module. Doing
so will cause a fault to be stored in the computer memory, which will cause the customer problems
during an inspection.
For any work or check on the electrical circuit of the tachograph, it is imperative to use a probe, taking
care not to damage the insulation of the wires when checking them.
83-42
vnx.su
INSTRUMENT PANEL
Tachograph
83
NOTES
Before carrying out any work on the tachograph, please read the introduction at the
start of the section. Any disconnection behind the tachograph will register a fault in the
memory.
NO SPEED INFORMATION ON THE INSTRUMENT PANEL OR FOR

THE OTHER COMPONENTS WHICH USE THE VEHICLE SPEED
SIGNAL
CHART 1
NO TACHOGRAPH DISPLAY AND ALL OTHER FAULTS
CHART 2
83-43
vnx.su
INSTRUMENT PANEL
Tachograph
83
CHART 1
No speed information on the instrument panel or for the other

components which use the vehicle speed signal
NOTES
memory.
Does the tachograph display a speed when the vehicle is

moving?
no
yes
Remove the tachograph from its housing without

disconnecting the connectors at the back.
Using a probe, check the continuity of the speed signal
line between track B6 of the tachograph module and
track 13 of the 15-track instrument panel connector.
Is continuity ensured ?
no
Repair
AFTER REPAIR
Carry out a road test to check the repair.

Have any fault cleared by an approved garage.
83-44
vnx.su
yes
See CHART 2.
INSTRUMENT PANEL
Tachograph
83
CHART 2
No tachograph display and all other faults
NOTES
memory.
Measurement to be taken with ignition and side lights on.
Remove the tachograph from its housing without

disconnecting the connectors at the back.
Using a probe, check the presence of + 12 V on the
following lines:
no
+ Battery line - track A1

+ After ignition line - track A3
+ Side lights line - track A2
Is continuity ensured?
yes
Using a probe, check the continuity of the following

earths:
Earth 1 - track A5
no
Earth 2 - track A6
Is continuity ensured?
yes
The tachograph module is faulty. The system must be

examined by an approved centre.
AFTER REPAIR
Carry out a road test to check the repair.

Have any fault cleared by an approved garage.
83-45
vnx.su
Repair.
INSTRUMENT
PANEL
183C
Navigation assistance: General Information
This system uses the following to operate:

a Central Communication Unit
a console (an integral part of the Central
Communication Unit),
an electronic navigation computer comprising
acceleration sensors (gyroscope) and a CD-ROM
reader,
a satellite link (satellite aerial) allowing the vehicle to
be located,
a screen to display written data and maps,
a speaker for giving voice instructions,
a CD-ROM with the maps of the country the vehicle
is delivered to,
an FM aerial for traffic information messages.
IMPORTANT:
With this type of navigation system, it is
essential to wait until the system has shut down
completely (approximately 45 seconds) before
disconnecting the battery.
The CARMINAT system comprises a screen and a
voice synthesiser to provide guidance for the driver.
This system can:
83C
find a specific location, such as:

a road, street or avenue,
a hotel,
public services,
a garage or petrol station.
etc.
NOTE:
select guidance modes in order to:

optimize journey time,
select the shortest distance
plan a route travelling on main roads
or take the scenic route,
avoid tolls.
Each mode is symbolized by a different icon that

appears on the state line on the lower part of the
screen.
store addresses in the address book.
display road maps of:

the present location,
or the destination,
display journey time or time of arrival.
receive written or spoken messages from the traffic

information system.
NOTE:
for information on operating the system and
descriptions of the various menus , refer to the driver's
handbook.
The Carminat system uses the vehicle speed signal
sent by the ABS computer to calculate the distance
travelled along with the reversing signal.
A multiplex network used exclusively by the Carminat
system links the navigation computer to the Central
Communication Unit and the display.
83C-1
vnx.su
If the vehicle ignition has been switched off, the

navigation system may need a few minutes to find its
exact location (see section on Relocation)
If the vehicle battery has been disconnected, the
system may need up to 20 minutes to calculate its
exact location. The vehicle must be outdoors, with
the navigation system switched on, in order to pick up
satellite signals via the satellite aerial.
The system can also operate without valid satellite
data. Under these circumstances, there may be a
loss of precision in pinpointing exact locations.
Once the exact position has been located by the
satellite system, the on-screen satellite symbol turns
from red to green.
When travelling on the motorway, the distance data
provided by the system to indicate exits will differ
from the information on the signs. This is because
motorway signs calculate distance from the start of
the motorway exit, while the CARMINAT system
calculates from the end of the exit.
INSTRUMENT PANEL
BASIC PRINCIPLES OF THE TRAFFIC
INFORMATION SERVICE
83C
Traffic information terminal processing reminder:

the system should be fitted with the 2001-A or more
recent cartographic CD-ROM,
TMC pictogram display logic:
red = no traffic information available in this
geographical location or poor reception,
black = no traffic information locators on the CDROM
green = the system is locked onto a frequency that
can supply traffic information.
In conjunction with navigation, the system uses

information on traffic conditions: TMC: Trafic
Message Channel.
The system uses:
the navigation computer which receives, locates and
recognizes the information received,
the TMC locators on the cartographic CD-ROM,
the information collected and disseminated (by public
authorities) in RDS - TMC format (communication
protocol).
IMPORTANT: The information collection and
dissemination services in Europe, for which
NISSAN is not responsible, are still being
developed.
The term TMC is replaced by the name of the service

operator that the system has locked onto (if the
operator uses a name).
The system can display in either text or pictogram
form. It suggests a detour if a problem is located on
the proposed itinerary.
83C-2
vnx.su
INSTRUMENT PANEL
EXAMPLES OF TRAFFIC INFORMATION PICTOGRAMS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Accident
Traffic jam
Slippery conditions
Strong winds
Slow traffic
Fog
Road works
Danger
Parking possible
Bad weather
Slow traffic
Traffic problems in both directions
Road partially closed or narrowed
Vehicle travelling in the opposite direction
Restricted speed
Vehicle breakdown
83C-3
vnx.su
83C
INSTRUMENT PANEL
DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
12
13
Central Communication Unit

Console
Carminat computer (CD-ROM reader)
Screen
Seat belt information (for display)
External temperature information (for display)
Radio
Voice synthesiser speaker
Steering wheel radio control
Radio aerial
Radio connection (mute)
Vehicle's multiplex connection
Satellite aerial
83C-4
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Central Communication Unit
To be able to operate, the Carminat navigation
computer must be connected to a Central
Communication Unit. Depending on the vehicle, this
may include the console.
The Central Communication Unit can:

adjust the clock,
act as a go-between for the vehicle's multiplex
network and the Carminat system network,
use multiplex data (depending on the vehicle),
control the radio from the steering wheel,
control braking conditions, and the vehicle and
system configurations,
control the display on the screen (via the CD-ROM
reader),
receive written or spoken messages from the traffic
information system (via the aerial)
control navigation messages,
transfer data from the radio for display.
83C-5
vnx.su
83C
INSTRUMENT PANEL
CONNECTOR ALLOCATIONS
30 track connector B (grey):

Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
15-track connector A (red):

Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
83C
Description
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Radio control satellite (track B1)
Radio control satellite (track A3)
Not used
83C-6
vnx.su
Description
Not used
Aerial amplifier output
Multiplex connection (multimedia)
Multiplex connection (multimedia)
Not used
Not used
Computer on-off output
Computer audio link
Computer audio link
Not used
Not used
Not used
Not used
Not used
Not used
Exterior temperature signal (input)
Exterior temperature signal (input)
Not used
Not used
Not used
External temperature output
Not used
Not used
Seat belt warning light
+ lighting
Radio connection (track 6)
Radio On/Off (track 5)
INSTRUMENT PANEL
83C
30-track connector C (green):

Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(D) and (E): radio aerial input and output
83C-7
vnx.su
Description
Not used
Not used
Not used
Not used
Not used
Multiplex connection (vehicle)
Multiplex connection (vehicle)
Not used
+ accessories
+ Before ignition
Radio mute control
Earth
Not used
Voice synthesiser computer
Voice synthesiser computer
Not used
Not used
Not used
Not used
Not used
Not used
Speaker output
Speaker output
Not used
Not used
Not used
Not used
Not used
Not used
Not used
INSTRUMENT PANEL
REMOVAL - REFITTING
IMPORTANT:
Wait until the system has shut down completely
(45 seconds) before disconnecting the battery.
The Central Communication Unit is removed using the
Ms. 1373 radio removal tools.
After refitting, initialize the system (refer to the
Initialization section).
The Central Communication Unit is located above the
radio.
83C-8
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Console
CONSOLE
The console may be integrated into the Central
Communication Unit or independent, depending on the
vehicle.
It comprises:
Rotary knob A, used for:

selecting different menus,
validating,
Button B, used for:
scrolling through the menu in manual mode,
select options in the different menus,
a menu button (M) (depending on the vehicle) which
allows you to return to the main menu,
a button (I) which repeats audio messages,
a button (C) which switches off audio messages,
buttons (+) and (-) which increase and reduce the
volume of audio messages.
83C-9
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Computer
REMOVAL - REFITTING
IMPORTANT:
Wait until the system has shut down completely
(45 seconds) before disconnecting the battery.
IMPORTANT:
The satellite aerial wire is very fragile. Do not bend or
trap it.
After refitting, initialize the system (refer to the
The computer is located in the lower section of the
dashboard.
It is removed with the radio removal tool Ms. 1373.
83C-10
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Screen
SCREEN
Special notes on the radio (depending on the

vehicle)
It is used to display:
the various menus,
the destination direction
the distance from the destination
the journey maps
the distance remaining until the next change of
direction,
the road maps
etc.
If the vehicle is fitted with an original radio, the display

will appear on the screen bar (radio on only).
When it is being adjusted, the radio display fills the
screen (for greater visibility) in list or preset mode.
NOTE:
If the information linked to the radio does not appear
on screen, refer to the Initialization section.
It lights up a few seconds after the + accessories is

switched on or the radio is switched on and displays
the security message.
Special notes on the clock
It will switch off approximately 45 seconds after the

ignition is switched off.
The clock is connected to the satellite connection. The

reference time is adjusted manually via the Clock
menu, but the satellite connection allows precise
adjustment.
NOTE:
The screen colour and brightness can be altered using
the Screen configuration menu:
daytime blue or dark blue (side lights).
night time blue or dark blue (side lights on).
1
2
3
4
5
6
7
8
9
83C
IMPORTANT:
Do not use cleaning products to clean the screen. It
should be wiped with a soft, dry cloth or a damp cloth.
Time
External temperature
Traffic Information message pictogram
Time of arrival or journey remaining (can be
configured)
Guidance mode pictogram
Disc present pictogram
Satellite reception quality pictogram
Radio display (depending on the vehicle)
Opening element indicator lights
83C-11
vnx.su
INSTRUMENT PANEL
CONNECTIONS
Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Shielding
Description
Not used
Earth
- Video signal
Red video signal
Green video signal
Blue video signal
Earth
Video synchronization signal
Earth
Brightness adjustment
Not used
Display On/Off
Not used
Not used
+ Before ignition
+ Before ignition
Earth shielding
83C-12
vnx.su
83C
INSTRUMENT PANEL
REMOVAL - REFITTING
83C
Swivel the screen, taking care not to scratch the

dashboard.
With the ignition off, remove:

the Central Communication Unit using the Ms. 1373
tools,
Open the protective housing.

the screen mounting bolts.
Pull the screen to unclip it from the dashboard.
Disconnect the connector by pressing on the bolt.

