Page 176 of 2492

DIESEL EQUIPMENT
Pre-post-heating unit
13
DIAGRAM KEY
104Ignition switch
163Starter
171Air conditioning clutch
206Air conditioning trifunction pressure switch
247Instrument panel
251Bi-function coolant temperature switch
257Pre-heating unit
398EGR solenoid valve
412Fast idle solenoid valve (AC version)
597Engine fuse box
642AC / pre-heating separation diode
645Passenger compartment fuse box
680Pre-heating unit n° 1
681Pre-heating unit n° 2
682Pre-heating unit n° 3
683Pre-heating unit n° 4
711Diesel fuel pump
741Altimetric capsule
743Altimetric relay
777Power feed for fuse boxConnector (A)
+ Bat+ before ignition feed
Connector (B)
1Feed to heater plugs 1 and 3
2Feed to heater plugs 2 and 4
Connector (C)
A1 / S2Load dependence solenoid valve
control
A2 / PCLoad lever microswitch information
A3 / CTNCTN type sensor coolant temperature
information
B1/+APC+ after ignition feed
B2 / DEMStarter information
B3 / TemPre-heating warning light control (via
earth)
C1 / S1Not used
C2 / -Bat Earth
C3 / ClimFast idle solenoid valve control during
post-heating phase
92206-2R
IDENTIFICATION OF CONNECTORS
13-30
Page 227 of 2492
IGNITION
Static ignition
17
99365R
K7M engine
Electrical connector
Track Allocation
1+anti-interference
condenser
2 +after ignition
3 coil control via computer
Connector
Track number+-
123 Coil connector track identification
Inscription on connector
Test to be made
between tracksResistance
K7M engine F3R engine
1 - 2 0.5 Ω0.2 Ω
1 - 3 1 Ω1 Ω
2 - 3 1 Ω1 Ω
HT - HT10 kΩ8 kΩ
F3R - K7M
engines
DIAGRAM
PRJ99029
KEY TO COMPONENTS
120Injection computer
597Engine fuse box
663Dual output ignition coil for cylinders
1 and 4
664Dual output ignition coil for cylinders
2 and 3
679Anti-interference condenser, connected to
coil:
-664 for F3R engines
-663 for K7M engines (dotted line)
17-3
Page 249 of 2492

INJECTION
Engine immobiliser function
17
This vehicle is fitted with a 2nd generation engine immobiliser system.
REPLACING THE INJECTION COMPUTER
The computers are supplied uncoded but are capable of being programmed with a code.
When replacing the computer, the vehicle code must be programmed in and then check that the immobiliser
system is operational.
To do this, carry out the following operations:
•Vehicle fitted with a PLIP engine immobiliser system
- Lock and unlock the doors using the PLIP.
- Turn the ignition on for a few seconds.
- Lock the doors using the PLIP, the immobiliser function is operational.
•Vehicle fitted with a coded key engine immobiliser system
Turn the ignition on for a few seconds then turn it off again.
CHECKING THE IMMOBILISER FUNCTION
•Vehicle fitted with a PLIP engine immobiliser system
- Turn the ignition off, lock the doors from inside the vehicle using the PLIP. The red immobiliser
warning light should flash.
- Turn the ignition on, The red immobiliser warning light should flash twice as fast.
•Vehicle fitted with a coded key engine immobiliser system
Remove the key from the ignition switch, after 10 seconds the red immobiliser warning light should flash.
TESTING AN UNCODED INJECTION COMPUTER FROM STOCK OR FROM A VEHICLE NOT FITTED WITH AN
IMMOBILISER SYSTEM
To avoid coding the injection computer before the test, it is vital to cut the + 12 V before ignition feed to the
immobiliser system. Remove the passenger compartment connection unit fuse (F39) (for more details, refer
to section 82).
NOTE : if the injection computer has been coded by mistake, a method exists for decoding it (refer to section
82).
SPECIAL NOTES
Using the XR25 it is possible to see if the injection computer is coded. The computer is uncoded if bargraph 2
right hand side is illuminated and if *22 = 2 DEF
A CODED COMPUTER FITTED TO A VEHICLE WITH AN ENGINE IMMOBILISER MAY NOT BE USED FOR TESTING
ANOTHER VEHICLE, REGARDLESS OF WHETHER THIS VEHICLE HAS AN ENGINE IMMOBILISER OR NOT.
17-25
Page 263 of 2492

