Espace III Service Repair Manual

SPECIFICATIONS
Engine - Clutch - Gearbox

01
SPECIFICATIONS
Engine - Clutch - Gearbox
01
SPECIFICATIONS
Vehicle identification
01
SPECIFICATIONS
01
LIFTING
Trolley jack
02
LIFTING
Axle stands
02
LIFTING
Underbody lifts
02
LIFTING
Underbody lifts
02
TOWING
All types
03
LUBRICANTS AND CONSUMABLES
Packaging
04
Packaging
04
Packaging
04
DRAINING AND FILLING
Engine
05
Engine
05
Engine
05
Gearbox
05
Automatic transmission
05
Automatic transmission
05
Power assisted steering
05
Braking circuit
05
Particle filter
05
TOOLING
Special tooling
06
VALUES AND SETTINGS
Dimensions
07
VALUES AND SETTINGS
Capacity - Grades
07
VALUES AND SETTINGS
Capacity - Grades
07
VALUES AND SETTINGS
Capacity - Grades
07
VALUES AND SETTINGS
Belt tension
07
VALUES AND SETTINGS
Belt tension
07
VALUES AND SETTINGS
Accessories belt tension
07
VALUES AND SETTINGS
F3R ENGINE Accessories belt tension
07
VALUES AND SETTINGS
F3R ENGINE Accessories belt tension
07
G8T TURBO VALUES AND SETTINGS
ENGINE Accessories belt tension
07
G8T TURBO VALUES AND SETTINGS
ENGINE Accessories belt tension
07
VALUES AND SETTINGS
Z7X ENGINE Accessories belt tension
07
VALUES AND SETTINGS
Z7X ENGINE Accessories belt tension
07
VALUES AND SETTINGS
Timing belt tension
07
VALUES AND SETTINGS
Timing belt tension
07
VALUES AND SETTINGS
Tightening the cylinder head
07
VALUES AND SETTINGS
07
VALUES AND SETTINGS
07
VALUES AND SETTINGS
Dimensions of the main braking components
07
VALUES AND SETTINGS
Values for checking the front axle geometry
07
VALUES AND SETTINGS
Values for checking the rear axle geometry
07
VALUES AND SETTINGS
Underbody heights
07
VALUES AND SETTINGS
Tyres, wheels and chains
07
VALUES AND SETTINGS
Brake limiter
07
ENGINE AND PERIPHERALS
Consumables
10
Identification
10
Oil pressure
10
Oil pressure
10
F ENGINE Removal - refitting : engine and transmission
10
10
10
10
10
10
10
10
10
Z ENGINE Removal - refitting : engine and transmission
10
Z7X ENGINE Removal - refitting : engine and transmission
10
10
10
10
10
10
10
10
10
10
10
G8T ENGINE Removal - refitting : engine and transmission
10
10
10
G ENGINE Removal - refitting : engine and transmission
10
10
10
10
10
10
10
10
F ENGINE Sump
10
TOP AND FRONT OF ENGINE
F ENGINE Accessories belt (removal - refitting)
11
F ENGINE Accessories belt (removal - refitting)
11
Z ENGINE Accessories belt (removal - refitting)
11
G ENGINE Accessories belt (removal - refitting)
11
11
11
G ENGINE Timing belt
11
11
11
11
11
11
11
11
11
F ENGINE Timing belt
11
11
11
G ENGINE Timing belt tension wheel
11
11
11
11
11
11
11
11
F ENGINE Accessories belt tension
11
Z - G ENGINES Accessories belt tension
11
G8T ENGINE Accessories belt tension
11
Z ENGINE Accessories belt tension
11
ALL TYPES Cylinder head gasket
11
F ENGINE Cylinder head gasket
11
G ENGINE Cylinder head gasket
11
Z7X ENGINE Cylinder head gasket
11
Z7X ENGINE Front cylinder head gasket
11
11
11
11
11
11
11
11
11
11
11
11
G8T ENGINE Oil filler
11
FUEL MIXTURE / TURBOCHARGING
F3R ENGINE General
12
F3R ENGINE General
12
Z7X ENGINE General
12
Z7X ENGINE General
12
F3R ENGINE Throttle body
12
F3R ENGINE Throttle body
12
Z7X ENGINE Throttle body
12
F3R ENGINE Manifolds
12
F3R ENGINE Manifolds
12
G8T ENGINE Manifolds
12
12
12
12
12
12
12
Z7X ENGINE Manifolds
12
12
12
12
12
12
12
12
G8T ENGINE Turbocharger: adjustments
12
12
12
G8T ENGINE Turbocharger: removal-refitting
12
G8T ENGINE Air-air exchanger
12
FUEL SUPPLY - PUMPS - PREHEATING
Air inlet
13
Air inlet
13
Air filter
13
Fuel injectors
13
F3R ENGINE Injector gallery
13
F3R ENGINE Injector gallery
13
Z7X ENGINE Injector gallery
13
ALL TYPES Fuel pump
13
ALL TYPES Fuel pump
13
ALL TYPES Fuel cut off in case of an impact
13
ALL TYPES Fuel filter
13
F3R ENGINE Fuel pressure
13
Z7X ENGINE Fuel pressure
13
Z7X ENGINE Fuel pressure
13
G8T ENGINE Specifications
13
G8T ENGINE Injection pump - presentation
13
G8T ENGINE Presentation
13
G8T ENGINE Tigthtening torques
13
G8T ENGINE Computer connectors
13
G8T ENGINE Location of components
13
G8T ENGINE Location of components
13
G8T ENGINE Adjusting idle speed
13
G8T ENGINE Adjusting idle speed
13
G8T ENGINE Load potentiometer
13
G8T ENGINE Injection pump: removal - refitting
13
13
13
13
G8T ENGINE Injection pump timing
13
G8T ENGINE Injection pump timing
13
G8T ENGINE Coded solenoid valve
13
G8T ENGINE Coded solenoid valve
13
G8T ENGINE Pre-postheating control
13
G8T ENGINE KSB cold start solenoid
13
G8T ENGINE ALFB load dependence control
13
G8T ENGINE Fast idle control
13
G8T ENGINE EGR control
13
G8T ENGINE Defect modes
13
G8T ENGINE Defect modes
13
G8T ENGINE Injectores holder
13
G8T ENGINE Diesel fuel filter
13
F ENGINE Mechanical power assisted steering pump
13
13
Z ENGINE Mechanical power assisted steering pump
13
G8T ENGINE Mechanical power assisted steering pump
13
13
Z ENGINE Mechanical power assisted steering pump
13
Mechanical power assisted steering pump
13
13
13
13
13
13
13
ANTIPOLLUTION
F3R ENGINE Oil vapour rebreathing
14
ANTIPOLLUTION
G8T ENGINE Oil vapour rebreathing
14
ANTIPOLLUTION
Z7X ENGINE Oil vapour rebreathing
14
ANTIPOLLUTION
F3R ENGINE Fuel vapour recirculation
14
ANTIPOLLUTION
Z7X ENGINE Fuel vapour recirculation
14
ALL TYPES ANTIPOLLUTION
PE T RO L Fuel vapour recirculation
14
14
14
14
14
14
PE T RO L Tesy for the presence of lead
14
STARTING - CHARGING
Alternator : specifications
16
STARTING - CHARGING
16
STARTING - CHARGING
16
STARTING - CHARGING
F ENGINE Alternator : removal - refitting
16
STARTING - CHARGING
Z ENGINE Alternator : removal - refitting
16
STARTING - CHARGING
Z ENGINE Alternator : removal - refitting
16
STARTING - CHARGING
G ENGINE Alternator : removal - refitting
16
STARTING - CHARGING
G ENGINE Alternator : removal - refitting
16
STARTING - CHARGING
F ENGINE Alternator : belt tension
16
STARTING - CHARGING
Z ENGINE Alternator : belt tension
16
STARTING - CHARGING
Z ENGINE Alternator : belt tension
16
STARTING - CHARGING
Starter : specifications
16
STARTING - CHARGING
F ENGINE Starter : removal - refitting
16
STARTING - CHARGING
Z ENGINE Starter : removal - refitting
16
STARTING - CHARGING
Z ENGINE Starter : removal - refitting
16
STARTING - CHARGING
G8T ENGINE Starter : removal - refitting
16
STARTING - CHARGING
G8T ENGINE Starter : removal - refitting
16
IGNITION - INJECTION
F ENGINE Static ignition
17
17
17
Z ENGINE Static ignition
17
Z ENGINE Static ignition
17
Z ENGINE Plugs: recommendations
17
F3R ENGINE General
17
F3R ENGINE Location of components
17
F3R ENGINE Location of components
17
F3R ENGINE Special notes for sequential injection
17
17
17
17