Separate the screen from its mounting by removing the
screws.
83C-13
vnx.su
INSTRUMENT PANEL
Navigation assistance: Aerial
SATELLITE AERIAL
It picks up satellite signals to allow the electronic
navigation computer (CD-ROM reader) to locate the
position of the car.
When the satellite reception is good, a green
pictogram (1) is displayed on screen.
When the satellite reception is poor (caused by going
through a tunnel or along a street surrounded by tall
buildings, etc.), a red pictogram is displayed on
screen.
NOTE:
Relocation is automatic once the battery has been
reconnected or the navigation computer has been
replaced: drive the vehicle to an outdoor open area
with the ignition off and wait a few minutes. When the
satellite reception is good, a green pictogram is
displayed on screen.
IMPORTANT:
The satellite aerial wire is very fragile. Do not bend or
clamp it.
NOTE:
The satellite aerial is also used for the hands-free
phone. Some vehicles are fitted with a dual band
aerial.
83C-14
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Aerial
REMOVAL - REFITTING
The aerial is fitted on the roof. The headlining must be
partially removed to remove the aerial.
IMPORTANT: the satellite aerial wire is very fragile;
do not bend or trap it.
83C-15
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Speaker
Special notes:
The speaker used for the navigation system is the front
right-hand radio speaker.
83C-16
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Initialization
This procedure must be carried out each time any
operation is performed on the system.
83C
INITIALIZATION
IMPORTANT:
If the vehicle is equipped with a radio, it must be
switched on during setting. If it is not, the steering
wheel radio control will not function and the screen will
not display radio data.
Switch off the ignition.
Wait for the system to shut down completely
(about 45 seconds),
3 Switch the radio on.
4 Switch on the ignition (wait about 20 seconds).
5 Press the buttons simultaneously (see table).
6 Read the vehicle part number (refer to the table).
7 Carry out the steering wheel control test,
8 The satellite aerial connection displays (Ok/Nok)
on the screen.
9 Exit setting using the rotary switch,
10 Switch off the ignition (1 minute).
Vehicle
PRIMASTAR
M and C
System configurations
Vehicle
with
out
radio
Entry
level
radio
Top of
the
range
radio
PRIMASTAR
0612
0602
1
2
83C-17
Keys
NOTE:
If the configuration does not correspond to the vehicle,
check the vehicle wiring (multiplex lines) and the part
numbers of the components.
vnx.su
INSTRUMENT PANEL
Navigation assistance: Change language
The system will be programmed in French by default
after the navigation computer has been replaced.
Change menus language

With the ignition switched on, press the eject
button to remove the electronic navigation
computer cartographic CD-ROM
The screen will display the message No CD in

reader.
Confirm OK by pressing the rotary knob.
Select the Language menu.
Change voice messages
With the ignition switched on, press the eject

button to remove the electronic navigation
computer map CD-ROM
The screen will display the message No CD in

reader.
Confirm OK by pressing the rotary knob.
Select the * Configurations menu then

Language.
You must carry out two operations to change the

language:
83C
NOTE:
if the desired language does not appear in the menu,
proceed as follows:
83C-18
Select other language.
The system prompts you to insert the language

CD-ROM.
Insert the CD-ROM, and then press the rotary knob

to confirm.
Select the language to be replaced (language 1 or

2) by turning the knob.
Use the rotary knob to select the language to load

from the list of available languages stored on the
CD-ROM and then confirm load.
Wait a few seconds, the screen will turn black and

then white and display a message in black and red
with a horizontal bar to show the loading time
remaining.
When loading is complete, the language CD-ROM

is ejected from the reader and OK is displayed on
screen.
Continue with voice message changing procedure.
Re-insert the cartographic CD-ROM into the

reader.
vnx.su
INSTRUMENT PANEL
Navigation assistance: Relocation
The vehicle has to be relocated after the electronic
navigation computer has been replaced or the battery
disconnected.
Drive the vehicle to an open area outdoors and wait for
a few minutes with the ignition switched on.
When the satellite reception is good, a green
pictogram (1) is displayed on screen.
If the vehicle is not correctly located on the map, drive

the vehicle to along various main roads on the mapped
routes
(0.6 to 1.8 miles (1 to 3 km) necessary).
NOTE:
The locating operation may take up to 20 minutes
maximum.
83C-19
vnx.su
83C
INSTRUMENT PANEL
Navigation assistance: Navigation menus
83C
Welcome message
Navigation
Adjustments
Language *
guidance
map
address book
monitor
emergency
configuration
Change voice
messages
language
Clock
System
Adjusting the set

time
(Expert mode)
Code: 4112
System test
Console Test
Config
Bus Test
CAN V
CAN M
IIC
configuration
Central
Communication
Unit type
software version
date of
manufacture
12 NC
checksum
Functions test
RDS/TMC
frequency
reception level
RDS quality:
Type
satellite
console
* depending on the version
83C-20
vnx.su
speed
+ After ignition
+ ACC
tyre pressure
monitor
battery
voltage
seat belt
+ light
reverse gear
external
temperature
INSTRUMENT PANEL
Navigation assistance: Navigation menus
83C
Welcome message
Adjustments
Guidance
Language
Navigation
Address
book
Card
Guidance
modes
Altering the
language on
the menus
Screen
config
Configuration
Traffic
information
(Code)
4112
sensor status
longitude
latitude
geographical height
number of satellites
Emergency
System
information
Monitor
Units
Volume
day colour
state line
map colour
night colour
brightness
adjustment
SDVC
voice
messages
volume
Fault finding
Read GPS
data
Language *
Configuration
Speed
correction
series number
product model
software version
week of manufacture
year of manufacture
CBS software
version
Read E/S
states
Read errors
Preadjustments
tachograph pulse
internal temperature
battery
injection button
steering
* depending on the version
83C-21
vnx.su
Simulation
usable simulation
unusable simulation
INSTRUMENT PANEL
Navigation assistance: Customer complaints
83C
THE SCREEN REMAINS BLACK

THE SCREEN IS BACKLIT OR FROZEN ON THE LOGO
THE DISPLAY ON THE SCREEN REMAINS FROZEN
THE SCREEN DISPLAYS: CONFIGURATION ERROR
NO SEAT BELT WARNING LIGHT DISPLAY
NO RADIO DISPLAY ON THE CARMINAT SCREEN (OR THE RADIO DISPLAY REMAINS FROZEN)
CLOCK NOT DISPLAYED OR INCORRECT
NO VOICE MESSAGES
NO TRAFFIC INFO MESSAGE ON THE SCREEN
POOR SATELLITE RECEPTION
83C-22
vnx.su
INSTRUMENT PANEL
83C
Navigation assistance: Fault finding charts

The screen stays black (no backlight)
Check the CD-ROM reader
supply.
Switch the ignition off for
more than 1 minute, then
press the eject button
Does the diode

light up?
yes
Check the supply fuse and

the wiring
(refer to the vehicle wiring
diagram).
Check the Central

Communication Unit power
supply.
Turn the ignition on and
activate the lighting control.
Does the Central

Communication
Unit light up?
Test the connector on the

CD-ROM reader:
+ 12 V supply
(track 1),
earth (track 10).
no
no
Are the tests

correct?
yes
Replace the CD-ROM
reader.
Test the green connector

on the Central
Communication Unit:
the +12 V feed
(track 10),
+ accessories feed
(track 9),
+ after ignition feed
(track 13) (depending on
the version),
the earth (track 12).
no
yes
Check the supply fuse and

the wiring
(refer to the vehicle wiring
diagram).
no
Are the tests

correct?
yes
Replace the central
communication unit.
83C-23
vnx.su
INSTRUMENT PANEL
83C
Check the connection

between the Central
Communication Unit and the
CD-ROM reader.
Switch the ignition off for more
than 1 minute, then switch it on
again. The CD-ROM reader
diode should light up.
no
Is the diode lit?
Test the computer power

supply (track 6) on the grey
connector (track 7) of the
Central Communication
Unit:
ignition off = 0 V,
ignition on = 12 V.
yes
Are the tests

correct?
Check the connection

between the CD-ROM
reader and the screen:
+ 12 V supply (tracks 15
and 16),
earth (tracks 2 and 9),
return feed (track 12),
(on = 12 V - off = 0 V)
Are the tests

correct?
yes
Check the wiring Central
Communication Unit - CDROM readerIf the wiring is
sound, replace the CD-ROM
reader.
no
If the wiring is sound, replace

the CD-ROM reader
yes
If the wiring is correct,

replace the screen.
83C-24
vnx.su
no
Replace the central

communication unit.
INSTRUMENT PANEL
83C

The screen is backlit or frozen on the Logo
Check the software
compatibility between the
components.
Switch on the ignition, check
if the console flashes.
Is the keyboard
flashing?
The system has not been

configured. Carry out the
setting procedure using the M
and C buttons.
no
yes
no
The vehicle shows a

problem with nonconformity of parts between
the Central Communication
Unit and the CD-ROM reader.
Check the part numbers in
the Parts Catalogue.
Does the screen

display the
configurations?
yes
The system is working
properly.
Check the multiplex

(multimedia) links between:
The Central
Communication Unit and
the CD-ROM reader,
the CD-ROM reader and
the screen.
83C-25
vnx.su
INSTRUMENT PANEL
83C

The display on the screen remains frozen (on any page)
The on screen display
remains frozen (on a map or
other screen).
Turn off the ignition and wait
until the system shuts down
completely (45 seconds
minimum).
Switch on the ignition again.
Has the fault

disappeared?
Test the multiplex link

between the CD-ROM reader
(tracks 9 and 18) and the
Central Communication Unit
(tracks 3 and 4).
no
yes
properly.
Repair
no
Are the tests

correct?
yes
Replace the CD-ROM
reader.
83C-26
vnx.su
INSTRUMENT PANEL
The screen displays "configuration error"
Turn off the ignition and wait
until the system shuts down
completely (40 seconds
minimum). Carry out the
initialization procedure using
the M and C buttons (refer to
the Initialization section).
Has the fault

disappeared?
The problem is not linked to

the navigation system.
Carry out a fault finding
procedure on the vehicle
(multiplex network test) using
a diagnostic tool.
no
yes
properly.
83C-27
vnx.su
83C
INSTRUMENT PANEL
No seat belt warning light display
The seat belt warning light
display is not working.
Carry out a self-test
procedure on the Central
Communication Unit to check
the condition of the Seat belt
input (wait about 5 seconds
for each change of state).
Check the voltage on the

grey connector (track 24):
seat belt buckled = 12 V,
seat belt unbuckled = 0 V.
Does the voltage

vary?
no
The problem is not linked

to the navigation system.
Check the vehicle wiring
(refer to the wiring diagram).
yes
Replace the Central
Communication Unit.
83C-28
vnx.su
83C
INSTRUMENT PANEL
No radio display on the carminat screen (or the radio display
remains frozen)
No radio display on the
Carminat screen.
Check that the radio is
being supplied and emits
sound.
Is the official
navigation message
displayed?
no
The screen is black or backlit,

refer to the relevant fault
finding procedure.
yes
When the radio is switched
on, carry out the
initialization procedure
using the M and C buttons
Check the configuration
number (refer to the
Does the
configuration
match?
no
yes
Exit the initialization
procedure and turn off the
system for about 1 minute.
The problem disappears.
83C-29
vnx.su
83C
INSTRUMENT PANEL
Switch on the radio and run

a self-test procedure from
Unit to test the IIC BUS.
Does the self-test

procedure display
BUS IIC: OK?
no
yes
Check the voltage on the
grey connector of the Central
Communication Unit
(track 27):
radio on = 12 V,
radio off = 0 V.
no
Does the voltage

vary?
yes
Replace the central

communication unit.
Test the continuity of the

wiring between the radio and
Unit. If the wiring is correct,
replace the radio.
83C-30
vnx.su
83C
INSTRUMENT PANEL
Unsatisfactory or no time display
Position the vehicle outside in
a good reception area and
check the satellite reception.
The pictogram should be
green.
Is the pictogram
green?
no
yes
Replace the central
communication unit.
83C-31
vnx.su
Refer to the fault finding

procedure: Poor satellite
reception.
83C
INSTRUMENT PANEL
83C
No voice messages
Check whether the voice
synthesiser off pictogram is
not lit.
no
Is it no unlit
Press the C button.

The pictogram should go
out.
no
yes
Is it no unlit
yes
Press the + button on the
console several times.
83C-32
vnx.su
In the Volume menu, change

the voice messages
parameter.
The pictogram should go out.
Replace the Central

Communication Unit.
INSTRUMENT PANEL
Do you hear the

message louder?
yes
Replace the navigation
speaker with another (e.g.
vehicle tweeter) and press
the + button.
Do you hear the

message louder?
no
Replace the CD-ROM

reader.
yes
Replace the navigation
system speaker.
83C-33
vnx.su
83C
INSTRUMENT PANEL
83C

No traffic information message on the screen
The traffic information

function works with the radio
aerial. The TMC pictogram
should be green.
no
Is the pictogram
green?
During the self-test

procedure, test the RDS/
TMC function.
The reception level should be
greater than 50% (vehicle
outdoors).
no
no
Does the
vehicle have- a
short aerial or
screen
printing?
yes
Is the level over

70 %?
yes
The vehicle is located outside

a service area.
The pictogram is black.
properly.
yes
Check the aerial amplifier
feed with the Central
Communication Unit
(track):
system on = 12 V,
system off = 0 V.
Is the voltage
correct?
Check the vehicle wiring.