INJECTION
Operating wiring diagram
17
KEY TO OPERATIONAL WIRING DIAGRAMS (E7J, F3R, K7M)
COMPONENT NO DESCRIPTION
109
119
120
146
147
149
193 to 196
218
222
224
225
228
236
238
242
244
247
250
272
310
319
341
371
398
437
565
597
645
649
663
664
679
746
772
777
927
MF
MHOn board computer
Automatic transmission computer
Injection computer
Pinking sensor (located under the inlet manifold for E7J engine)
Absolute pressure sensor
TDC sensor
Injectors
Fuel pump
Throttle position potentiometer
Power assisted steering pressostat
Diagnostic socket
Idle speed regulation micromotor
Fuel pump relay (in engine fuse box)
Injection feed locking relay
Oxygen sensor
Coolant temperature sensor
Instrument panel
Vehicle speed sensor
Air temperature sensor
Ignition power module
Air conditioning control panel
Idle speed regulation solenoid valve
Fuel vapour recirculation solenoid valve
Exhaust gas recirculation solenoid valve (EGR)
Throttle body heater (under throttle body)
Throttle body assembly
Engine fuse box
Passenger compartment connection unit
Idle speed regulation stepping motor
Dual ignition coil n°1 (cylinders 1 and 4)
Dual ignition coil n° 2 (cylinders 2 and 3)
Radio anti-interference condenser
Cylinder reference sensor
Heater relay (in engine fuse box)
Power fuse board (near battery)
Inertia switch
Rear right hand electrical earth
Engine electrical earth (located on the cylinder block between the starter and the al-
ternator for the E7J engine)
17-39
Page 315 of 2492

CLUTCH
Fault finding
20
The clutch is slipping :
- when stopped, handbrake on, at 2000 to
3000 rpm, impossible to stall the engine
when letting the clutch in,
- with 4th or 5th gear engaged, the engine
seems to race.
Check the travel of
the fork (1)
INCORRECT
KEY
Fault found
Check
Operations to be
carried out
(*)Depending on version
(1)See "Removal - Refitting" chapter(2)Grommet placed on the end of the clutch
cable on the gearbox end Check the
clearance
INCORRECTCORRECT
CORRECTINCORRECT
CORRECT
Check the
condition of the
pins and support
points
INCORRECT
Replace the
faulty partsCheck the condition
of the pedal and the
assistance spring (*)
Replace the
faulty parts
Replace the
fork
OILYWORN
Check the condition
of the clutch
Replace the
clutchReplace the clutch and
repair the leak
INCORRECT
Repair the
automatic
adjustment
device
INCORRECTCORRECT
CORRECT
Check the
automatic
adjustment device
CORRECT
Check the condition
of the cable and the
anti-noise rubber
washer (2)
Check the
condition of the
fork
20-5
Page 331 of 2492
MANUAL GEARBOX
Diagnostic
21
Grinding noise when
engaging a gear
Remove the gearbox
Check the synchro and
the synchro spring of
the faulty gear
Clunking when each gear is
engaged
(after checking clutch)
Remove the gearbox
Check the synchros
and the synchro hubs
Impossible to engage gears
(after checking the clutch)
Check the
adjustment of
the selection
linkage
IncorrectCorrect
Condition
of the parts of
the linkage
CorrectIncorrect
Remove the gearbox
Check the gearbox
locking system
Replace the faulty
parts
Adjust the linkage
Adjust the linkage
Operations to be
carried out
KEY
Check
21-6
Page 334 of 2492
MANUAL GEARBOX
Gearbox (Removal - Refitting)
REMOVAL
- Put the vehicle on a two post lift.
- Disconnect the battery.
- Remove the front wheels.
- Remove the engine undertray.
- Drain the gearbox.
LEFT HAND SIDE OF THE VEHICLE:
Remove:
- the wheel arch (protection),
- the track rod end using tool T.Av. 476.
SPECIAL TOOLING REQUIRED
B.Vi. 31-01 Set of pins
T.Av. 476 Ball joint extractor
21
Bolts of the rear linkage of the suspended
engine mountings (tie-bar) 6
Bolts for securing battery mounting on body 2
Driveshaft gaiter mounting bolt 2.4
Gearbox mounting bolt 3.5
Gearbox control rod bolt 2.8
Shock absorber base bolt 17
Track rod end nut 3.5
Stub-axle key nut 6
Support mounting bolts 4.5
Wheel bolts 9
Caliper guide bolts 2.7
TIGHTENING TORQUES (in daN.m)
All engines
85965R
Remove:
- the two mounting bolts from the caliper by se-
curing the caliper to the suspension spring to
avoid stretching the pipe,
- the three mounting bolts of the driveshaft gai-
ter.
92122R2
21-9
Page 351 of 2492
MANUAL GEARBOX
Speedometer drive gear
REPLACEMENT
1st case :
Only the speedo gear or the pin is damaged.
REMOVAL
The gearbox does not have to be completely dis-
mantled.
Release the left hand driveshaft.
Remove the sunwheel spider.
Rotate the differential by hand so that the speedo
gear is accessible.
Unclip the pin by pulling it vertically using a pair
of long nose pliers.
Using these pliers, remove the gear from its hou-
sing.
REFITTING
Refit a new speedo gear using a pair of flat nose
pliers.
The gear and its pin should be refitted by hand.
The pin must be correctly positioned with respect
to the key lugs on the gear due to the elasticity of
the lips of the pin.
21
Ensure that it is correctly clipped in.
Refit the sunwheel spider.
2nd case :
The speedo gear and crown wheel are damaged
The gearbox has to be removed and the final drive
has to be dismantled.
88577S
86053S
Correct Incorrect
21-26