17
F3R - Z7X IGNITION - INJECTION
ENGINES Immobiliser function
17
F3R - Z7X IGNITION - INJECTION
ENGINES Injection / air conditioning programming
17
F3R ENGINE Idle speed correction
17
F3R ENGINE Idle speed RCO correction
17
F3R ENGINE Richness regulation
17
F3R ENGINE Richness regulation
17
F3R ENGINE Adaptive richness regulation
17
17
17
Power assisted steering pressostat
17
Z7X ENGINE General
17
Z7X ENGINE Injection fault warning light
17
Z7X ENGINE Coolant temperature sensor
17
Z7X ENGINE Pinking sensor
17
Z7X ENGINE Throttle position potentiometer
17
Z7X ENGINE Idle speed regulation valve
17
Idle speed regulation valve
17
Oxygen sensor
17
Z7X ENGINE TDC sensor
17
COOLING - ENGINE MOUNTING - EXHAUST-FUEL THANK
Specifications
19
Precautions
19
Filling and bleeding
19
Testing
19
F3R ENGINE Diagram
19
Z7X ENGINE Diagram
19
G8T ENGINE Diagram
19
F3R ENGINE Cooling assembly
19
19
19
Z7X - G8T COOLING - ENGINE MOUNTING - EXHAUST-FUEL THANK
ENGINES Cooling assembly
19
F - G ENGINES Water pump
19
Z7X ENGINE Water pump
19
ALL TYPES Heater matrix clipped unions
19
ALL TYPES Heater matrix clipped unions
19
ALL TYPES Suspended engine mountings
19
ALL TYPES Suspended engine mountings
19
F ENGINE Suspended engine mountings
19
Z ENGINE Suspended engine mountings
19
G ENGINE Suspended engine mountings
19
ALL TYPES General
19
ALL TYPES General
19
ALL TYPES Expansion box and catalytic converter
19
Expansion box and catalytic converter
19
Expansion box and silencer
19
Expansion box and silencer
19
Main fuel tank: removal - refitting
19
Main fuel tank: removal - refitting
19
General
19
Filler neck
19
Filler neck
19
CLUTCH
Identification
20
CLUTCH
General
20
CLUTCH
General
20
CLUTCH
Consumables
20
CLUTCH
F ENGINE Mechanism - Disc
20
CLUTCH
F ENGINE Mechanism - Disc
20
CLUTCH
G ENGINE Mechanism - Disc
20
CLUTCH
G ENGINE Mechanism - Disc
20
CLUTCH
F ENGINE Thrust pad - Fork
20
CLUTCH
G ENGINE Flywheel
20
MANUAL GEARBOX
F ENGINE Identification
21
G8T MANUAL GEARBOX
TURBO ENGINE Identification
21
MANUAL GEARBOX
ALL TYPES Ratios
21
MANUAL GEARBOX
ALL TYPES Lubricants
21
MANUAL GEARBOX
Special notes
21
MANUAL GEARBOX
Consumables / Parts to be systematically replaced
21
MANUAL GEARBOX
F ENGINE Removal - Refitting
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
G ENGINE Removal - Refitting
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
F ENGINE 5th gear linkage on the vehicle
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
21
MANUAL GEARBOX
F ENGINE Clutch shaft lip seal (guide tube)
21
MANUAL GEARBOX
F ENGINE Clutch shaft lip seal (guide tube)
21
MANUAL GEARBOX
F ENGINE Speedometer drive
21
MANUAL GEARBOX
F ENGINE Differential output seal
21
MANUAL GEARBOX
F ENGINE Differential output seal
21
AUTOMATIC TRANSMISSION
Use / Identification
23
Identification of computer
23
Gear ratios / Gear change thresholds
23
Consumables / Parts to be systematically replaced / Oil
23
Oil change frquency
23
Draining - Filling - Levels
23
Draining - Filling - Levels
23
Service warning light
23
Oil cooler
23
Replacing the strainer
23
Hydraulic distributor
23
23
23
23
Removal - Refitting
23
Removal - Refitting
23
Removal - Refitting
23
Computer / Throttle potentiometer
23
Oil pressure sensor
23
Multifunction switch
23
Speed sensor / Solenoid valves
23
Engine torque reduction / Kickdown switch
23
Injection computer / Automatic transmission computer connection / Fault finding
23
Wiring
23
Full load/no load validation
23
Accelerator control compensator
23
23
23
23
DRIVESHAFTS
General
29
DRIVESHAFTS
Consumables
29
DRIVESHAFTS
Front transverse driveshafts
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
29
DRIVESHAFTS
Gaiter at wheel end
29
DRIVESHAFTS
Gaiter at wheel end
29
DRIVESHAFTS
Gaiter at wheel end
29
DRIVESHAFTS
Gaiter at wheel end
29
RC 491 DRIVESHAFTS
JOINT Gaiter at gearbox end
29
RC 491 DRIVESHAFTS
29
RC 491 DRIVESHAFTS
29
RC 491 DRIVESHAFTS
29
RC 490 DRIVESHAFTS
29
RC 490 DRIVESHAFTS
29
RC 490 DRIVESHAFTS
29
RC 490 DRIVESHAFTS
29
DRIVESHAFTS
Gaiter bearing
29
DRIVESHAFTS
Gaiter bearing
29
DRIVESHAFTS
Gaiter bearing
29
GENERAL
General diagram of braking circuits
30
FRONT GENERAL
AXLE Tightening torques (in daN.m)
30
FRONT GENERAL
30
REAR GENERAL
30
REAR GENERAL
30
REAR GENERAL
30
GENERAL
Measuring points
30
GENERAL
Underbody heights / Consumables
30
GENERAL
Parts to be renewed when they are removed / Brake fluid
30
GENERAL
Brake unions and pipes
30
GENERAL
Influence of angles
30
GENERAL
Influence of angles
30
GENERAL
Cheking - adjusting the front axle assembly
30
GENERAL
Fault finding for the front axle assembly
30
GENERAL
Fault finding for braking
30
GENERAL
30
GENERAL
30
GENERAL
Bleeding the brake circuit
30
GENERAL
Bleeding the brake circuit
30
FRONT AXLE
Lower wishbone
31
FRONT AXLE
Lower wishbone
31
FRONT AXLE
Lower wishbone
31
FRONT AXLE
Lower wishbone rubber bushes
31
FRONT AXLE
Lower wishbone rubber bushes
31
FRONT AXLE
Lower wishbone ball joint
31
FRONT AXLE
31
FRONT AXLE
31
FRONT AXLE
Brake pads
31
FRONT AXLE
Brake pads
31
FRONT AXLE
Front brake calipers
31
FRONT AXLE
Front brake calipers
31
FRONT AXLE
Brake discs
31
FRONT AXLE
Stub axle carrier bearing
31
FRONT AXLE
31
FRONT AXLE
31
FRONT AXLE
31
FRONT AXLE
Stub axle carrier
31
FRONT AXLE
Spring and shock absorber assembly
31
FRONT AXLE
Spring and shock absorber assembly
31
WITH SPRING FRONT AXLE
COMPRESSOR Spring and shock absorber
31
WITH SPRING FRONT AXLE
COMPRESSOR Spring and shock absorber
31
FRONT AXLE
Anti-roll bar
31
FRONT AXLE
Anti-roll bar
31
FRONT AXLE
Anti-roll bar
31
FRONT AXLE
Front sub-frame
31
FRONT AXLE
Front sub-frame
31
FRONT AXLE
Front sub-frame
31
FRONT AXLE
Front sub-frame
31
FRONT AXLE
Front sub-frame
31
REAR AXLE
Tightening torques (in daN.m)
33
REAR AXLE
Tightening torques (in daN.m)
33
REAR AXLE
Rear axle assembly
33
REAR AXLE
Rear axle assembly
33
REAR AXLE
Rear axle assembly - Self-leveling
33
REAR AXLE
Rear axle assembly - Self-leveling
33
REAR AXLE
Brake drum
33
REAR AXLE
Brake drum
33
REAR AXLE
Brake cylinder
33
REAR AXLE
GIRLING Brake linings (drum)
33
REAR AXLE
33
REAR AXLE
33
REAR AXLE
33
REAR AXLE
BREMBO Brake pads (disc)
33
REAR AXLE
33
REAR AXLE
33
REAR AXLE
BREMBO Rear brake calipers
33
REAR AXLE
Brake disc
33
REAR AXLE
Bearing - Hub
33
REAR AXLE
Stub axle (drum)
33
REAR AXLE
Stub axle (disc)
33
REAR AXLE
Shock absorber
33
REAR AXLE
Spring - except self-leveling
33
REAR AXLE
Pneumatic spring
33
REAR AXLE
Transverse link / Guide bar rubber mounting
33
REAR AXLE
Suspension arm rubber mounting
33
WHEELS AND TYRES
Specifications
35
WHEELS AND TYRES
Specifications
35