If the wiring is correct,
replace the Central
Communication Unit.
no
yes
83C-34
vnx.su
INSTRUMENT PANEL
Check:
the aerial connections to
Unit, to the aerial base and
the cut-off plate,
the bent or clamped
wires,
tightening of the aerial
pillar.
no
Repair or replace.
Are they correct?
yes
Replace the radio aerial.
83C-35
vnx.su
83C
INSTRUMENT PANEL
83C

Poor satellite reception
Poor satellite reception: the
pictogram is red.
When the radio is switched

on, carry out the setting
procedure.
Does the screen

display GPS aerial
connected?
Check the aerial

connections from the
CD-ROM reader to the aerial
base and the cut-off plate.
no
yes
Exit the initialization
procedure and turn off the
system for approximately
1 minute.
The problem is caused by
geographical disturbance
The relocation procedure
may last for approximately
20 minutes maximum.
The pictogram should be
green.
If the fault persists, replace
the satellite antenna.
Repair.
no
Are they correct?
yes
Using a multimeter, check
the voltage on the aerial
cable and the CD-ROM
reader (between the core
and the casing).
The voltage should be about
4.5 V.
Replace the satellite aerial.
no
Are they correct?
yes
Replace the CD-ROM
reader.
83C-36
vnx.su
CONTROLS - 184
SIGNALS
Rotary switch
84
REMOVAL
WARNING: handling pyrotechnic systems (air

bags and pretensioners) close to a source of
heat or a flame is prohibited: there is a risk of
triggering.
Remove the steering wheel air bag. To do this, insert a

screwdriver into hole (1) then move it upwards (2).
IMPORTANT: before removing an air bag

cushion, lock the computer using the diagnostic
tool.
NOTE: The diagnostic socket is located under the
steering wheel.
84-1
vnx.su
CONTROLS - SIGNALS
Rotary switch
84
WARNING: it is essential to mark the position of

the rotary switch and ensure that the wheels are
straight when removing it, so that the strip is
centred.
Remove:
the steering wheel,
the half cowlings.
Disconnect the stalks (wiper, radio and lighting control)
and the rotary switch connector (air bag).
Remove the stalks by pressing on the tabs (4).
Undo bolt (3) then release the steering column

assembly.
84-2
vnx.su
CONTROLS - SIGNALS
Rotary switch
REFITTING
Special notes on the air bag
Check that the wheels are straight, tighten the rotary

switch mounting bolt.
Put the switch in place and lock it.
84
Position the cushion on the steering wheel.

Reconnect the connectors.
IMPORTANT: After refitting everything, carry out a
check using the diagnostic tool. If everything is
correct, unlock the computer or see the Fault finding
section.

foolproofing devices. The steering wheel should be
inserted freely into the splines. Be careful not to
damage them.

4.4 daNm.
84-3
vnx.su
CONTROLS - SIGNALS
Wiper control stalk
CONNECTION (fullest version)
Track
A1
A2
A3
A4
A5
A6
A7
B1
B2
B3
B4
B5
B6
B7
Description
Windscreen wiper timer control
Windscreen wiper high-speed control
Windscreen wiper low-speed control
Windscreen washer pump control
Not used
+ After ignition
Rear screen washer pump control
Rear screen wiper control
Rear windscreen wiper park position
+ After ignition
Earth
Not used
Driving assistance scroll button
NOTE: The front and rear screen wiper and washer controls can be checked
using an ohmmeter.
Track
A4 / B4
A3 / A7
A2 / A7
A1 / A7
B1 / B4
B2 / B4
B5 / B7
Description
Windscreen washer pump control
Windscreen wiper low-speed control
Windscreen wiper high-speed control
Rear screen wiper intermittent control:
Rear screen washer pump control
Rear screen wiper intermittent facility
Dfilement Aide la conduite
84-4
vnx.su
84
CONTROLS - SIGNALS
Lighting stalk
CONNECTION (fullest version)
Track
A1
A2
A3
A4
A5
A6
A7
B1
B2
B3
B4
B5
B6
B7
Description
Front fog lights relay supply
Not used
Rear fog light control
Horn control
Earth
Side lights
+ Battery (protected: side lights)
+ Battery (protected: dipped headlights)
Not used
Dipped headlights
+ Battery (protected: main beam headlights)
Headlight main beam
NOTE: The lighting controls can be checked using an ohmmeter. The horn
control goes through connector C via the rotating connector.
Tracks (closed
circuit)
A6 / A7
A5 / A6
B1 / B2
B3 / B5
B6 / B7
A1 / B3
A3 / B3
Description
Side lights control
Dipped headlights control
Main beam headlights control (permanent or
flash)
Fog light control (front)
Rear fog light control
84-5
vnx.su
84
CONTROLS - SIGNALS
Track
1
2
3
4
Description
Not used
Earth
Flasher timer (+ before ignition feed)
Timed flasher
Checks with multimeter

Track
Description
2 and 3
Hazard warning lights off
2 and 3
Hazard warning lights on
84-6
vnx.su
Value
Infinite
resistance
0 ohms
84
CONTROLS - SIGNALS
Central door locking switch
Track
A1
A2
A3
B1
B2
B3
Description
+ After ignition
Earth
Locking
Unlocking
+ Before ignition
Warning light supply
Checks with multimeter

Track
A1 / A2
A2 / A3
A2 / B1
Description
Lighting switch
Locking
Unlocking
84-7
vnx.su
Value
30 ohms
0 ohms
0 ohms
84
CONTROLS - SIGNALS
Driver's electric window switches
84
Passenger window control

Track
ACTIONS
A1/A2
B3/A2
A1/B4
B3/B4
None
Passenger
opening
Passenger
closing
CONNECTION
Track
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
NOTE: The tests and connections for the electric

windows are the same for left-hand drive and righthand drive.
Driver's one-touch window
Driver's window control

(check the resistance using an ohmmeter).
ACTIONS
Track
A4 / B4
B5 / B4
None
Basic opening
One-touch opening
0*
0**
Basic closing
0**
0*
One-touch closing
NOTE:
* = 1st position
** = 2nd position
84-8
vnx.su
Description
Passenger side electric window control
+ Before ignition
+ After ignition
Driver's side electric window control
Not used
Not used
Not used
Not used
Earth
Not used
CONTROLS - SIGNALS
One-touch electric window unit
REMOVAL
84
CONNECTION
Remove the lining from the driver's door.

(See Bodywork section).
Disconnect connector (1) on the one-touch window
unit.
Remove the two mounting bolts (2).
Track
A1
A2
A3
A4
A5
B1
B2
B3
B4
B5
84-9
vnx.su
Description
(raise)
+ After ignition
Not used
Not used
(lower)
Earth
Driver's window riser motor
Not used
Not used
Driver's window riser motor
CONTROLS - SIGNALS
Passenger electric window switch
84
CONNECTION
Track
A1
A2
A3
B1
B2
B3
NOTE: The tests and connections for the electric

windows are the same for left-hand drive and righthand drive.
Passenger electric window switch
(check the resistance using an ohmmeter).
Track
ACTIONS
A1/A3
B2/B1
B1/A2
A2/A3
None
Closing
Opening
84-10
vnx.su
Description
Connection with driver's switch (A1)
Earth
Connection with driver's switch (B3)
+ After ignition
CONTROLS - SIGNALS
Heated rear screen
HEATED REAR SCREEN SWITCH
Track
A1
A2
A3
B1
B2
B3
Description
+ After ignition
Not used
Ignition warning light
Earth
Not used
OPERATION (check the resistance using a

multimeter)
Action
Track B1/B2
Pause
Pressed
84-11
vnx.su
84
CONTROLS - SIGNALS
Heated windscreen
ELECTRICALLY HEATED WINDSCREEN SWITCH
Track
A1
A2
A3
B1
B2
B3
Description
+ After ignition
Not used
Ignition warning light
Heated windscreen control
Earth
Not used
OPERATION (check the resistance using an

ohmmeter)
Action
Track A1/B1
Pause
Pressed
84-12
vnx.su
84
CONTROLS - SIGNALS
Door locks
84
OPERATION
Each vehicle has a different door locking system appropriate to the equipment level fitted.
basic locking version
deadlocking version
Deadlocking (in some countries) enables the door handles on the inside to be deactivated. This function can be
used to prevent the door being opened from the inside if the window is smashed.
NOTE: vehicles fitted with UCH model (N3) include an alarm fitted as standard.
OPERATION (most comprehensive version)
Result on locks
Operation of
direction indicators
Operation of horn
1 short press
locking of opening
elements + alarm
2 flashes
1 long press
Opening elements
locking + alarm
+ spatial protection
2 flashes
1 signal
2nd short press
deadlocking of the
opening elements
5 flashes
2nd long press
opening element
deadlocking + alarm
+ spatial protection
5 flashes
unlocking of the
opening elements
1 flash
Locking
Unlocking
1 short or long press
84-13
vnx.su
1 signal
CONTROLS - SIGNALS
Door locks
CONNECTION (passenger door)
84
CONNECTION (side doors)

Track
Unlocking
Locking
Deadlocking*
* Deadlock version only.

NOTE: the fuel filler flap and tailgate motors have two
wires. The UCH controls their locking and unlocking.
Track
Unlocking
Locking
Deadlocking*
10
* Deadlock version only.
84-14
vnx.su
CONTROLS - SIGNALS
Electric door mirror
CONNECTION (most comprehensive version)

Door mirror mounting bolts
84
Track
0.8
1
2
3
4
5
6
7
8
EXTERIOR REAR-VIEW MIRRORS

The components of the electric door mirrors are:
two motors for adjustment (vertical and horizontal),
an external temperature gauge on the passenger
side,
a heating system (according to model).
NOTE: The door trim does not need to be removed to
remove the door mirrors.
Description
Door mirror demisting
Door mirror demisting
Not used
Temperature sensor
Temperature sensor
Horizontal adjustment motor
Motor common line
Vertical adjustment motor
The resistance of the demisting system is

approximately 13 .
The exterior temperature sensor resistance should be
2,500 at approximately 20 C.
NOTE: the door mirror and the rear screen heating is
switched on by the same switch.
84-15
vnx.su
CONTROLS - SIGNALS
door mirror control
DOOR MIRROR CONTROLS
84
Left-hand door mirror

Functions
Track
Step-up
A3/B3
B4/A2
Step-down
A3/A2
B4/B3
Left
B4/B3
A1/A2
Right
B4/A2
A1/B3
Right-hand door mirror

Functions
Step-up
B2/B3
B4/A2
Step-down
B2/A2
B4/B3
Left
B4/B3
B1/A2
Right
B1/B3
B4/A2
CONNECTION
Track
A1
A2
A3
A4
B1
B2
B3
B4
Description
Left/right control for the driver's door
mirror
+ Before ignition
Up/down control for the driver's door
mirror
Not used
Left/right control for the passenger door
mirror
Up/down control for the passenger door
mirror
Earth
Shared motor
84-16
vnx.su
Track
CONTROLS - SIGNALS
External temperature sensor
84
The temperature gauge is located in the passenger

side door mirror (depending on the version).
NOTE: the lower reflective glass is made of tough

plastic.
REMOVAL
Unclip the temperature gauge and cut wires (3) to

about four centimetres.
Take off the lower reflective glass from the door mirror
using a mastic knife (1) then finish removing it with tool
(2) Car. 1363.
REFITTING
Rejoin the two temperature sensor wires using heatshrink sleeves.
Fix the glass in place again with double sided tape.
NOTE: The external temperature sensor resistance
should be approximately 2500 at 20 C.
84-17
vnx.su
WIPERS
185
Windscreen wiper
85

Ele. 1294-01 Windscreen wiper arm removing tool
Operating notes
The wiper control settings controlled by the UCH relate
only to the timed and intermittent modes (washer
pump activation).
The continuous low speed and continuous high speed
settings are not handled by the UCH, but rather
directly by the wiper stalk.
REMOVAL
Check that the wiper motor is in the park position.
NOTE: it is not necessary to remove the bonnet.
Take off the scuttle panel grille.
Disconnect:
the battery,
the motor connector.
Remove:
the clips (D),
the mounting rail (E) from the scuttle panel grille (by
sliding it out),
Remove:
the right and left wiper arms, using the special tool
El. 1294-01,
the plenum chamber seal,
the scuttle panel grille side trims attached with
clips (A),
the scuttle panel grille attached with clips (B),
the sealing rings (C),
the water drainage pipes, from each end of the
plenum chamber,
the screen washer pipe.
85-1
vnx.su
WIPERS
Windscreen wiper
85
the plenum chamber mounting bolts (F),

the wiper mechanism mounting bolt (G),
the bolt connecting the plenum chamber to the air
inlet unit,
the sealing rings (H).
Release the plenum chamber/wiper motor mechanism

assembly.
REMOVAL OF THE WIPER MECHANISM

Remove the two nuts (K) that secure the mechanism.
REMOVING THE MOTOR

Remove:
the motor/mechanism connection tie-rods,
the motor shaft nut (I) and release the tie-rod,
the motor mounting bolts (J).
85-2
vnx.su
WIPERS
Windscreen wiper
85
REFITTING
Refit:
the nuts (1) that attach the mechanism to the plenum
chamber (tightening torque: 0.8 daNm),
the wiper motor, tightening the mounting bolts (2) to
the torque (0.8 daNm),
Fit the assembly (plenum chamber, mechanism, wiper

motor) on the vehicle.
Attach:
the plenum chamber,
the bolt connecting the air inlet unit to the plenum
chamber,
the scuttle panel grille mounting rail,
the sealing rings (H),
the water drainage pipes,
the screen washer pipe,
the scuttle panel grille,
the sealing rings (C),
the scuttle panel grille side trims,
the plenum chamber seal.
WARNING: before refitting the tie-rod (3), it is

essential to ensure that the wiper motor is in the
park position.
the connection tie-rods (4).

