Page 251 of 2492

INJECTION
Computer configuration as a function of the gearbox type17
F3R engine
To check that storing has been correctly carried out, turn the ignition on using fault finding fiche n° 27, bar-
graph 20 LH side should be extinguished, bargraph 19 RH or LH side should be illuminated.
There is a method for configuring the computer which does not require the use of the XR25. To do this:
- turn the ignition on,
- start the engine,
- accelerate the engine to a speed greater than 2500 rpmfor 10 seconds,
- turn the ignition off,
- turn the ignition on again and start the engine,
- accelerate the engine to a speed greater than 2500 rpm for 10 seconds,
- turn the ignition off.
The memorisation procedure is the same as that described previously.
NOTE : the configuration procedure using the XR25 may be used to reconfigure an incorrectly configured
computer (automatic transmission instead of manual gearbox). The procedure which does not use the XR25
will however only work for an unconfigured blank injection computer from stock.
17-27
Page 276 of 2492
COOLING
Filling - bleeding
19
There is no water control valve.
Coolant circulates continuously in the heater
matrix, assisting with engine cooling.
FILLING
The following bleed screws must be opened:
- on the top of the radiator,
- on the heating hose,
- on the thermostat mounting(except E7J- K7M
engines ).
Fill the circuit at the expansion bottle opening.
Close the bleed screws as soon as fluid runs out in
a continuous jet.
Start the engine (2 500 rpm).
Adjust the level by overflow for approximately
4 minutes.
Close the expansion bottle.
BLEEDING
Let the engine run for 20 minutes at
2 500 rpm,until the engine cooling fan operates
(time required for automatic degassing).
Check the fluid level is close to the "Maximum"
mark.
NEVER OPEN THE BLEED SCREWS WHEN THE
ENGINE IS RUNNING.
TIGHTEN THE EXPANSION BOTTLE CAP WHEN THE
ENGINE IS WARM.
19-2
Page 277 of 2492

COOLING
Checking
2 - Checking the rating of the expansion bottle
cap
If fluid passes through the expansion bottle cap
valve, the cap must be replaced.
On the pump M.S. 554-07 fit tool M.S. 554-06 and
fit this to the valve to be checked.
Increase the pressure which should stabilise at the
calibration value for the cap valve, with a test to-
lerance of
± 0.1 bar.
Valve rating value:
19
1 - Checking the cooling circuit sealing
Replace the expansion bottle cap with tool
M.S.
554-01.
To this, connect tool M.S. 554-07.
Let the engine warm up then turn the ignition off.
Pump to put the circuit under pressure.
Stop pumping at 0.1 bar less than the rating value
of the expansion bottle cap.
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 cap fit-
ted with a new seal.
SPECIAL TOOLING REQUIRED
M.S.554-07 Kit for checking cooling circuit sealing
M.S.554-01 Adaptor for M.S. 554-05
M.S.554-06 Adaptor for M.S. 554-05
97871R
Engine Valve colour Rating (in bar)
F8Q - E7JBrown 1.2
K7M - F3RBlue 1.6
19-3
Page 288 of 2492

EXHAUST
General
19
POSITIONING THE AFTER SALES SLEEVE
95478R1
Once a clip has been fitted once, do not re-use it.
To avoid any leaks from the exhaust, it is impor-
tant to position the sleeve over the two exhaust
pipes correctly. This means that the pipe should fit
against the lugs inside the sleeve.
Begin by positioning the sleeve on the old section
of the exhaust pipe then adjust the diameter of
the clip by tightening it gently.
Check the positioning of the pipe on the lugs.
Fit the new replaced part.
Before fitting the sleeve on the pipe, mastic may
be applied to the inner ring of the sleeve to pre-
vent a leak.
(Exhaust mastic Part Number : 77 01 421 161
SODICAM).
IMPORTANT :
the bolt and nut assembly on the
sleeve must be aligned vertically to avoid any risk
of contact with the body.The nut on the clip has a groove (A) to ensure the
clip is tightened to the correct torque. When tigh-
tening, when this groove is no longer visible, it
clicks and the nut is then tightened correctly (2.5
daN.m).
NOTE:
there are 2 sleeves of different diameters :
- 50 mm diameter : F3R- K7M - E7J engines
- 45 mm diameter : F8Q engine
IMPORTANT:
- check there is no contact between the exhaust
pipe and the body,
- check the exhaust pipe heat shields are in good
condition and are all present.
99227S
19-14
Page 289 of 2492

EXHAUST
Catalytic converter
19
NOISE FROM THE EXHAUST PIPE
The vehicle should be tested in order to localise
the source of the noise (if necessary with the cu-
stomer present). The fault should then be repro-
duced when the vehicle is stationary, if possible.
To do this, accelerate sharply in order to cover a
wide range of engine resonance.
Having reproduced the noise:
- ensure there is no contact between the
exhaust pipe and the vehicle body,
- check the alignment, conformity and
condition of the exhaust system,
- attempt to eliminate the noise noted by
tightening the exhaust pipe or the heat
shields at fault.
If the noise is found to be caused by the catalytic
converter, remove it and carry out the following
checks:
- visual examination of the inside of the shell
(melted monolyth).
- listen to the catalytic converter after shaking
it (split monolyth or foreign body present).
If the monolyth has melted, the cause must be
determined (see chapter 14: checks to be made
before the anti-pollution test) and check that
catalytic particles have not blocked the exhaust
system further down the pipe.
Only if one of the observations specified above is
noted should the catalytic converter be replaced.
19-15
Page 299 of 2492
FUEL TANK
Gauge
19
For petrol engines, the pump and gauge sender
unit are an inseparable assembly.
For diesel engines, there is no pump submerged in
the fuel tank, there is only a gauge sender unit.
For removing the gauge sender unit refer to the
section FUEL TANK "Pump - sender unit".
Checking the gauge sender unit
Ensure the resistance varies by moving the float.
DisplayValue between terminals
A1 and B1 (in Ω)
4/4 7 maximum
3/4 54.5 ± 7
1/2 98 ± 10
1/4 155 ± 16
Minimum 300 ± 20
Display Height H (in mm)
4/4 48
3/4 90
1/2 133
1/4 147
Minimum 190
Measuring the height H
With the gauge sender unit removed, place it on a
flat surface.
H is the height measured between the float pin
and the working surface.
NOTE : these value are given for information only.
19-25
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 316 of 2492
CLUTCH
Fault finding
The gearbox clunks.
Clutch pedal fully pressed down :
- vehicle stationary,
- engine running.
INCORRECTCORRECT
Check the automatic
adjustment system
INCORRECT INCORRECT CORRECT
Replace the clutch fork or
check that it is correctly
positioned
CORRECT
Replace the faulty
parts
Replace the faulty
parts
Toothed sector
jammed or spring
broken
INCORRECT
CORRECTINCORRECT
Clutch stuck
Free the clutch
Rare case, may occur
after the vehicle has been
stopped for a long time
(several months)
Replace the faulty parts
Clutch operation
Check the condition
of the pedal
CORRECT
20
(1)Grommet placed on the end of the clutch cable on
the gearbox end
Check the condition of
the cable and the anti-
noise rubber washer
(1)
20-6