WHEELS AND TYRES
Specifications / Chains
35
WHEELS AND TYRES
Wheel balancing
35
WHEELS AND TYRES
Emergency spare wheel winch
35
STEERING ASSEMBLY
Exploded view
36
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Axial ball joint
36
STEERING ASSEMBLY
Power assisted steering unit
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
Identification of steering ball joints
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering column
36
STEERING ASSEMBLY
Steering wheel - rotary switch
36
STEERING ASSEMBLY
36
STEERING ASSEMBLY
36
MECHANICAL ELEMENT CONTROLS
Master cylinder
37
Master cylinder
37
Brake servo
37
Brake servo
37
Brake servo
37
Brake servo
37
Brake servo
37
Brake servo
37
Air filter - Brake servo non-return valve
37
Handbrake control lever
37
Handbrake control (adjustment)
37
Handbrake control (adjustment)
37
Brake pipes
37
Braking compensator
37
Braking compensator
37
Clutch control cable
37
G ENGINE Hydraulic clutch control
37
37
37
37
Clutch pedal - pedal assembly / Pedal mounting
37
Clutch pedal - pedal assembly / Pedal mounting
37
F ENGINE External gear control - Linkage F3R
37
37
37
37
37
37
37
G ENGINE External gear control - Cable G8T
37
37
37
ELECTRONICALLY CONTROLLED HYDRAULIC SYSTEMS
Self levelling suspension
38
38
38
38
38
38
38
38
38
38
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
Bosch ABS
38
GENERAL
Dimensions and engines
40
GENERAL
40
GENERAL
Trolley jack - Axle stands
40
GENERAL
Trolley jack - Axle stands
40
GENERAL
Underbody lift
40
GENERAL
Underbody lift
40
GENERAL
Towing
40
GENERAL
Description of parts (plastic)
40
GENERAL
Description of parts (metal)
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
Opening clearances (flush futting)
40
GENERAL
40
GENERAL
40
GENERAL
40
GENERAL
Key to symbols
40
GENERAL
Key to symbols
40
GENERAL
Key to symbols
40
GENERAL
Key to symbols
40
GENERAL
Key to symbols
40
GENERAL
Operations for replacing a welded compenent
40
GENERAL
General repair instructions
40
GENERAL
40
GENERAL
40
GENERAL
Setting up welding equipment
40
GENERAL
Setting up welding equipment
40
GENERAL
Bonding panels and trim
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Plastic repairs
40
GENERAL
Recommended bodywork produkts
40
GENERAL
Collision Diagnosis
40
GENERAL
Collision Diagnosis
40
GENERAL
Collision Diagnosis
40
GENERAL
Sub-frame dimensions
40
GENERAL
Sub-frame dimensions
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Repair bench
40
GENERAL
Special tooling
40
LOWER STRUCTURE
Front end cross member (reinforcement) (A)
41
LOWER STRUCTURE
Front end cross member (reinforcement) (A)
41
LOWER STRUCTURE
Radiator cross member mounting (B)
41
LOWER STRUCTURE
Side member closure panel, front section (C)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Front end side cross member (D)
41
LOWER STRUCTURE
Front end side cross member (D)
41
LOWER STRUCTURE
Front side member, front part section (E)
41
LOWER STRUCTURE
Front side member, front part section (E)
41
LOWER STRUCTURE
Front side member extension (F)
41
LOWER STRUCTURE
Front side member extension (F)
41
LOWER STRUCTURE
Battery tray (G)
41
LOWER STRUCTURE
Battery tray (G)
41
LOWER STRUCTURE
Battery tray (G)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front half unit (H)
41
LOWER STRUCTURE
Front jacking point mounting cross member (I)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear lower cross member (J)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear bumper cross member (K)
41
LOWER STRUCTURE
Side floor, part section (L)
41
LOWER STRUCTURE
Rear side member (M)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Securing clevice (N)
41
LOWER STRUCTURE
Securing clevice (N)
41
LOWER STRUCTURE
Towing ring (O)
41
LOWER STRUCTURE
Towing ring (O)
41
LOWER STRUCTURE
Guide bar clevice (P)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Front cross member - 2nd row seats (Q)
41
LOWER STRUCTURE
Front cross member - 2nd row seats (Q)
41
LOWER STRUCTURE
Rear cross member - 2nd row seats (R)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Cross member - 3rd row seats (S)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear axle cross member, part section (T)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Valance reinforcement (U)
41
LOWER STRUCTURE
Valance reinforcement (U)
41
LOWER STRUCTURE
Valance, front and rear sections (V)
41
LOWER STRUCTURE
Valance, front and rear sections (V)
41
LOWER STRUCTURE
Complete rear side member (W)
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
41
LOWER STRUCTURE
Rear floor, part section (X)
41
UPPER FRONT STRUCTURE
Wing (A)
42
Wing (A)
42
Wing (A)
42
Wing (A)
42
Wing (A)
42
Air - water separator unit (B)
42
Scuttle panel grille (C)
42
Headlight carrier panel assembly (D)
42
42
42
42
42
Cowl side panel, part section (bumper mounting) (E)
42
42
42
Wheel arch (schock absorber cup) (F)
42
42
42
42
42
42
Gearbox mounting (G)
42
42
42
Lower stretcher (H)
42
Lower stretcher (H)
42
Lower stretcher (H)
42
Bulkhead, part section (I)
42
42
42
42
42
Windscreen aperture lower cross member and upper engine compartment panel (J)
42
42
42
UPPER SIDE STRUCTURE
Front pillar (A)
43
Front pillar (A)
43
Front pillar (A)
43
Front pillar (A)
43
Centre pillar with lining (B)
43
43
43
43
Centre pillar trim (C)
43
Sill panel (D)
43
Sill panel (D)
43
Sill panel (D)
43
Sill panel (D)
43
Sill panel (D)
43
Sill panel (D)
43
UPPER REAR STRUCTURE
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing panel (A)
44
Wing corner (B)
44
Rear pillar (B)
44
Rear pillar (B)
44
Rear pillar (B)
44
Rear wheel arch with inertia reel (C)
44
44
44
44
44
44
Rear end pillar (D)
44
Rear end pillar (D)
44
Rear end pillar (D)
44
Rear end pillar (D)
44
Bumper mounting side support (E)
44
Bumper mounting side support (E)
44
Rear quarter panel lining (F)
44
44
44
TOP OF BODY
Top of body (A)
45
TOP OF BODY
Top of body (A)
45
TOP OF BODY
Top of body (A)
45
TOP OF BODY
Top of body (A)
45
TOP OF BODY
Top of body (A)
45
TOP OF BODY
Roof (B)
45
TOP OF BODY
Roof (B)
45
TOP OF BODY
Roof (B)
45
SIDE OPENING ELEMENTS
Door panel (eg : front door)
47
47
47
47
Door panel (eg : raer door)
47
Complete door
47
Complete door
47
Complete door
47
NON-SIDE OPENING ELEMENTS
Bonnet
48
Bonnet
48
Tailgate
48
Tailgate
48
Tailgate
48
HEATING
General
61
HEATING
Heating / distribution unit
61
HEATING
Operating principle
61
HEATING
Operating principle
61
HEATING
Operating principle
61
HEATING
Stepping motor
61
HEATING
Stepping motor
61
HEATING
Fan motor control
61
HEATING
distribution units
61
HEATING
Heater matrices
61
HEATING
Particle filter
61
AIR CONDITIONING