the tie-rod (3) on the wiper motor by placing it parallel
to the axis (A), facing the passenger side (tightening
torque 2.1 daNm),
NOTE: for right-hand drive vehicles, the tie-rod (3)

must face the opposite direction to the illustration.
Reconnect:
the wiper motor connector,
the battery.
Switch on the ignition to set the motor in park position.
Clean the wiper arm shaft splines.
Fit the wiper arms with new nuts and tighten them to a
torque of 2.1 daNm.
85-3
vnx.su
WIPERS
Windscreen wiper
CONNECTOR ALLOCATIONS
The motor connection is the same on left-hand and
right-hand drive vehicles.
Track
1
2
3
4
5
Description
Park position
+ After ignition
Intermittent or low speed supply
High speed
Earth
85-4
vnx.su
85
WIPERS
Rear screen wiper
The procedure and connection of the motors is the same for both hinged door and tailgate versions.
Ele. 1294-01 Windscreen wiper arm removing tool
Wiper mechanism bolt
0.8
Wiper arm
1.2
REMOVAL
Check that the wiper motor is in the park position.
Remove:
the wiper arms,
the trim panel.
Disconnect the supply connector from the wiper motor.
Remove the three motor mounting bolts (A).
REFITTING
Adhere to the wiper motor tightening torques
(0.8 daNm).
Reconnect:
the supply connector,
the battery, after having refitted the motor to set it in
park position.
Clean the wiper arm shaft splines.
Fit a new bolt and tighten it to a torque of 1.2 daNm.
85-5
vnx.su
85
WIPERS
Rear screen wiper
MOTOR CONNECTION
The connection of the motors is the same for both
hinged door and tailgate versions.
Track
1
2
3
Description
Wiper control
Park position
Earth
85-6
vnx.su
85
WIPERS
Electric washer pump
Depending on the vehicle's equipment, a basic electric
pump may be fitted for the windscreen washer alone,
or a bi-directional pump to supply liquid from the same
tank to both front and rear windscreen washers with an
electrical supply from two connector tracks.
85
REMOVAL - REFITTING
To reach the washer pump it is necessary to remove:
the front right wheel,
the wheel arch liner.
There are two scenarios:

Track
Description
Earth
+ 12 volts
When the pipes are fed via the black outlet (A), the
windscreen washer operates.
Track
Description
+ 12 volts
Earth
When the pipes are fed via the white outlet (B), the
rear screen washer operates.
When removing the washer pump (bi-directional),

mark the two pipes before disconnecting them.
85-7
vnx.su
RADIO
186
Radio
86
Radio operation
REMINDER:
Four geographical zones can be programmed in FM.
The Tuner has three selection modes visible on the
screen and accessible from the panel:
manual mode (MANU),
preselected mode (PRESET),
alphabetical order mode (LIST).
Cassette player operation

The tape plays automatically once the tape source has
been selected on the satellite or on the panel.
NOTE:
Only the Dolby fast forward and rewind with search
controls can be selected by specific buttons.
NOTE:
The voice synthesiser or the car phone Mute function
will stop the cassette playing.
1 On/Off
2 <and> buttons enabling you to change the
configuration mode
3 + and - buttons enabling you to make adjustments
4 Source button
CD function (SINGLE CD)

The CD player can play conventional discs and any
audio tracks on a CD-ROM.
Four versions of radio may be fitted:

radio + cassette with or without display,
integrated radio + single or multi CD player with or
without integrated display.
CDs can be played in order or tracks can be chosen at

random.
NOTE:
Random play from a single disc only is possible when
a CD changer is being used.
The radio features allow you to:

listen to the radio (four geographical zones can be
programmed for FM radio),
display the name of the station using RDS,
switch automatically to the best transmitter (AF),
receive road traffic and travel information (AT),
receive news flashes and emergency bulletins (PTY
NEWS).
Heat protection
If the radio temperature is too high for it to function
properly, the volume is automatically lowered (without
changing the display volume).
86-1
vnx.su
RADIO
Radio
86
Code protection
Configuration
The radio is protected by a four digit code. This code

must be entered via the control satellite or the audio
equipment keypad each time the battery is
disconnected.
NOTE:
To select the zone in which the Tuner is to be used,
press buttons 2 and 5 with the power on. Wait
approximately two minutes. Enter the four digit code
and then:
Select the relevant zone:
America
Japan
Asia
Arabia
Others (Europe, Africa, etc.)
select the tone curve appropriate for the vehicle
0: no regulation
configuration of number of speakers REAR ON/OFF
Entering the code with the control on the steering

wheel:
press the bottom button on the control to confirm an
entry.
Input using the car radio keypad:
to confirm a number, press the next button on the
keypad (see the driver's handbook).
If the code is entered incorrectly, the radio will cease to
function for: one minute for the first mistake, two
minutes for the second mistake, four minutes for the
third mistake etc.
Some settings must be made after the code has been
entered for the first time (see section on
Configuration). These settings are stored when the
battery is disconnected.
NOTE:
The code can be scrambled by pressing buttons 2
and 5, at the same time as the equipment is switched
on. Wait two minutes.
NOTE:
These configurations are not required when the secret
code is entered after the power supply has been cut.
Expert mode
To shift to configuration mode (Expert mode), press
and hold the source button for about four seconds
until you hear a beep. This allows you to adjust the
following functions:
AF mode activation (automatic retuning),
volume control in relation to vehicle speed (5 for
maximum change, 0 for no change),
activation of Loudness mode,
activation of Assisted radiomode
configuration of the number of speakers (2 or 4),
selection of manual or dynamic list.
NOTE:
Pressing the source button once when entering the
configurations cancels the changes.
86-2
vnx.su
RADIO
Radio
86
Volume control
Self-test mode
The volume can be configured in relation to the car

speed. To operate this function:
select the desired volume control by using the expert
mode, (press and hold the source button until you hear
a beep): 5 for maximum change, 0 for no change.
The self-test mode checks some of the main functions:
NOTE:
Ensure this function is fully operational by checking
that the radio is correctly wired.
testing the speakers

The speakers are fed one at a time if you press buttons
2 and 4 simultaneously. This is confirmed by the
display.
testing the reception level (after display of the

frequency)
The display shows the radio reception information if
you press buttons 1 and 6 simultaneously:
9 or letter: good reception
if 3: poor signal
If 2: no stereo
NOTE:
The radio is equipped with tone modification according
to the vehicle. Refer to the Configuration section to
change vehicle type.
testing the buttons

To enter this mode, press button 3 and the on/off
button at the same time. Every time a button is pressed,
it will appear on the display. The mode exits
automatically once all the buttons have been pressed.
86-3
vnx.su
RADIO
Radio
86
Connector allocations
Black connector (A)
Track
1
2
3
4
5
6
7
8
Description
Vehicle speed signal
Not used
Voice synthesiser signal (mute)
Battery supply
Aerial amplifier supply
Lighting supply
Accessories supply
Earth
Yellow connector (B)

Track
Description
1
2
3
4
5
6
Display connection (track 13) or satellite*

Not used or satellite*
Earth shielding (track 12) or satellite*
Brown connector (C)

Track
1
2
3
4
5
6
7
8
* If the vehicle does not have an instrument panel

display, the control satellite on the steering wheel is
connected to the radio.
Description
+ Rear right speaker
- Rear right speaker
+ Rear right speaker
- Rear right speaker
+ Front left speaker
- Front left speaker
+ Front left speaker
- Front left speaker
NOTE:
The speakers are connected in parallel on each
output.
Connector (D) is used to connect to a CD changer
(depending on the version).
86-4
vnx.su
RADIO
Radio
86
CONNECTION
The radio control on the steering wheel is linked to the display set into the
dashboard.
CONTROL CONNECTION WITH DISPLAY

Control (connector A)
Display (connector B)
Track (A1)
Track (14)
Track (A2)
Track (13)
Track (A3)
Track (10)
Track (B1)
Track (9)
Track (B2)
Track (11)
Track (B3)
Track (12)
86-5
vnx.su
RADIO
Display
TRACK ALLOCATION
86
15-track grey connector

Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Red 15-track connector

Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Radio control connection (track B1)
Radio control connection (track A3)
Not used
86-6
vnx.su
Description
Not used
Not used
Earth
Lighting
Light supply
+ accessories
+ battery
External temperature output
Earth (radio track 6)
Radio on signal (radio track 5)
Radio connection (Track 1)
ELECTRONIC ASSISTANCE
187 EQUIPMENT
UCH
87
LOCATION
The UCH (1) is located close to the steering column

under the instrument panel.
Insert a 6 mm diameter rod into the opening (1)

behind the steering wheel.
This computer contains most of the electronic units,

including the engine immobiliser decoder.
Lift (2) the driver's airbag in order to slide it.

Unclip the connector safety clip.
There are three UCH models, depending on the level

of equipment installed in the car:
Version N1 standard
Version N2 top of the range
Version N3 with alarm function
Disconnect the generator supply connector.

Remove the driver's airbag.
Disconnect the supply connector from the horn.

REMOVAL
IMPORTANT:
It is essential to mark the position of the rotary switch
and ensure that the wheels are straight when
removing it, so that the strip is centred.
IMPORTANT:
The pyrotechnic systems (pretensioners or airbags)
must not be handled near to a heat source or flame they may be triggered.
IMPORTANT:
Before removing a driver's front airbag module, lock
the computer. When this function is activated all the
ignition lines are inhibited and the airbag warning
light on the instrument panel illuminated when the
ignition is switched on.
Remove:
the steering wheel,
the steering column casing,
Disconnect the connectors from the UCH, then unclip
it to remove it from its housing.
87-1
vnx.su
ELECTRONIC ASSISTANCE EQUIPMENT

UCH
REFITTING
87

4.4 daNm.
IMPORTANT:
When refitting the steering wheel, it is essential to
check that the wheels are straight.
Special notes on the airbag

Put the connector in place and lock it.
Position the driver's front airbag module on the
steering wheel.
IMPORTANT:
After refitting everything, carry out a check using the
diagnostic tool.
If everything is correct, unlock the computer or see
the "Fault finding" section.

IMPORTANT:
The steering wheel splines are made so that the wheel
can be fitted in one position only. The steering wheel
should fit back into the splines easily. Be careful
not to damage them.
87-2
vnx.su

UCH
87
NO exit the programming procedure,
A new UCH is not programmed with a code. You must

therefore program a code into a new UCH fitted to a
vehicle to make the UCH operational.
YES the tool displays: Select configuration type

(type N1, N2 or N3).
To perform this procedure, at least one of the vehicle's

old keys and the repair code are required and the
injection computer must be correctly coded (for more
information, see Section 82).
IMPORTANT:
If a code is programmed into the UCH, the UCH is
assigned to the vehicle and it is impossible to erase
the code or program in another one.
NOTE:
For the N2 and N3 UCH, inverted wiper blades and
automatic door locking are configured by default.
Then the tool displays CONFIGURATION OPTIONS
FOR VEHICLE TYPE
TYPE N2
DEADLOCKING WITH or WITHOUT,
REPLACEMENT ALARM WITH or WITHOUT
IMPORTANT:
The keys submitted during this procedure will only
work if:
they have already been coded on the vehicle,
or they are new (not coded).
TYPE N3
DEADLOCKING WITH or WITHOUT
Then the tool asks you:
UCH CONFIGURATION PROCEDURE

ARE THE CONFIGURATIONS CORRECT?
Using a diagnostic tool:
YES or NO
Set up a dialogue with the Connection unit system,
In the Command menu, Specific command,
confirm CF 718 UCH type,
The tool displays the message Warning!, the first
stage of the procedure involves erasing the UCH
configurations. If the procedure is interrupted after
this stage, the computer will be completely
deconfigured.
If the answer is YES, the following message appears:

The UCH has been configured, check that there is
no fault. If there is a fault on a configured option,
check that the component in question is present.
If the component is present, deal with the fault
according to the fault-finding procedures, if it is
absent, deconfigure the option in question by
restarting configuration of the UCH.
YES or NO,
If the answer is NO, restart the procedure.
87-3
vnx.su

UCH
Allocation of the UCH (most comprehensive).
P201 CONNECTOR (40-TRACK) BROWN

Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Description
+ battery
Not in use
Right-hand indicator control
Left-hand indicator control
Not in use
Not in use
Door locking warning light
Door unlocking control
Door locking control
Ultrasound alarm sensor
Alarm supply
Bonnet switch
Not in use
87-4
vnx.su
87

UCH
UCH features
87
Level 1
Level 2
Level 3
See
section
Control of indicators and hazard warning lights
Timed interior lighting control
Dialogue with instrument panel
83
Heated rear screen supply interval
Windscreen and rear screen wipers control
85
Multiplex connection interface
88
Opening elements management
Opening elements control (central locking)
84
Radio frequency remote control
82
Interface with fault finding tool
Transponder control (engine immobiliser)
82
Accessories relay control/+ after ignition
Alarm connection (first fitting)
87-5
vnx.su

UCH
P201 CONNECTOR (40-TRACK) GREEN
Track
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Description
Hazard lights warning light
Ignition switch
Rear door body flange switches
Wiper and windscreeen washer control
Side lights control
Front door body flange switches
Not in use
Not in use
Not in use
Not in use
Not used
+ after ignition feed
Not in use
Not in use
Airbag connection
Not in use
Not in use
Fault finding line

Track
1
2
3
4
5
6
7
8
9
Description
Rear courtesy light
Right-hand direction indicator
Left-hand direction indicator
Door unlocking
Door locking
+ lighting
+ door locking
Door unlocking

Track
1
2
3
4
5
6
Description
+ indicator
Windscreen wiper supply
+ windscreen wiper
Interval supply
Earth
87-6
vnx.su
87
187

Vdiag No.: 04

Passenger compartment connection unit
87
DIAGNOSTICS - INTRODUCTION
This document presents the general fault finding procedure applicable to all UCH computers on PRIMASTAR
vehicles with all engine types.
To perform fault finding on this system, it is essential to have the following items available:
the tools listed under Special tooling required.

