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STARTING - CHARGING
Alternator
16
- the alternator drive belt, together with bolt (3)
and shaft (4), removing through opening (5),
REMOVAL
With the vehicle on a 2 post lift, disconnect:
- the battery,
- the alternator electrical connections.
Remove:
- the power assisted steering belt by slackening
the three bolts (1) and the nuts (2) for the ten-
sioner, E 7 J and
K 7 M engines
SPECIAL TOOLING REQUIRED
Mot. 1273 Tool for testing belt tension
T. Av. 476 Ball joint extractor
Upper shock absorber mounting bolt 3
Track rod end nut 3.5
Wheel bolts 9
TIGHTENING TORQUES (in daN.m)
98747R198745R2
- the front right hand wheel,
- the track rod end (6) using tool T. Av. 476,
98712R
16-3
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Alternator
16
- the two upper shock absorber mounting bolts
(7).
98709R1
Press downwards on the front axle assembly to
make removing the alternator easier through the
front right hand wheel arch.
REMOVAL
Refitting is the reverse of removal.
Special notes:
- do not refit the old drive belt, renew it,
- refer to section 07 for tension values. E 7 J and
K 7 M engines
16-4
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Alternator
16
REMOVAL
(there are no special notes for engines fitted with
power assisted steering)
To release the alternator shaft the following must
be removed:
- the mounting bolts (1) for the coils,
- the two bolts (2) from the coil mounting.
Slacken bolt (3) then slide the mounting down.
98899R1
REFITTING
Refitting is the reverse of removal. F 3 R engine
16-5
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Alternator
16
REMOVAL
Disconnect:
- the battery,
- the alternator electrical connections.
Remove the mounting bolt for the diesel fuel pipe
retaining bracket and move it to one side.
98837R
Slacken bolt (A) then bolt (B), to just past the
shoulder, while holding the automatic tensioner
plate with a 9 mm wrench (Eg. : FACOM J 151 rat-
chet), then slacken the belt by moving the ratchet
in the direction of the arrow. F 8 Q engine
with AC
98837-1R
Remove:
- the lower timing cover,
- the belt,
- the alternator mounting bolts,
- the alternator.
REFITTING(Special note)
Refitting is the reverse of removal.
The belt is tensioned by moving the automatic
tensioner plate against the stop at bolt (B), wi-
thout forcing it, using a 9 mm wrench (Eg. :
FACOM J 151 ratchet ).
98837-1R1
NOTE : do not refit a belt once it has been remo-
ved.
16-6
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Alternator
16
OPTIMA 5800 diagnostic station
CHECKING THE CHARGING CIRCUIT USING THE DIAGNOSTIC STATION
The OPTIMA 5800 diagnostic station is used to test the alternator by measuring the voltage and current flow,
with and without electrical consumers.
NOTE : the ampermetric clamp on the station is of the inductive type (measuring range : 0 to 1000 A). It may
be positioned without disconnecting the battery, whichallows computers to retain their memory and set-
tings.
Depending on the engine, the ampermetric clamp may be positioned in different locations (the diagnostic
station will detect incorrect positioning) :
- F3R, F8Q engines : directly at the alternator output, the arrow on the clamp pointing towards the alterna-
tor.
- E7J, K7M engines : on the cable connecting the positive battery terminal to the alternator (this cable
crosses the battery compartment partition).
Measurements are made in three stages:
- measurement of battery voltage, ignition off,
- measurement with no consumers of the regulated voltage and current flow,
- measurement with the maximum number of consumers of the regulated voltage and current flow.
At the end of the test, the values noted will form the basis of a diagnostic report message:
- 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 = > check the alternator flow with reference to its specifications:
Engine E7J K7M F3R F8Q
Without air conditioning 75 (45) 75 (50) 75 (50) 75 (50)
With air conditioning / 110 (80) 110 (80) 110 (80)
Notes for the table: - Current values in Amps.
- The value in brackets corresponds to the minimum flow which should be
supplied by the alternator when all consumers are connected.
FAULT FINDING
SPECIAL TOOLING REQUIRED
16-7
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Alternator
16
If the measured flow is too low, check:
- if the alternator is worn (brushes....),
- the battery connections,
- the engine earth strap,
- the conformity of the alternator,
- the belt tension.
If the flow measured is correct and the regulated voltage is too low, the alternator is not at fault.
The fault is caused by :
- the vehicle having too many consumers or,
- the battery being discharged.
FAULT FINDING (cont)
16-8
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Starter motor
16
VEHICLE ENGINE STARTER
BA0E
E7JVALÉO D 6 R A 133
MITSUBICHI M 002 T 48381
BA0F - BA0L
K7MVALÉO D 6 R A 133
BA0G
F3RVALÉO D 6 R A 133
BOSCH 0001107047
BA0G - BA0AF8QBOSCH 000 1110114BOSCH B 001115006
REMOVAL
There are no special notes for removing and refit-
ting the starter.
Check the centring dowel (B) is present, which
should be located in the position shown on the ta-
ble.
86070R1
Engine Location of dowel
E 7 J / K 7 M Y
F 3 R
F 8 QZ
16-9
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Starter motor
16
OPTIMA 5800 diagnostic station
CHECKING THE STARTER USING THE DIAGNOSTIC STATION
The starter may be tested using the OPTIMA 5800 diagnostic station, by measuring the battery voltage and
the current used during the starting phase. The following operating faults may be detected:
- battery fault (voltage drops when the starter is activated),
- starter jammed (the current used is too high),
- starter fault (the current used is too low).
To carry out the test the vehicle must be prevented from starting:
- E7J, K7M engines : disconnect the engine speed sensor (on the clutch bellhousing),
- F3R engines : disconnect the engine speed sensor (on the gearbox),
- F8Q engines : disconnect the fuel shut off on the pump and insulate the terminal.
NOTE :
- an open circuit on the engine speed sensor or the ignition creates a fault which is memorised in the injec-
tion computer. Erase this fault using the XR25 (see injection section),
- if the vehicle is fitted with an immobiliser, just lock the doors using the PLIP.
FAULT FINDING
SPECIAL TOOLING REQUIRED
16-10