General
62
AIR CONDITIONING
General
62
AIR CONDITIONING
General
62
AIR CONDITIONING
Fan
62
AIR CONDITIONING
Operating principle
62
AIR CONDITIONING
Operating principle
62
AIR CONDITIONING
Operating principle
62
AIR CONDITIONING
Fan
62
AIR CONDITIONING
Fan
62
AIR CONDITIONING
Evaporator - Pressure relief valve
62
AIR CONDITIONING
Condenser - Dehydration canister
62
AIR CONDITIONING
Condenser - Dehydration canister
62
AIR CONDITIONING
F ENGINE Compressor
62
AIR CONDITIONING
F ENGINE Compressor
62
AIR CONDITIONING
Z ENGINE Compressor
62
AIR CONDITIONING
Z ENGINE Compressor
62
AIR CONDITIONING
Evaporator temperature sensor
62
AIR CONDITIONING
Recycling motor
62
AIR CONDITIONING
Fan motor
62
AIR CONDITIONING
Fan speed regulator
62
AIR CONDITIONING
Trifunction pressostat
62
AIR CONDITIONING
Quick release unions
62
AIR CONDITIONING
Quick release unions
62
GENERAL
Safety - Tooling
70
INTERIOR BODY TRIM
View of the assembly
71
INTERIOR BODY TRIM
Headlining (A)
71
INTERIOR BODY TRIM
Headlining (A)
71
INTERIOR BODY TRIM
Headlining (A)
71
INTERIOR BODY TRIM
Headlining (A)
71
INTERIOR BODY TRIM
Headlining (A)
71
INTERIOR BODY TRIM
Headlining (A)
71
INTERIOR BODY TRIM
Roof trim panels (B)
71
INTERIOR BODY TRIM
Rear wheel arch lining (C)
71
INTERIOR BODY TRIM
Centre pillar lining (D)
71
INTERIOR BODY TRIM
Inner sill lining (E)
71
INTERIOR BODY TRIM
Front floor (F)
71
INTERIOR BODY TRIM
Rear floor with anchorages (G)
71
INTERIOR BODY TRIM
Rear floor with anchorages (G)
71
INTERIOR BODY TRIM
Rear floor with rails (H)
71
INTERIOR BODY TRIM
Rear floor with rails (H)
71
SIDE OPENING ELEMENTS TRIM
Front door lining (A)
72
72
72
72
Rear door lining (B)
72
72
72
NON SIDE OPENING ELEMENTS TRIM
Bonnet lining (A)
73
Tailgate lining (B)
73
Tailgate mouled trim with opening window (C)
73
TRAYS AND REAR SHELF
Tailgate sun screen (A)
74
Sun screen (B)
74
Fold down table - Rear shelf (C)
74
FRONT SEAT FRAMES AND RUNNERS
Complete seat (A)
75
Complete seat (A)
75
Runners and adjusting base E1 (B)
75
Runners and adjusting base E1 (B)
75
Mechanical runners and pivoting seat base (C)
75
Mechanical runners and pivoting seat base (C)
75
Electric seats (D)
75
Electric seats (D)
75
Electric seats (D)
75
Electric seats (D)
75
REAR SEAT FRAMES AND RUNNERS
Complete seat (A)
76
Frame and fixes base E1 with rails (B)
76
Frame and base with runners (C)
76
Rails and sliders (D)
76
FRONT SEAT TRIM
Seat back trim (A)
77
FRONT SEAT TRIM
Seat back trim (A)
77
FRONT SEAT TRIM
Seat back trim (B)
77
FRONT SEAT TRIM
Seat back trim (B)
77
REAR SEAT TRIM
Seat squab trim (A)
78
REAR SEAT TRIM
Seatback trim (B)
78
REAR SEAT TRIM
Seatback trim (B)
78
SEAT ACCESSORIES
Front elbow rests / Rear elbow rests
79
BATTERY - HEADLIGHTS
Special notes
80
Special notes
80
Lens units
80
Lens units
80
Lens units
80
Remote adjustement
80
Remote adjustement
80
Indicators
80
Fog lights
80
REAR AND INTERIOR LIGHTS
Rear lights
81
Rear lights
81
Rear lights
81
Courtesy lights
81
Courtesy lights
81
Courtesy lights
81
Courtesy lights
81
Fuses
81
Fuses
81
IMMOBILISER
Description of the coded key immobiliser
82
IMMOBILISER
Description of the coded key immobiliser
82
IMMOBILISER
Ring / Decoder unit
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
IMMOBILISER
Operation
82
INSTRUMENT PANEL
Dashboard
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Instrument panel
83
INSTRUMENT PANEL
Setting instrument panel parameters
83
INSTRUMENT PANEL
Fuel level sensor
83
INSTRUMENT PANEL
Fuel level sensor
83
INSTRUMENT PANEL
Fuel level sensor
83
INSTRUMENT PANEL
Oil level and temperature sensor
83
INSTRUMENT PANEL
Coolant temperature sensor
83
INSTRUMENT PANEL
Coolant temperature sensor
83
INSTRUMENT PANEL
Cruise control
83
INSTRUMENT PANEL
Cruise control
83
INSTRUMENT PANEL
Cruise control
83
INSTRUMENT PANEL
Cruise control
83
INSTRUMENT PANEL
Cruise control
83
INSTRUMENT PANEL
Cruise control
83
CONTROLS -SIGNALS
Windscreen wiper stalk
84
CONTROLS -SIGNALS
Windscreen wiper stalk
84
CONTROLS -SIGNALS
Lights stalk
84
CONTROLS -SIGNALS
Lights stalk
84
CONTROLS -SIGNALS
Rotary switch under steering wheel
84
CONTROLS -SIGNALS
84
CONTROLS -SIGNALS
Stalk mounting
84
CONTROLS -SIGNALS
Ignition switch
84
CONTROLS -SIGNALS
Heating controls
84
CONTROLS -SIGNALS
Switches on door
84
CONTROLS -SIGNALS
Switches on door
84
CONTROLS -SIGNALS
Switches on door
84
CONTROLS -SIGNALS
Switches on door
84
CONTROLS -SIGNALS
Switches on door
84
CONTROLS -SIGNALS
Switches on door
84
CONTROLS -SIGNALS
Roof console switches
84
CONTROLS -SIGNALS
Roof console switches
84
CONTROLS -SIGNALS
Switches on dashboard
84
CONTROLS -SIGNALS
84
CONTROLS -SIGNALS
84
CONTROLS -SIGNALS
Switches on seat
84
CONTROLS -SIGNALS
Door switch
84
CONTROLS -SIGNALS
Cigar lighter
84
CONTROLS -SIGNALS
Instrument panel lighting rheastat / Clock
84
WIPERS
Front windscreen wiper
85
WIPERS
Front windscreen wiper
85
WIPERS
Rear screen wiper
85
WIPERS
Rear screen wiper
85
WIPERS
Electric washer pump
85
WIPERS
Electric headlight washer pump
85
WIPERS
Windscreen washer reservoir
85
RADIO
Radio diagram
86
RADIO
Ampli-tuner
86
RADIO
Dashboard
86
RADIO
Cassette reader
86
RADIO
Compact disc reader
86
RADIO
Infrared receiver
86
ELECTRICAL ASSISTANCE EQUIPMENT
Passenger compartment connection unit
87
Passenger compartment connection unit
87
Air-conditioning relay / Child safety relay
87
Heated rear screen relay / Rear fog light relay
87
Rear / Front passenger compartment lighting relay
87
Front fog light relay / After-ignition relay
87
After-ignition relay / Front wiper timer
87
Diagnostic socket
87
Engine connection unit
87
87
87
87
Flasher unit
87
Wiper timer
87
One-touch window control unit
87
Sunroof
87
Sunroof
87
WIRING
Heated rear screen
88
WIRING
Heated rear screen
88
WIRING
Heated rear screen
88
WIRING
Exterior rear view mirrors
88
WIRING
88
WIRING
88
WIRING
88
WIRING
Heated seats
88
WIRING
Heated seats
88
WIRING
Infrared remote control
88
WIRING
88
WIRING
88
WIRING
88
WIRING
Airbag and seat belt pretensioners
88
WIRING
Special tooling
88
WIRING
Special tooling
88
WIRING
Special tooling
88
WIRING
Central computer
88
WIRING
Central computer
88
WIRING
Central computer
88
WIRING
Central computer
88
WIRING
Seat belt pretensioners / Driver's airbag
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
88
WIRING
Passenger airbag
88
WIRING
Passenger airbag
88
WIRING
Passenger airbag
88
WIRING
Passenger airbag
88
WIRING
Replacing the computer
88
WIRING
88
WIRING
88
WIRING
88
Technical Note 3444A
JE0K - JE0S
Basic manual: Workshop Repair Manual 315 and Technical Note 3426A
SPECIAL FEATURES OF THE ESPACE