Refer to the information in the Introduction.
Read the faults stored in the computer memory and use the Interpretation of faults section of the documents.
REMINDER: each fault is interpreted for a given type of storage (fault present, fault stored, fault present or
stored). The specified checks for dealing with each fault are therefore only to be performed if the fault declared by
the diagnostic tool can be identified in the document by its type. The storage type should be considered when
using the fault finding tool after the ignition has been switched off and switched back on.
Perform the conformity check (appearance of possible incorrect operations not yet declared by the system's selftest procedure) and apply the associated fault finding strategy according to results.
Use the fault finding strategy for each Customer complaint if the fault persists.
Diagnostic tool (Consult II)
Electrical bornier El. 1622,
Multimeter.
87-1
vnx.su

Vdiag No.: 04

87

.GENERAL INFORMATION
The UCH is available in three versions for production vehicles and two versions for UCHs sold in After-Sales.
FUNCTIONS PROVIDED BY THE UCH

direction indicators and hazard warning lights
interior lights (timed and separate front/rear with N2 / N3)
timed feed
windscreen wiper with integrated functions (timer and intermittence)
UCH N1
UCH N2
UCH N3
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
blade inversion
rear screen de-icing timer (switch)
communication with the instrument panel via the multiplex network
encoded transponder / engine immobiliser
fault finding
automatic relocking
locking / unlocking opening elements management
central locking / opening elements management
unlocking on impact
door locking indicator lights (electric door Locking indicator light)
radio-frequency system (remote control)
alarm function management
87-2
vnx.su
*
*
*
*

Vdiag No.: 04

87

CENTRAL LOCKING OPERATION
Central locking disengages all exterior and interior means of opening the doors.
This covers all five doors: driver's, passenger, right hand and left hand sliding side doors and boot.
Door locking and unlocking with UCH N3 (alarm and deadlocking of doors).
LOCKING
UNLOCKING
Result on locks
operation of direction
indicators
1 short press
locking of opening
elements + alarm
2 flashes
1 long press
opening element locking

+ alarm + volumetric
2 flashes
2nd short press
central locking of the

opening elements
5 flashes
2nd long press
central locking of
opening elements +
volumetric protection
inhibited
5 flashes
1 short or long
press
unlocking of the opening

elements
1 flash
87-3
vnx.su
operation of horn
1 beep
1 beep

Vdiag No.: 04


UCH track assignments: all options (N3)
P202 Connector (15-track)
BROWN
Track
Description
Rear courtesy light
RH direction indicator
LH direction indicator
Door unlocking
Locking of the opening elements
+ lighting
+ locking of doors
Door unlocking
GREEN
Track
Description
+ direction indicator
Windscreen wiper feed
+ windscreen wiper
Timed feed
Earth
87-4
vnx.su
87

Vdiag No.: 04


UCH track assignments: all options (N3)
P201 (40 tracks)
Track
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Track
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
BROWN
Description
+ battery
Not used
Not used
Not used
Door unlocking switch
Door locking switch
Alarm ultrasonic sensor
Alarm feed
Bonnet switch
Not used
GREEN
Description
Hazard lights warning light
Transponder signal
Rear door body flange switches
Windscreen wiper and washer switch
Side lights control
Front door switches
Not used
Not used
Not used
Not used
Not used
+ after ignition
Not used
Not used
Airbag connection
Not used
Not used
Diagnostic line
87-5
vnx.su
87

Vdiag No.: 04

87
DF039
PRESENT
OR
STORED
NOTES
UCH INTERNAL ELECTRICAL FAULT

Special point: if there is a fault stored in the memory, check that there are no other
faults present and clear the fault.
Replace the UCH.
AFTER REPAIR
Follow the instructions.

87-6
vnx.su

Vdiag No.: 04

87
DF119
PRESENT
WINDSCREEN WIPER PARK POSITION
OR STORED
NOTES
activation of the windscreen wiper timing.
Check that the windscreen wiper park position state ET005 is active every time the wiper blade arrives at the
rest position, then becomes inactive again.
Check the connection and condition of the UCH 15-track connector and repair it if necessary.
Check the insulation, continuity and absence of interference resistance on the following connections:
Track 1 windscreen wiper motor
Earth
Check the motor.
Check the assembly of the wiper.
Replace the windscreen wiper motor if necessary.
AFTER REPAIR

87-7
vnx.su

Vdiag No.: 04

87
DF128
PRESENT
VEHICLE SPEED NOT AVAILABLE
OR STORED
NOTES
None.
Special notes: if there is a fault stored in the memory, check that there are no other
faults present and clear the faults.
Is the vehicle speed signal present on the instrument panel?
YES
NO
AFTER REPAIR
Carry out a fault finding check on the multiplex network: see Section 88 Multiplex
network wiring.
Perform the fault finding procedure for the ABS and instrument panel.

87-8
vnx.su

Vdiag No.: 04

87
DF130
PRESENT
INCORRECT CONFIGURATION OF THE INSTRUMENT PANEL
OR STORED
NOTES

Special point: if there is a fault stored in the memory, check that there are no other
faults present and clear the fault.
Carry out instrument panel configuration (see instrument panel, Section 83).
AFTER REPAIR

87-9
vnx.su

Vdiag No.: 04

DF131
PRESENT
CENTRAL DOOR LOCKING BUTTON CIRCUIT

OR STORED
NOTES
Application of the fault finding procedure to the stored fault.

Fault appears when door locking button is activated.
Check that locking button state ET038 is active when door locking is activated.
Check that unlocking button state ET039 is active when door unlocking is activated.
Check the connection and condition of the central door locking button connector.
Check the connection and condition of the UCH 40-track connector if necessary.
Check the insulation and continuity of the connections:
40-track connector: UCH track 13
Track B1 door locking button
40-track connector: UCH track 14
Track A3 door locking button
Earth
Track A2 door locking button
AFTER REPAIR
Follow the instructions.

87-10
vnx.su
87

Vdiag No.: 04

87
DF145
PRESENT
OR
STORED
NOTES
OPENING ELEMENT WARNING LIGHT CIRCUIT

the indicator light command.
Check the connection and condition of the central door locking button connector and repair it if necessary.
40-track UCH connector track 12
Passenger compartment fuse box
AFTER REPAIR

87-11
vnx.su

Vdiag No.: 04

IMPACT DETECTION INFORMATION

DF175
STORED
NOTES
No fault present.
Application of the fault finding procedure to the stored fault.
Carry out the fault finding procedure on the airbag computer.

Carry out a fault finding test on the multiplex network: see Section 88 Multiplex network wiring.
AFTER REPAIR

87-12
vnx.su
87

Vdiag No.: 04

87
DF176
PRESENT
OU
MEMORISE
NOTES
AIRBAG MULTIPLEX SIGNAL ABSENT
Conditions for applying the fault finding diagnostic procedure to a fault stored:
The fault is declared present when the ignition is switched on.
Is the airbag warning light on?
YES
network wiring.
NO
Carry out the fault finding procedure on the airbag circuit.

network wiring.
AFTER REPAIR

87-13
vnx.su

Vdiag No.: 04

87
NOTES
Order
Function
Test conditions: engine stopped, ignition on .
Parameter or state
Check or action
Display
and notes
PR002: Battery
voltage
Power supply
12 < X < 12.5 V
ET002: + 12 V after
ignition
ACTIVE
ET242: Engine
running
Lighting
Windscreen
wiper
Opening
elements
NO
Fault finding
If there is a problem:
carry out a diagnostic
check on the charging
circuit
refer to state ET002 fault
finding
None
ET020: Side lights

control
ACTIVE when side lights are

switched on
if INACTIVE
finding
ET029: Right-hand
indicator control
ACTIVE when right-hand direction

indicator is switched on
if INACTIVE
finding
ET028: Left-hand
indicator control
ACTIVE when left-hand direction

indicator is switched on
if INACTIVE
finding
ET022: Hazard
warning lights control
ACTIVE when hazard lights are

switched on
if INACTIVE
finding
ET032: Windscreen
washer control
ACTIVE when windscreen washer

is switched on
if INACTIVE
finding
ET035: Windscreen
wiper timing
ACTIVE when windscreen wiper

switch is in intermittent position
if INACTIVE
finding
ET005: Windscreen
wiper park position
ACTIVE when intermittent

windscreen wiper is stopped
if there is a problem:
procedure on fault
DF119: Windscreen
wiper park position
ET192: Front doors
OPEN when front doors open
finding
ET111: Rear doors
OPEN when rear doors open
finding
87-14
vnx.su

Vdiag No.: 04

87
NOTES
Order
Function
Opening
elements
(continued)
Parameter or state
Check or action
Display
and notes
ET038: Locking
button
PRESSED when the electric door

locking button is pressed to lock
doors, then released
ET039: Unlocking
button
PRESSED when the electric door

locking button is pressed to unlock
doors, then released
ET220: Locking with

radio-frequency key
SHORT PRESS
lock opening elements
LONG PRESS
unlock opening elements and
volumetry inhibition (on UCH N3)
ET221: Unlocking
with radio-frequency
key
SHORT PRESS
unlock opening elements
LONG PRESS
unlock opening elements
(on UCH N3)
Fault finding
procedure for states
ET038 and ET039
procedure for states
ET220 and ET221
ET217: Opening
element locking
indicator light
ON when opening elements closed

OFF when opening elements open
finding
ET012: Source last

opening elements
activation
TRF when locking with the remote

control
central door locking when
locking with the central button
None
UNLOCKING
LOCKING
None
ET105: Last opening

elements activation
ET010: Valid radiofrequency key
State YES when locking or

unlocking the vehicle with the
remote control
finding
ET193: Radiofrequency signal

received
State YES when locking or

unlocking the vehicle with the
remote control
finding
0 mph (0 km/h)
Speed
PR001 Vehicle
speed
Switch
ET008: Rear de-icing

switch
PRESSED
RELEASED
87-15
vnx.su
None
finding

Vdiag No.: 04

87
FAULT FINDING - STATUS INTERPRETATION
+ 12 V AFTER IGNITION
ET002
ET002 INACTIVE, ignition on
Check the passenger compartment fuse.

Use a multimeter to check the presence of + 12 V at the fuse holder with the ignition on.
Use a multimeter to check the presence of + 12 V on track 33 of the UCH 40-track connector with the ignition
on.
If the voltage is present, replace the UCH.
If the voltage is absent, check the continuity and insulation from earth between track 33 of the UCH 40-track
connector and the 10A fuse in the passenger compartment fuse box.
ET002 ACTIVE, ignition off
Use a multimeter to check the absence of + 12 V at the passenger compartment fuse holder with the ignition
off.
If the voltage is absent, replace the UCH.
AFTER REPAIR
87-16
vnx.su

Vdiag No.: 04

87
REAR DE-ICING SWITCH

ET008
NOTES
Check that no fault is present.

Switch on the ignition.
ET008 RELEASED: button pressed
Check the heated rear screen fuse.

Change it if necessary.
Check the condition and connection of the de-icing button connector and replace it if necessary.
With the button pressed, use a multimeter to check the presence of an earth on track 4 of the 40-track UCH
connector.
If there is no earth, check the continuity and insulation between track 4 of the 40-track UCH connector and the
de-icing switch.
Replace the de-icing switch.
AFTER REPAIR
87-17
vnx.su

Vdiag No.: 04

VALID RF (radio-frequency) KEY

ET010
NOTES

The state shows YES when the vehicle's remote control is pressed.
If the state shows NO, try again with a different key from the vehicle.
ET010 remains NO: when the remote control is pressed
Resynchronize the keys switching the ignition on (+ after ignition feed).

If the fault persists, refer to state ET193: RF signal received.
AFTER REPAIR
87-18
vnx.su
87

Vdiag No.: 04

SIDE LIGHTS SWITCH

ET020
NOTES

Activate the side lights switch.
The state should be ACTIVE.
ET020 INACTIVE: side lights on
Check the condition and connection of the lights switch connector and replace it if necessary.
Check the connection and condition of the UCH 40-track connector and replace it if necessary.
Ensure the continuity and insulation of the connection between:
Track B1 lights stalk
AFTER REPAIR
87-19
vnx.su
87

Vdiag No.: 04

87
HAZARD WARNING LIGHTS SWITCH

ET022
NOTES

Activate the side lights switch.
ET022 INACTIVE
Check the direction indicators feed fuse (10 A).

Check the condition and connection of the hazard warning lights switch connector and repair it if necessary.
Check the continuity of the connection between
Hazard warning lights switch track 2
Earth
Check the insulation, continuity and the absence of interference resistance on the connection:
Hazard warning lights switch track 3
Track 36 UCh 40-track connector
Check the operation of the hazard warning lights control.
AFTER REPAIR
87-20
vnx.su

Vdiag No.: 04

LH DIRECTION INDICATOR SWITCH

ET028
ET029
NOTES
RH DIRECTION INDICATOR SWITCH

Activate the right-hand or left-hand direction indicator switch.
ET028 or ET029 INACTIVE
Check the 10 Amp direction indicators feed fuse .

Check the connection and condition of the direction indicators stalk connector.
Repair it if necessary.
direction indicator light switch track A6
earth
Disconnect the 40-track UCH connector and activate the right or left direction indicator.
Check the continuity and insulation:
Right-hand direction indicator switch track A5
Track 6 40-track connector UCH
Left-hand direction indicator switch track A7
Track 7 UCH 40-track connector
AFTER REPAIR
87-21
vnx.su
87

Vdiag No.: 04

WINDSCREEN WASHER SWITCH

ET032
NOTES

Move the windscreen wiper switch to the rear screen washer position.
ET032 INACTIVE
Check the windscreen washer relay feed fuse.

Check the connection and condition of the direction indicators stalk connector.
Check the continuity and insulation of the following connections:
UCH P201 40-track connector track 24
Windscreen wiper switch track A4
Earth
Wiper stalk track B5
+ After ignition
Windscreen wiper stalk tracks B4 and A7
Check the correct operation of the washer pump, in particular the continuity and insulation of the
connections:
Pump track 2
Track A4 wiper stalk
Pump track 1
Track B1 wiper stalk
AFTER REPAIR
87-22
vnx.su
87

Vdiag No.: 04

WINDSCREEN WIPER TIMER

ET035
NOTES

Move the windscreen wiper switch to the intermittent wiping position.
ET035 INACTIVE
Check the fuse.

Check the connection and condition of the windscreen wiper switch connector.
Repair it if necessary.
Check the continuity and insulation of the following connections:
Wiper stalk track A6
Earth
Wiper stalk track B5
+ After ignition
Wiper stalk tracks B4 and A7
AFTER REPAIR

87-23
vnx.su
87

Vdiag No.: 04

87
FRONT DOORS
ET192
ET111
NOTES
REAR DOORS

Open the front and rear doors.
Check that for each open door the corresponding state is active and for each closed door the corresponding
state is inactive.
Check the connections between the door wiring and the passenger compartment wiring and the continuity and
insulation between:
the lock concerned and the UCH,
the lock concerned and earth.
Repair if necessary (see the wiring diagrams for the vehicle concerned).
Open the door, disconnect the lock and close the lock.
Pull the door handle to open the lock and check that there is no longer any continuity between the earth input
track and the track on the UCH.
AFTER REPAIR

87-24
vnx.su

Vdiag No.: 04

87
RF (radio-frequency) SIGNAL RECEIVED

ET193
NOTES

The state shows YES when the remote control is pressed.
If the state shows NO, try again with a different key from the vehicle.
ET193 NO: when the remote control is pressed.

Press the remote control button of another PRIMASTAR vehicle or blank key: Check that the state changes to
YES when it is pressed.
If state is YES, replace the remote control of the vehicle with a fault.
If state is NO, replace the UCH.
AFTER REPAIR

87-25
vnx.su

Vdiag No.: 04

87
OPENING ELEMENT LOCKING WARNING LIGHT

ET217
NOTES

Get inside the vehicle and lock the doors with the electric door locks button.
Check that when pressing the central door locking button, the corresponding state is active.
If the state remains inactive:
Fuse box
If necessary, replace the UCH.
AFTER REPAIR

87-26
vnx.su

Vdiag No.: 04

87
LOCKING WITH RF KEY (radio-frequency)

ET220
ET221
UNLOCKING WITH RF KEY (radio-frequency)
None.
NOTES
Door locking and unlocking with UCH N3 (alarm and central locking of doors).
LOCKING
UNLOCKING
Result on locks
operation of direction
indicators
1 short press
locking of opening
elements + alarm
2 flashes
1 long press
opening elements
locking + alarm +
inhibited
2 flashes
2nd short
press
central locking of the

opening elements
5 flashes
2nd long press
central locking of
opening elements +
inhibited
5 flashes
1 short or long
press
unlocking of the opening

elements
1 flash
operation of horn
1 beep
1 beep
When the vehicle is locked with the volumetric protection inhibited, manually opening one of the doors will cause the
alarm and the hazard warning lights to operate for 25 seconds.
When the vehicle is locked with the volumetric protection activated, the ultrasonic sensors are active after 7
seconds.
If a hand is passed in front of the sensors, this will cause the alarm and the hazard warning lights to operate for
25 seconds.
AFTER REPAIR

87-27
vnx.su

Vdiag No.: 04

87
NOTES
These customer complaints should only be investigated after a complete check

has been run using the diagnostic tool.
No communication with the UCH
CHART 1
Lights
None of the direction indicator lights operate
CHART 2
side lights do not operate
CHART 3
dipped beam headlights do not operate
CHART 4
main beam headlights do not operate
CHART 5
reversing lights do not operate
CHART 6
front fog lights do not operate
CHART 7
rear fog lights do not operate
CHART 8
Wipers, washers, de-icing
rear screen washer does not operate.
CHART 9
windscreen wiper low speed does not operate
CHART 10
windscreen wiper high speed does not operate
CHART 11
rear screen wiper does not operate.
CHART 12
windscreen washer does not operate.
CHART 13
rear screen de-icing does not operate
CHART 14
87-28
vnx.su

Vdiag No.: 04

87
No communication with the UCH
CHART 1
NOTES
None.

Check:
the connection between the diagnostic tool and the diagnostic socket (wiring in good condition),
the engine and passenger compartment fuses.
Check for the presence of + 12 V before ignition on track 16, for + 12 V after ignition on track 1 and for an
earth on tracks 4 and 5 of the diagnostic socket.
Connect the bornier and check the insulation, continuity and absence of unwanted resistance on the
following connections:
Fuse box
+ After ignition supply
Earth
Track 7 of the diagnostic socket (line K)
AFTER REPAIR
87-29
vnx.su

Vdiag No.: 04

87
CHART 2
NOTES
Direction indicators do not operate
Only consult this customer complaint after a complete check using the
diagnostic tool.
Check the bulbs.
Check the condition of the fuses and change them if necessary.

Activate the hazard warning lights switch and check that the hazard warning lights switch state ET022 is
active.
If not, refer to the section dealing with this state.
Activate the right-hand or left-hand direction indicators and check that the right-hand direction indicator switch
and left-hand direction indicator switch states ET028 and ET029 are active.
If not, refer to the section about these states.
Check the condition of the UCH 15-track connector and replace it if necessary.
15-track connector track A4
Left-hand indicator
15-track connector track A3
Right-hand indicator
AFTER REPAIR
87-30
vnx.su

Vdiag No.: 04

CHART 3
NOTES
Side lights do not operate
diagnostic tool.
Check the bulbs.
Activate the side lights switch and check that the Side lights switch state ET020 is active.
Check the side lights feed fuses F31 and F32, and replace them if necessary.
Switch track B1
Side lights fuses (10A) F31 and F32
Fuses (10A) F31 and F32
Left-hand and right-hand side lights
AFTER REPAIR
87-31
vnx.su
87

Vdiag No.: 04

87
CHART 4
NOTES
Dipped headlights do not operate
diagnostic tool.
Check the bulbs.
Check the dipped beam headlights feed fuses F29 and F30, and replace them if necessary.
Switch track B5
Dipped beam headlight fuses (10A) F29 and F30
Dipped beam headlight fuses (10A) F29 and F30
AFTER REPAIR
87-32
vnx.su
Left-hand and right-hand dipped headlights

Vdiag No.: 04

CHART 5
NOTES
Main beam headlights do not operate
diagnostic tool.
Check the bulbs.
Check the main beam headlights feed fuses F27 and F28, and replace them if necessary.
Switch track B7
Main beam headlights fuses (10A) F27 and F28
Main beam headlight fuses (10A) F27 and F28
headlights
AFTER REPAIR
87-33
vnx.su
Left-hand and right-hand main beam
87

Vdiag No.: 04

Reversing lights do not operate
CHART 6
NOTES
diagnostic tool.
Check the bulbs.
Check fuse F14 (25A), repair if necessary.

Check the reversing light switch + after ignition feed on track 2.
Reversing light switch track 1
Reversing lights
Replace the switch if necessary.
AFTER REPAIR
87-34
vnx.su
87

Vdiag No.: 04

Front fog lights do not operate
CHART 7
NOTES
diagnostic tool.
Check the bulbs.
Check fuse F9 (15A), replace if necessary.

Side lights operating.
Check the front fog light relay + after ignition feed on track 1.
Earth
Track A2 front fog light relay
Fuse (F9) feed
Front fog lights
AFTER REPAIR
87-35
vnx.su
87

Vdiag No.: 04

Rear fog lights do not work
CHART 8
NOTES
diagnostic tool.
Check the bulbs.
Check fuse F33 (10A), replace if necessary.

Fuse F33 feed
Rear fog lights
Replace the fuse box if necessary.
AFTER REPAIR
87-36
vnx.su
87

Vdiag No.: 04

Rear screen washer does not work
CHART 9
NOTES
diagnostic tool.
Check fuses F14 (25A) and F15 (25A).

Check the wiper switch + after ignition feed on tracks A7 and B4.
Switch track B1
Track 1 screen washer pump
Switch track A4
Replace the screen washer pump if necessary.
AFTER REPAIR
87-37
vnx.su
87

Vdiag No.: 04

87
CHART 10
NOTES
Windscreen wiper low speed does not operate
diagnostic tool.
Activate the AC064 Windscreen wiper low speed command and check the operation of the windscreen
wiper.
Does the windscreen wiper operate?
YES
Switch track A1
NO
Check fuses F14 (25A) and F15 (25A) .

Check the + after ignition feed to the switch on tracks A7 and B4.
Switch track A1
Switch track A4
Track B3 UCH 15-track connector
Switch track A3
AFTER REPAIR
87-38
vnx.su

Vdiag No.: 04

CHART 11
NOTES
Windscreen wiper high speed does not work
diagnostic tool.

Switch track A2
Track 4 wiper motor
AFTER REPAIR
87-39
vnx.su
87

Vdiag No.: 04

87
Rear screen wiper does not operate
CHART 12
NOTES
diagnostic tool.

Switch track B2
Track B9 rear wiper timer
Earth
Tracks B1 et B4 rear screen wiper timer
Fuse (F14) feed
Track B9 rear wiper timer
Remove the timer relay and put a shunt across the tracks B5 and B3. Check the rear screen wiper relay feed
on tracks C1 and C5.
Earth
Tracks C4 and C2 rear screen wiper relay
Replace the rear screen wiper relay if necessary.
Check the operation of the motor.
Rear screen wiper assembly.
Replace the rear screen wiper motor if necessary.
AFTER REPAIR
87-40
vnx.su

Vdiag No.: 04

Windscreen washer does not work
CHART 13
NOTES
diagnostic tool.
Press the side lights switch and check that windscreen washer switch state ET032 is active.
Switch track A4
Switch track B1
Replace the screen washer pump if necessary.
AFTER REPAIR
87-41
vnx.su
87

Vdiag No.: 04

CHART 14
NOTES
Heated rear screen does not operate
diagnostic tool.
Press the rear screen de-icing switch and check that state ET008 Rear de-icing button is pressed.
Check the following fuses: F16 (15A), F13 (30A), F24 (15A) and F35 (10A).
Activate the AC043 heated rear screen command.
Can you hear the relay clicking?
YES

Rear screen relay
Track A5 heated rear screen
Earth
Heated rear screen
NO

Fuse F13 feed
Track A3 rear screen relay
Fuse F35 feed
Fuse F24 feed
AFTER REPAIR
87-42
vnx.su
87
WIRING
Multiplex network
Multiplex
network
DESCRIPTION OF THE FAULT FINDING STAGES
88
188
DESCRIPTION OF THE MULTIPLEX NETWORK

The multiplex network consists of a twisted pair of wires connected to several vehicle computers.
These two wires are called CAN H and CAN L (connections 133 B and 133 C).
Two of the computers on the network contain an internal resistance of 120 between the two wires: the injection
computer and the UCH.
More than 200 data items are passed through this network. They are transmitted by some computers and used by
others.
For example: the injection computer sends the engine speed, the instrument panel computer displays it.
TESTING THE MULTIPLEX NETWORK:
NOTES
Switch on the ignition and wait 10 seconds before starting the test.
This step is the essential starting point for any computer fault finding procedure.
It ensures that the network is correctly connected to the terminals of each computer and that the information is
correctly sent to it and received by it.
The network test is the only function which can be selected after the choice of vehicle type.
After the network test, the other functions become accessible once more.
88-1
vnx.su
Multiplex
network
WIRING
Multiplex network
88
0 - Failure of the test