FITTED WITH THE G9T ENGINE
77 11 297 982 AUGUST 2000 EDITION ANGLAISE
"The repair methods given by the manufacturer in this document are based on the All copyrights reserved by Renault.
technical specifications current when it was prepared.
Copying or translating, in part or in full, of this document or use of the service part
The methods may be modified as a result of changes introduced by the manufacturer reference numbering system is forbidden without the prior written authority of Renault.
in the production of the various component units and accessories from which his
vehicles are constructed."
© RENAULT 2000
Contents
Page
13 DIESEL EQUIPMENT
Technical specifications 13-1
Special features 13-3
Cleanliness 13-6
Location of components 13-8
Injection warning light 13-11
Immobiliser function 13-12
Injection programming/air
conditioning 13-13
Idle speed correction 13-15
Pre-postheating control 13-16
Heater plugs 13-17
Thermoplunger 13-18
Low pressure pump
(supercharging pump) 13-20
Fuel filter 13-21
High pressure pump 13-22
Injectors 13-27
Rail protector 13-31
Injector rail 13-37
Checking diesel pressure
and flow 13-39
Pressure sensor 13-40
Pressure regulator 13-41
113
DIESEL EQUIPMENT
Specifications 13
Engine
Depollution
Vehicle Gearbox Cubic
Bore Stroke Compression Catalytic standard
Type Index capacity
(mm) (mm) ratio converter
(cm 3 )
JE0 K PK1 G9T 718 87 92 2 188 18/1 ◊ C93 Euro 2000