It is possible that the network test cannot be carried out.
To carry out this check, the tool investigates the Air bag and UCH (Passenger compartment ECU) computers
to find out the network topology (diagram) version and which computers are present on the network of the
vehicle being repaired.
If no configuration is detected, check the feeds to the computers (Air bag and UCH in particular). After checking
and repairing the feeds if necessary, refer to "Multiplex network out of service" diagnostic.
If the configurations are inconsistent between the computers, the tool asks the user to reconfigure the
computers. Refer to the "Network configuration" section.
1 - Result of the test
The tool displays a diagram of the network showing the faulty, not diagnosed and good segments (see
screen below).
A segment is the length of the CAN H and CAN L twisted pair connecting two components (computer,
cable joint, or connection).
1: Test result
2 and 3: list of faulty segments and/or unrecognized computers
4: network diagram:
green segment: operational segment
red segment: faulty segment
black segment: segment not checked
green computer: present and recognized

red computer: recognized but not present
white computer: cannot be checked
88-2
vnx.su
Multiplex
network
WIRING
Multiplex network
88

2 - Dealing with faulty segments
a) All segments are faulty or not checked:
The tool offers two screens: one shows the network diagram with the faulty segments and the other shows the
network diagram and the unrecognized computers (non-conforming computers), undetected computers (which have
not answered the tool), or computers which cannot be checked (ones which are present on the multiplex network but
cannot be checked with the tool).
You can switch from one diagram to the other at any time.
If all the segments are faulty and if no computer has responded, there is a problem with the power supply to the
computers.
Deal with faults according to the procedure shown in the section:
"MULTIPLEX NETWORK OUT OF SERVICE".
b) Only a few segments are faulty
The tool offers two screens:
One with the network diagram showing the faulty segments and the other with the network diagram showing the
computers not recognized (computers not meeting the specification), not detected (not responding to the tool) or
those which cannot be checked.
You can switch from one diagram to the other at any time.
If there are unrecognized or undetected computers at the ends of faulty segments, check the feeds and the
conformity of the computers first by carrying out a diagnostic check on each computer.
Deal with faults according to the procedure shown in the section:
"MULTIPLEX SEGMENT FAULT".
3 - Absence of faults, or segments which cannot be checked
If no fault is detected by the diagnostic tool, it is advisable to refer to the "SEGMENT NOT CHECKED" section to
make sure that these segments are functioning correctly.
88-3
vnx.su
WIRING
Multiplex network
Multiplex
network
88
DIAGNOSTICS - MULTIPLEX NETWORK OUT OF SERVICE
First check that the computers have a power supply.

Switch off the ignition, remove the key, check that the side lights are off and wait
1 minute.
NOTES
Take the measurements via the diagnostic socket of the vehicle.
Finding the fault

type
NOTES
Use the diagram of the multiplex network of the vehicle

(diagram of the diagnostic socket).
Measure the resistance between tracks 6 and 14 of the diagnostic socket.

What is the resistance?
The two lines are short-circuited.

Refer to the section "Help with finding network short circuits".
Between 60
and 130
For track 6 and track 14, measure earth continuity and the voltage.
Establish which track is short-circuited to earth or to + battery.
Refer to the section "Help with finding network short circuits".
Open circuit
Disconnect the injection and verify that the two multiplex network tracks are continuous with
the diagnostic socket:
AFTER REPAIR
Yes
Check the resistance between the two network tracks on the injection computer.
If the resistance is not 120 > replace the computer.
No
Choose tracks on another computer as reference (e.g.: UCH) and repeat the
measurement.
If the result is the same, there is a danger that the CAN wire joints may be
damaged.
In that case, check the continuity of the whole multiplex network.
If the wire joints are damaged, replace the passenger compartment harness.
Perform another multiplexed network test.

Clear the stored faults on all the computers connected to the network.
The immobiliser warning light may be on. In that case, leave the ignition on for
30 seconds, switch off and wait at least one minute. Turn the ignition on again, the light
should go out. If it does not, refer to the injection computer diagnostic.
88-4
vnx.su
WIRING
Multiplex network
Multiplex
network
88
DIAGNOSTICS - MULTIPLEX SEGMENT FAULT
First check that the computer at the end of the segment is correctly fed (earth,
+ battery, + accessories or + after ignition).
Always check the computer specification.
NOTES
Warning: the tool may not be able to precisely identify the faulty segment. It will
suggest several in order of failure probability. Start by checking the first segment.
Disconnect the ends of the segment.

(If one of the ends is a wire joint, the two wires cannot be disconnected.
In that case, disconnect a computer located at the end of a good segment, starting from the wire joint, e.g.: On
Board Diagnostic (OBD) socket)
Verifier the continuity of the two tracks (see help table on the next page).
Check the condition of the connectors.
Reconnect and try again.
Has the fault been rectified?
No
AFTER REPAIR
Are there other faulty segments?
Yes
Deal with the other faulty segments using the same procedure.
No
First replace the computer at the end of the segment having the highest
probability of being faulty.
If in doubt, always replace computers with an impedance (UCH and injection)
last.

88-5
vnx.su
Multiplex
network
WIRING
Multiplex network
88
DIAGNOSTICS - SEGMENTS NOT DIAGNOSED
On this vehicle, the only segments which cannot be diagnosed are:
NOTES
diagnostic socket segment

Communication Control Unit segment
(data communication/multimedia option)
If there are others, verify that all the computers have been identified.
Reminder: the instrument panel cannot be checked and it does not have a K line
but it is, however, present on the multiplex network.
To test the other segments, simply switch on the ignition and open the driver's door.
It must be shown as open on the central display.
Refer to the appropriate section of the Information/Navigation system.
In the event of a fault, refer to the "Multiplex segment fault" section.
AFTER REPAIR

88-6
vnx.su
WIRING
Multiplex network
Multiplex
network
88
DIAGNOSTICS - HELP WITH FINDING NETWORK SHORT CIRCUITS
Use the diagram of the multiplex network of the vehicle (diagram of the
diagnostic socket).
NOTES
Switch off the ignition and remove the ignition key.

Verify that the side lights are off.
Wait 1 minute.
In the event of a short-circuit to + battery, leave the battery connected.
The procedure consists of gradually disconnecting the network components and isolating the faulty section.
Disconnect the grey passenger compartment/engine connection (R 67)
Check the condition of the connections to the connector on the engine side and to the connector on the
passenger compartment side,
verify whether the fault has disappeared on the passenger compartment side and engine side.
Which is the faulty section?
After each disconnection:
Verify whether the fault has disappeared (in which case, replace the computer),
Check the condition of the connectors and clips and that their insulation is correct.
Reconnect.
Engine
The recommended order for disconnecting engine computers is as follows:

First disconnect the automatic gearbox or the LPG computer.
Disconnect the injection computer and identify the faulty section:
injection / passenger compartment connection
passenger
compartment
The recommended order for disconnecting passenger compartment computers is as

follows:
Disconnect:
instrument panel,
Communication Control Unit.
Air bag,
UCH.
88-7
vnx.su
WIRING
Multiplex network
Multiplex
network
88
DIAGNOSTICS - HELP WITH FINDING NETWORK SHORT CIRCUITS
If the fault has not disappeared check the condition of the wiring.
If the fault is not visible, replace the wiring.
Input
Connector
Output
CAN H
CAN L
F4R injection
S2000
Black
A4
A3
F9Q injection
EDC15VM+
Black
A7
A6
G9U injection
EDC15C3
Black
A7
A6
LPG injection
Sagem 4C
Brown
A2
A1
Black
Carminat
Airbag
ACU3
Grey
58
59
UCH
Sagem
Brown
20
19
Instrument panel
Sagem
Red
10
11
R67 connector
Clip holder
White
AFTER REPAIR
Connector
Brown
CAN H
CAN L
10

88-8
vnx.su
WIRING
Multiplex network
Multiplex
network
88
INCONSISTENT NETWORK CONFIGURATION
On this vehicle, the computers containing the configuration are:

UCH
air bag
NOTES
The configuration is entered with the ignition on.

It is run automatically during a network test, when the tool detects a fault on one
of the computers.
It can be run from the multiplex network test result screens (command button at
bottom right of screen).
The tool shows both configurations: for the UCH and the air bag.
Select the computer to be modified.
The tool displays the configuration of the other computer at the same time.
(see next screen page)
The steps are as follows:
choice of network topology version
This is the multiplex network diagram version. This version is increased with each development change of the
multiplex network harness for this vehicle.
This information is available in the world vehicle database or in the other computer.
Choice of the vehicle's computers present on the network
There are as basic:
Air bag,
injection system,
the UCH,
instrument panel (computer cannot be tested by the tool).
+ the vehicle options:
"Navigation or data communication" Central Communications Unit, (computer cannot be tested by the tool).
88-9
vnx.su
WIRING
Multiplex network
Multiplex
network
88
WARNING:
If a computer is connected to the multiplex network but it is not one of the two computers configured (air bag
and UCH), it will not be checked during the multiplex network test.
In order to include a computer in the configuration, it is necessary to produce a configuration inconsistency by
making the instrument panel absent from the air bag, then restart the test.
The tool will show a configuration error and display a list of all the computers available for the vehicle type.
Correct the configuration by making the instrument panel present on the air bag, then enter the missing
computer as present on the air bag and then on the UCH.
Repeat the multiplex network test.
CONFIGURATION SCREEN
An illustration of the empty configuration screen is shown above

In column (1), a list of the possible computers and the topology version.
In column (2), the existing configuration in the computer not selected.
In column (3), the existing configuration in the computer selected.
In column (4), the desired configuration for the computer selected.
AFTER REPAIR
88-10
vnx.su
INDEX OF FUNCTIONS
FUNCTIONS
PLATE NUMBERS
ACCESSORIES SOCKET
0091 - 0092
ADDITIONAL HEATING
0023
AIR BAG
0013 - 0014
AIR CONDITIONING
0034 - 0035
ALARM
0015
ANTI-LOCK BRAKING SYSTEM
0018
BASIC HEATING
0024 - 0025
BRAKE FLUID AND HAND BRAKE WARNING LIGHTS
0112
BRAKE LIGHTS
0068 - 0069 - 0074
CHARGE AND STARTER CIRCUIT
0026 - 0027
CIGARETTE LIGHTER
0016
COURTESY LIGHTING
0042 - 0043 - 0044 - 0045 - 0046 - 0047
DIAGNOSTICS SOCKET
0093
DIESEL FILTER HEATER
0097
DIESEL PRE AND POSTHEATING
0089
DIPPED, MAIN BEAM AND POSITION LIGHTS
0064 - 0065 - 0066 - 0067
DIRECTION INDICATORS AND HAZARD WARNING LIGHTS
0070 - 0071 - 0072 - 0073
DOOR LOCKING
0028 - 0029 - 0030 - 0031 - 0032 - 0033
EARTH
0001 - 0002 - 0003 - 0004 - 0005 - 0006 - 0007 0008 - 0009 - 0010
ELECTRIC REAR-VIEW MIRRORS
0102
ELECTRONIC INJECTION
0081 - 0082 - 0083 - 0084
ENGINE COOLING SYSTEM
0098 - 0099 - 0100 - 0101
ENGINE FUSE BOARD
0087 - 0088
EXTERNAL TEMPERATURE INDICATOR
0077 - 0078 - 0079 - 0080
FRONT AND REAR FOG LIGHTS
0053 - 0054 - 0055 - 0056 - 0057
FRONT AND REAR SCREEN WASHER/WIPERS
0050 - 0051 - 0052
FRONT ELECTRIC WINDOWS
0085
FRONT WINDSCREEN WASHER AND WIPER
0049
FUEL LEVEL INDICATOR
0075
HEADLIGHT HEIGHT ADJUSTMENT
0036
HEATED SEATS
0103
HORN
0021
IMMOBILISER
0017
INSTRUMENT PANEL
0108 - 0109
NAVIGATION
0011 - 0012
OIL LEVEL INDICATOR
0076
OIL PRESSURE WARNING LIGHT
0110 - 0111
PASSENGER COMPARTMENT FUSE BOARD
0086
PASSENGER COMPARTMENT INTER-CONNECTION UNIT
0022
PRE-EQUIPMENT ALARM
0090
RADIO AND PERIPHERALS COMMUNICATION
0094 - 0095
RADIO AND TELEPHONE PRE-EQUIPMENT
0096
REAR WINDOW DE-ICING
0037 - 0038 - 0039
REAR-VIEW MIRROR DEMISTING
0041
REVERSING LIGHTS
0059 - 0060 - 0061 - 0062 - 0063
SIDE LIGHTS
0058
STORAGE COMPARTMENT LIGHTING
0048
THERMOPLUNGERS
0113
1-1
vnx.su
INDEX OF FUNCTIONS
FUNCTIONS
PLATE NUMBERS
TOWBAR ATTACHMENT
0019 - 0020
0104 - 0105 - 0106 - 0107
WINDSCREEN DE-ICING
0040
1-2
vnx.su
vnx.su
DG/RETROE
ELECTRIC REARVIEW MIRRORS
X83
vnx.su
DG/SGACHA
HEATED SEATS
X83
vnx.su
F9Q760,F9Q762/SSNAV
X83
vnx.su
F4R720/SSNAV
X83
vnx.su
F9Q760,F9Q762/NINAV3
X83
vnx.su
F4R720/NINAV3
X83
vnx.su
ABS
INSTRUMENT PANEL
X83
vnx.su
SSABS
INSTRUMENT PANEL
X83
vnx.su
F4R720/CHAUFO
X83
vnx.su
F4R720/CA,CACHFA,F9Q760,F9Q762
X83
vnx.su
NAVIGATION
DG/NINAV3/RAD08,RAD09
X83
vnx.su
NAVIGATION
DD/NINAV3/RAD08,RAD09
X83
vnx.su
X83
vnx.su
F9Q760,F9Q762
THERMOPLUNGERS
X83
vnx.su
E83/ATREM,SDRQAR
EARTH
X83
vnx.su
ABS
EARTH
X83
vnx.su
F9Q760,F9Q762
EARTH
X83
vnx.su
F4R720
EARTH
X83
vnx.su
CA,CACHFA/PROJAB/RAD10
EARTH
X83
vnx.su
EARTH
X83
vnx.su
F83/LAC/PARV27/ATREM
EARTH
X83
vnx.su
J83/MINBUS/DG/LAC/HAYVIT/EMPT10
EARTH
X83
vnx.su
J83/DG/CAVCAR/PARV18/EMPT10
EARTH
X83
vnx.su
EARTH
X83
vnx.su
AIR BAG
E83,F83/ABLAV/ABPA01
X83
vnx.su
AIR BAG
J83/DG/ABLAV/ABPA01/EMPT10
X83
vnx.su
ANTIDI
ALARM
X83
vnx.su
CIGARETTE LIGHTER
X83
vnx.su
ANTID,ANTIDI
IMMOBILISER
X83
vnx.su
ABS
ANTILOCK BRAKING SYSTEM
X83
vnx.su
E83/ATREM
TOWBAR ATTACHMENT
X83
vnx.su
F83,J83/ATREM
TOWBAR ATTACHMENT
X83
vnx.su
HORN
X83
vnx.su
PASSENGER COMPARTMENT INTERCONNECTION UNIT
X83
vnx.su
F4R720/CACHFA,CHAUFA,CHORAD
ADDITIONAL HEATING
X83
vnx.su
CHORAD,CHOREC
BASIC HEATING
X83
vnx.su
CHAUFO
BASIC HEATING
X83
vnx.su
F9Q760,F9Q762
X83
vnx.su
F4R720
X83
vnx.su
E83/DG/CPE
DOOR LOCKING
X83
vnx.su
J83/DG/SUPCPE/HAYVIT
DOOR LOCKING
X83
vnx.su
F83/DD/CPE/PARV18,PARV27/H20
DOOR LOCKING
X83
vnx.su
J83/DG/CPE/HAYVIT
DOOR LOCKING
X83
vnx.su
F83,J83/DG/CPE/PARV18,PARV27
DOOR LOCKING
X83
vnx.su
E83/DD/CPE
DOOR LOCKING
X83
vnx.su
F9Q760,F9Q762/CA,CACHFA
AIR CONDITIONING
X83
vnx.su
F4R720/CA,CACHFA
AIR CONDITIONING
X83
vnx.su
X83
vnx.su
F83/LAC/RETROE/PARV18,PARV27
REAR WINDOW DEICING
X83
vnx.su
J83/LAC/RETROE/HAYVIT
REAR WINDOW DEICING
X83
vnx.su
J83/LAC/RETROE/PARV18,PARV27
REAR WINDOW DEICING
X83
vnx.su
F9Q760,F9Q762
WINDSCREEN DEICING
X83
vnx.su
RETROE
REARVIEW MIRROR DEMISTING
X83
vnx.su
J83/DG/1PLCVO/ANTIDI
COURTESY LIGHTING
X83
vnx.su
E83/ANTID
COURTESY LIGHTING
X83
vnx.su
F83/DD/1PLCTL/ANTIDI
COURTESY LIGHTING
X83
vnx.su
J83/MINBUS/DG/1PLCVO/ANTID
COURTESY LIGHTING
X83
vnx.su
F83/DG/1PLCTL/ANTID
COURTESY LIGHTING
X83
vnx.su
J83/DG/1PLCVO/ANTID
COURTESY LIGHTING
X83
vnx.su
X83
vnx.su
E83
X83
vnx.su
J83/HAYVIT
X83
vnx.su
J83/ADAC/HAYVIT
X83
vnx.su
J83/PARV18
X83
vnx.su
E83/PROJAB/ATREM
X83
vnx.su
F83,J83/PROJAB/ANTID
X83
vnx.su
F83,J83/ANTID/SDRQAR
X83
vnx.su
F83,J83/ANTID/ATREM
X83
vnx.su
E83/PROJAB/SDRQAR
X83
vnx.su
DG/RUNLI
SIDE LIGHTS
X83
vnx.su
E83/SDRQAR
REVERSING LIGHTS
X83
vnx.su
E83/ATREM
REVERSING LIGHTS
X83
vnx.su
F83,J83/ANTID
REVERSING LIGHTS
X83
vnx.su
F83,J83/ANTID/ATREM
REVERSING LIGHTS
X83
vnx.su
F83,J83/ANTID/SDRQAR
REVERSING LIGHTS
X83
vnx.su
E83/RETROE/SSNAV/RAD08/SDRQAR
X83
vnx.su
F83,J83/RETROR/SSNAV/HAYVIT/RAD10/SDRQAR
X83
vnx.su
E83/RETROE/SSNAV/RAD08/ATREM
X83
vnx.su
F83,J83/RETROE/NINAV3/PARV18,PARV27/RAD08/ATREM
X83
vnx.su
E83/ABS/ATREM/F9Q760,F9Q762
BRAKE LIGHTS
X83
vnx.su
E83/SDRQAR/ABS/F4R720
BRAKE LIGHTS
X83
vnx.su
F83,J83/ABS/HAYVIT/ATREM/F4R720
BRAKE LIGHTS
X83
vnx.su
E83/ATREM
X83
vnx.su
E83/SDRQAR
X83
vnx.su
F83,J83/SDRQAR
X83
vnx.su
F83,J83/ATREM
X83
vnx.su
X83
vnx.su
OIL LEVEL INDICATOR
X83
vnx.su
DG/RETROE/NINAV3/RAD08
X83
vnx.su
DG/RETROE/SSNAV/RAD08
X83
vnx.su
DD/RETROE/SSNAV/RAD08
X83
vnx.su
DD/RETROE/NINAV3/RAD08
X83
vnx.su
X83
vnx.su
F9Q760,F9Q762/CHAUFO
X83
vnx.su
F4R720/CA,CACHFA
X83
vnx.su
F4R720/CHAUFO
X83
vnx.su
DG
X83
vnx.su
X83
vnx.su
F9Q760,F9Q762
ENGINE FUSE BOARD
X83
vnx.su
F4R720
ENGINE FUSE BOARD
X83
vnx.su
F9Q760,F9Q762
X83
vnx.su
PREEQUIPMENT ALARM
X83
vnx.su
E83,F83
ACCESSORIES SOCKET
X83
vnx.su
J83/EMPT10
ACCESSORIES SOCKET
X83
vnx.su
DIAGNOSTICS SOCKET
X83
vnx.su
DD/PRETEL/RETROE/SSNAV/RAD08
X83
vnx.su
DG/PRETEL/RETROE/SSNAV/RAD10
X83
vnx.su
DG/PRETEL/RETROR/SSNAV/RAD10
RADIO AND TELEPHONE PREEQUIPMENT
X83
vnx.su
F9Q760,F9Q762
X83
vnx.su
X83
vnx.su
F4R720/CA,CACHFA
X83
vnx.su
F4R720/CHAUFO
X83
vnx.su
F9Q760,F9Q762/CHAUFO
X83
INDEX OF FUNCTIONS
FUNCTIONS
PLATE NUMBERS
ACCESSORIES SOCKET
0091 - 0092
ADDITIONAL HEATING
0023
AIR BAG
0013 - 0014
AIR CONDITIONING
0034 - 0035
ALARM
0015
ANTI-LOCK BRAKING SYSTEM
0018
BASIC HEATING
0024 - 0025
0112
BRAKE LIGHTS
0068 - 0069 - 0074
0026 - 0027
CIGARETTE LIGHTER
0016
COURTESY LIGHTING
0042 - 0043 - 0044 - 0045 - 0046 - 0047
DIAGNOSTICS SOCKET
0093
0097
0089
0064 - 0065 - 0066 - 0067
0070 - 0071 - 0072 - 0073
DOOR LOCKING
0028 - 0029 - 0030 - 0031 - 0032 - 0033
EARTH
0001 - 0002 - 0003 - 0004 - 0005 - 0006 - 0007 0008 - 0009 - 0010
ELECTRIC REAR-VIEW MIRRORS
0102
0081 - 0082 - 0083 - 0084
0098 - 0099 - 0100 - 0101
ENGINE FUSE BOARD
0087 - 0088
0077 - 0078 - 0079 - 0080
0053 - 0054 - 0055 - 0056 - 0057
0050 - 0051 - 0052
0085
0049
0075
0036
HEATED SEATS
0103
HORN
0021
IMMOBILISER
0017
INSTRUMENT PANEL
0108 - 0109
NAVIGATION
0011 - 0012
OIL LEVEL INDICATOR
0076
0110 - 0111
0086
PASSENGER COMPARTMENT INTER-CONNECTION UNIT
0022
PRE-EQUIPMENT ALARM
0090
0094 - 0095
RADIO AND TELEPHONE PRE-EQUIPMENT
0096
REAR WINDOW DE-ICING
0037 - 0038 - 0039
REAR-VIEW MIRROR DEMISTING
0041
REVERSING LIGHTS
0059 - 0060 - 0061 - 0062 - 0063
SIDE LIGHTS
0058
0048
THERMOPLUNGERS
0113
1-1
vnx.su
INDEX OF FUNCTIONS
FUNCTIONS
PLATE NUMBERS
TOWBAR ATTACHMENT
0019 - 0020
0104 - 0105 - 0106 - 0107
WINDSCREEN DE-ICING
0040
1-2
vnx.su

VNX - Su Primastrar PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

VNX - Su Primastrar PDF

Uploaded by

Copyright:

vnx.

Edition: September 2002

QUICK REFERENCE INDEX

ENGINE LUBRICATION &

MODEL X83 SERIES

ENGINE CONTROL SYSTEM

FRONT & REAR AXLE

FRONT & REAR SUSPENSION

BODY & TRIM

HEATER & AIR CONDITIONER

STARTING & CHARGING SYSTEMS

NISSAN EUROPE N.V.

IMPORTANT SAFETY NOTICE

NISSAN EUROPE N.V.

All dimensions are expressed in millimetres (mm) unless stated otherwise.

Tightening torques are shown in decaNewton metres (daNm).

Pressures are expressed in bar (reminder: 1 bar = 100 000 Pa).

Electrical resistance is given in ohms ().

Voltages are expressed in volts (V).

EQUIPMENT AND TOOLING

: Body type (van)

maximum weight under full load

maximum permitted gross train weight

maximum load on front axle

maximum load on rear axle

exterior colour code

interior colour code

WORKS PRODUCTION INFORMATION

limited series specification supplement

special series specification supplement

paintwork and body colour grade

vehicle interior colour scheme

SIGNIFICANCE OF THE IDENTIFICATION NUMBER

See description below

SIGNIFICANCE OF THE TECHNICAL SPECIFICATIONS

2 - REMOVING AND REFITTING HEAVY

Various cases have to be considered:

For your safety, take care to ensure that the vehicle is

If this is not possible, place the lifting pads on the jack

This is because removing heavy components (such as

FITTING THE SAFETY STRAPS

Securing the vehicle with straps allows work to be

Straps are available under Part no.: 77 11 172 554.

Check the strap before each use.

This type of strap should only be used to immobilise a

REAR (vehicle with towing equipment)

REAR (vehicle without towing equipment)

MOLYKOTE "33 Medium"

MOBIL CVJ 825 Black star or MOBIL EXF57C

HARDENER KIT (RHODORSEAL 5661)

AUTO blue seal

0.5 litre bottle of DOT 4

AUTO grey seal

LUBRICANT CLEANING AGENTS

Super-concentrated unseizing agent

"DECAPJOINT" (FRAMET) for cleaning the gasket

VALUES AND 107

After an oil change, check using the

After replacing the oil filter

* Check with dipstick

Brake fluids must be approved by the Technical Department.

Power assisted steering

VALUES AND SETTINGS

VALUES AND SETTINGS

PROCEDURE FOR TIGHTENING THE CYLINDER HEAD