JE0 S
ENGINE SPEED (rpm) SMOKE DENSITY
Homologation
IDLING SPEED Max. - no load Max. - under load Max. - Max
value
800 ± 10 4500 4250 ± 100 0.44 m-1 2.5 m-1
DESCRIPTION BRAND/TYPE SPECIAL NOTES
High pressure pump BOSCH CP1 Pressure from 250 to 1350 bar
Supercharging pump (low

BOSCH EKP3 Pressure from 2.5 to 4 bar
pressure)
Fitted to the injection rail
Diesel pressure sensor BOSCH Resistance: tracks 1,2 and 1,3 at 4.3 MΩ
tracks 2,3 at 1050Ω
Solenoid injector
Injectors BOSCH Resistance: < 2 Ω
Maximum pressure 1525 bar
Integrated with the high pressure pump
Pressure regulator -
Resistance: ≈ 5 Ω at 20˚ C
Injection computer BOSCH EDC15C 4.2 3 connector computer (32/48/48 tracks)
With pre-postheating function controlled by the
Pre-postheating unit NAGARES BED/7-12
injection computer
BERU
Heater plugs or Resistance: 0.6 Ω connector removed
CHAMPION
Double track potentiometer
track 1 potentiometer earth n˚2
track 2 potentiometer earth n˚1
Accelerator potentiometer HELLA track 3 potentiometer signal n˚1
track 4 potentiometer supply n˚1
track 5 potentiometer supply n˚2
track 6 potentiometer signal n˚2
Integrated in the flow meter
Air intake temperature sensor SIEMENS
Resistance between 100 Ω and 40 Ω
13-1
DIESEL EQUIPMENT
Specifications 13
DESCRIPTION BRAND/TYPE SPECIAL NOTES
Diesel temperature sensor ELTH Resistance ≈ 2050 Ω at 25˚ C ± 123 Ω
Engine speed sensor MGI Resistance: 200 to 270 Ω at 23˚
Integrated in the computer
Atmospheric pressure sensor BOSCH track 1 controlled earth

track 2 pressure signal
track 3 sensor supply
Camshaft sensor ELECTRIFIL Hall effect sensor
track A controlled earth

Turbocharging pressure sensor DELCO track B pressure signal
track C sensor supply
Turbocharger operating BITRON/

Resistance: 16.5± 1.7 Ω at 25˚ C
solenoid SIEMENS
Flow meter with integrated air temperature sensor

track 1: air temperature
track 2: earth
Air flow meter SIEMENS track 3: 5 V reference
track 4: + 12 V after injection relay
track 5: air flow signal
track 6: earth
Solenoid valve resistance: 8 ±0.5 Ω at 20˚ C (tracks 1 and 5)

EGR solenoid valve PIERBURG
Potentiometer resistance: 4 KΩ ±1.6 at 20˚ C (tracks 2 and 4)
Calibration:
Turbocharger GARRETT 120 mbar for rod travel between 1 and 4 mm
400 mbar for a stroke between 10 and 12 mm
Thermoplungers EUROPALU Resistance: 0.45 ± 0.05 Ω at 20˚ C - 4 x 300 Watts
NTC C type sensor
Coolant temperature sensor ELTH track 2 controlled earth

track 3 coolant temperature
Track 2/3 resistance: 2252 Ω±112 Ω
Damper flap solenoid valve EATON Resistance: 43 to 49 Ω at 25˚ C
Turbulator flap solenoid valve

EATON Resistance: 43 to 49 Ω at 25˚ C
(SWIRL)
13-2
DIESEL EQUIPMENT
Special notes 13
The common rail direct high pressure injection system is intended to deliver a specific quantity of diesel to the
engine at a specific time.
DESCRIPTION
The system consists of:

– a low pressure pump (1) (located between the air intake unit and the fuel filter),
– a fuel filter (2),
– a high pressure pump (3),
– a high pressure regulator (4) mounted on the pump,
– an injection rail (5) fitted with a diesel pressure sensor,
– a repriming valve (6) (open when operating normally),
– a fuel cooler (7),
– four solenoid injectors,
– various sensors,
– an injection computer.
Removal of the interior of the high pressure pump and the injectors is prohibited.
13-3
DIESEL EQUIPMENT
Special notes 13
OPERATION
The common rail direct high pressure injection system is a sequential diesel injection system (based on the
operation of multipoint injection for petrol engines).
This new injection system reduces operating noise, lowers the quantity of polluting gas and particles and produces
significant engine torque at low engine speeds thanks to a pre-injection procedure.
The low pressure pump (also called the supercharging pump) supplies the HP pump, through the filter with pressure
of between 2 and 4 bar.
The HP pump generates the high pressure sent to the injection rail. The 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 well 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
be started,
– controls each injector electrically and individually after determining these two values.
The volume injected into the engine is determined as a function of:

– the duration of injector control,
– the injector opening and closing speed,
– the needle stroke (determined by the type of injector),
– the nominal hydraulic flow of the injector (determined by the type of injector),
– the high pressure rail pressure controlled by the computer.
FOR ANY INTERVENTION IN THE HIGH PRESSURE INJECTION SYSTEM YOU MUST RESPECT THE
CLEANING AND SAFETY ADVICE SPECIFIED IN THIS DOCUMENT.
13-4
DIESEL EQUIPMENT
Special notes 13
POST-REPAIR CHECK
Reprime the circuit using the priming bulb.
After any operation, check that there are no diesel leaks. Start the engine at idle speed until the fan starts up, then
accelerate several times under no load.
IMPORTANT: the engine must not run with diesel containing more than 10 % diester.
The system can inject the diesel 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 injector on the cylinder head,
– of the pressure regulator,
– of the pressure sensor.
When the high pressure pump, injectors, supply, return and high pressure output unions are repaired or
removed, the bores should be fitted with new and appropriate core seals to avoid impurities.
WARNING: ALL PIPES REMOVED MUST BE REPLACED.
Follow the method described below when replacing the high pressure pipe:
– remove the high pressure pipe, holding the filter rod on the injector with a lock-wrench,
– fit the cleanliness plugs,
– undo 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,
– tighten the injector side union to torque,
– tighten the high pressure rail connection to torque.
It is prohibited to remove the interior of the pump.
It is vital that you replace the fuel return pipe placed on the injectors during removal.
The diesel temperature sensor is not removable. It is part of the fuel return rail.
It is forbidden to loosen a high pressure pipe connection when the engine is running.
13-5
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,
– seizing of a component or a component which is not sealed.
All After-Sales operations must be performed under very good cleanliness conditions. This means that no impurities
(particles a few microns in size) have penetrated into the system during removal or into the circuits via the fuel
unions.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE POLLUTING ELEMENTS?
The elements which contaminate are:

– metal or plastic chips,
– paint,
– fibres:
● of cardboard,
● of brushes,
● of paper,
● of clothing,
● of cloths.
– foreign bodies such as hair,
– ambient air,
– etc.
WARNING: it is impossible to clean the engine using a high pressure washer because of the risk of damaging
connections. Also the 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 parts sold at 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 hermetically resealable plastic bags for storing removed parts. There is less risk of parts
stored in this way being exposed to impurities. The bags can be used only once, and once used they must be
thrown away.
● Ensure that lint-free cleaning wipes are available (SODICAM wipes, part no. 77 00 211 707). The use of
conventional cloth or paper is prohibited.These generate lint and may contaminate the system's fuel circuit.
Each lint free cloth should only be used once.
13-6
DIESEL EQUIPMENT
Cleanliness 13
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
● Use new thinner for every operation (used thinner contains impurities). Pour it into a clean receptacle.
● Use a clean brush which is in good condition for every operation, (the brush must not shed its bristles).
● 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 are left.
● Wash your hands before and during the operation if necessary.
● Leather protective gloves must be covered with latex gloves (available from SODICAM).
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
● All openings made in the circuit must be plugged immediately to prevent pollution from penetrating the circuit. The
plugs to be used are available from the Parts Stores. They must not be reused under any circumstances.
● Reseal the bag hermetically, even if it has to be reopened only a short time later. Ambient air carries contamination.
● All components of 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.
Such items are liable to permit 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.
13-7
DIESEL EQUIPMENT
Location of components 13
193 injector control

218 fuel pump
243 oil level sensor
251 engine coolant dual function temperature sensor
398 exhaust gas recirculation solenoid valve control
436 wastegate control
799 air duct air flow sensor
866 diesel injection computer
925 boiler connector
927 impact sensor
980 preheating plugs relay unit
1013 phase sensor
1071 turbocharging pressure sensor
1075 air cut-out solenoid valve control (stop damper)
1162 control for inlet manifold turbulator flap control
13-8
DIESEL EQUIPMENT
1 Injector
2 Injector diesel return pipe
3 Pressure sensor
4 Common injection rail
5 HP pump/rail supply pipe
6 High pressure pump
7 Pressure regulator
13-9
DIESEL EQUIPMENT
11 Air flow meter with air temperature sensor
12 Inlet turbulator control
13 Damper flap control
14 EGR control
15850-3M
8 Cylinder marking sensor

9 Turbocharger
10 Priming catalytic converter
16030M1
15848M
13-10
DIESEL EQUIPMENT
Injection warning light 13
Vehicles using the high pressure diesel system are fitted with two injection warning lights used during the preheating
phase and in case of an injection fault.
WARNING LIGHT PRINCIPLE
● When ignition is switched on, the preheating light is lit during the preheating phase and then goes out (see section
13 "Pre-postheating control").
● The fault warning light lights up when there is a fault on the injection system. These faults are:
– Internal computer fault
– Engine speed fault (1)
– Main relay or low pressure pump fault (1)
– Injector fault (1)
– TDC sensor and camshaft sensor consistency fault (1)
– Fuel pressure sensor fault
– Fuel pressure regulator solenoid valve fault (1)
– Accelerator potentiometer fault
– Immobiliser fault
– Computer supply voltage fault
– Condenser voltage fault (1)
– Turbocharging pressure sensor fault
– Turbocharger solenoid valve fault
(1) In this case, the injection system cuts out.
If a fault is present when the ignition is switched on, the warning light lights up for a few seconds during the
preheating phase, goes out and then lights up again if the fault persists.
NOTE: the OBD (On Board Diagnostic) warning light (symbolised by an engine), illuminated when the ignition is
switched on, is never illuminated when the engine is running.
13-11
DIESEL EQUIPMENT
Immobiliser function 13
This vehicle is fitted with an engine immobiliser controlled by a key recognition system.
REPLACING AN INJECTION COMPUTER
The injection computers are supplied without a code but they must all be programmed with one.
When the computer is replaced, the vehicle code must be programmed in and then a check must be made to ensure
that the immobiliser system is operational.
To do this, simply 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).
IMPORTANT:
These vehicles have a specific injection computer which does not function unless coded.
Consequently, we strongly advice that you do not test computers borrowed from the shop or on another
vehicle so that coding and decoding problems, which could leave them useless, are avoided.
13-12
DIESEL EQUIPMENT
Injection/air conditioning programming 13
INJECTION COMPUTER / AIR CONDITIONING COMPUTER CONNECTION
The compressor is of the variable capacity type.
The injection computer and the air conditioning computer are connected by two wires:
The injection computer "AC OUT" connection to the air conditioning computer transmits authorisation or inhibition of
compressor operation.
The "AC ON" connection is used by the air conditioning system computer to request control of the air conditioning
compressor from the injection computer.
When air conditioning is selected, the idle speed rises above 800 rpm to reach a maximum speed of 875 rpm.
13-13
DIESEL EQUIPMENT
Injection/air conditioning programming 13
COMPRESSOR OPERATION PROGRAMMING
During certain stages of operation, the diesel injection computer inhibits the compressor.
Engine start programming
The compressor is inhibited for 5 seconds after the engine has started.
Recovery of performance
During a significant change in the position of the accelerator pedal, if the engine speed is less than 3000 rpm and if
the vehicle speed is less than 70 mph (110 km/h), operation of the compressor is inhibited for 5 seconds.
Recovery of output when the vehicle starts moving
If the potentiometer position is greater than 50 %, if the engine speed is less than 2250 rpm and if the vehicle speed
is below 20 km/h, the compressor is inhibited for 5 seconds.
Anti-stall protection
If the no load position is not detected and if the engine speed is less than 675 rpm, the compressor is inhibited. It is
restarted after 5 seconds if the engine speed has increased.
Thermal protection programming
The compressor does not start in cases where the coolant temperature is greater than + 112 ˚C.
The compressor is restarted after inhibition at 110 ˚C. The coolant temperature warning light illuminates at 120 ˚C
and extinguishes at 115 ˚C.
13-14
DIESEL EQUIPMENT
Idle speed correction 13
IDLE SPEED CORRECTION AS A FUNCTION OF COOLANT TEMPERATURE
CORRECTION AS A FUNCTION OF THE ELECTRICAL CAPACITY
The purpose of this correction is to compensate for the drop in voltage due to operation of a consumer component
when the battery is at low charge. To correct this, the idle speed is increased, allowing the alternator to rotate faster
and consequently increase 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 around 12 volts. Idle speed may reach a speed of 900 rpm.
IDLE SPEED CORRECTION WHEN THE POTENTIOMETER IS FAULTY
If the accelerator pedal potentiometer is faulty, idle speed is held at 1200 rpm.
If the information from the accelerator pedal position potentiometer and the brake switch information does not
correspond, the speed is changed to 1250 rpm.
IDLE SPEED CORRECTION WHEN DRIVING
The idle speed when driving is 875 rpm, with the vehicle moving at more than 2.5 km/h.
13-15
DIESEL EQUIPMENT
Pre-postheating control 13
The pre-postheating function is controlled by the preheating unit.
PRE-POST HEATING 2) Starting the engine

OPERATING PRINCIPLE
The plugs remain supplied while the starter is being
1)Switching on the "Preheating" ignition activated.
a) Variable preheating
3 "Postheating" while the engine is running
The warning light lighting time and the supply to
heater plugs time depends on the coolant During this phase, the plugs are supplied
temperature and the battery voltage. continuously depending on coolant temperature.
For idle speed without

depression of the accelerator
pedal.
In all cases the injection warning light lighting time

cannot exceed 15 seconds.
b) Fixed preheating
After the warning light goes out the plugs remain X = Time
supplied for a fixed period of 10 seconds. Y = Coolant temperature ˚C
13-16
DIESEL EQUIPMENT
Heater plugs 13
The preheating plug resistance is 0.6 Ω (connector
disconnected).
TIGHTENING TORQUE (in daN.m)
Heater plug 1.1
Plugs may be removed without the need to open the

high pressure circuit.
REMOVAL
Unclip the plug connector.
Clean around the plug to prevent any dirt entering the

cylinder.
Unscrew and then remove the plugs.
REFITTING
Proceed in the reverse order to removal.
Ensure that no impurities can enter the cylinder during

this operation.
13-17
DIESEL EQUIPMENT
Thermoplunger 13
The four thermoplungers are located on a water unit Control strategy
fixed under the manifold at the battery.
When the thermoplungers are operating the idle speed
The purpose of the system is to reheat the coolant. is increase to 900 rpm.
The thermoplungers are supplied with 12 volts by Thermoplungers cannot operate in the case of:
three relays when the engine is running. One relay – preheating,
controls two thermoplungers, the two other relays – post heating,
control one thermoplunger each. This enables control – if the engine speed is below 700 rpm.
of one, two, three or four thermoplungers as required.
If the conditions mentioned above apply, the
The thermoplunger resistance is: thermoplungers are controlled according to a
0.45 ± 0.05 Ω at 20 ˚C. characteristics map linked to the air and coolant
temperature.
17526M
Unshaded zone: Thermoplunger not supplied

Shaded zone: Thermoplunger supplied
13-18
DIESEL EQUIPMENT
Thermoplunger 13
If the battery voltage is > 13.5 volts
if not then
Thermoplungers not supplied Two thermoplungers supplied
If after 20 seconds the battery

voltage is
> 13.5 volts
if not then
Thermoplungers not supplied Two thermoplungers supplied
If after 20 seconds the battery

voltage is
> 13.5 volts
if not then
Thermoplungers Three thermoplungers supplied if

not supplied the battery voltage is > 13.5 volts
and if the conditions mentioned
above are fulfilled
13-19
DIESEL EQUIPMENT
Low pressure pump (supercharging pump) 13
The supercharging pump is an electric pump located
against the right-hand side member.
PAY STRICT ATTENTION TO THE RULES

REGARDING CLEANLINESS DURING
REPLACEMENT.
IMPORTANT: note that there is a quantity of diesel

and residual pressure in the pipes.
17527M1
13-20
DIESEL EQUIPMENT
Fuel filter 13
The fuel filter is located in the engine compartment. It is contained in an unremovable cartridge. This cartridge
contains a regulating valve which limits the flow of diesel circulating to the engine.
To replace the filter it is therefore necessary to replace the whole unit.
REMOVAL REFITTING
It is vital that you respect the position of the

connections to the filter.
REGARDING CLEANLINESS
Be careful not to squeeze or damage the pipes.
IMPORTANT: note that there is a quantity of diesel IMPORTANT:

and residual pressure in the pipes. A fuel cock (R) is fitted to the fuel filter at the level of
the diesel return pipe to the tank.
Disconnect the pipes on the filter which:
– feed the engine (1), It should be in open position for normal operation.
– come from the fuel tank (2) (low pressure pump),
– return to the tank (3) via the fuel cock, To reprime the circuit after an intervention, a filter
– return from the engine (4), change or a fuel fault you should:
– which return to the tank via the temperature – close the fuel cock (R),
exchanger (5). – start the low pressure pump by switching on the
ignition several times,
– start the engine,
– OPEN THE FUEL COCK (the valve is open when the
two coloured lines are aligned).
18240-1M1
It is necessary to periodically bleed the water trapped

in the diesel filter via the bleed plug (6).
13-21
DIESEL EQUIPMENT
High pressure pump 13
IT IS PROHIBITED TO REMOVE THE INTERIOR OF
THE PUMP.
SPECIAL TOOLING REQUIRED
Mot. 1503 Tool for fitting rubber pads.

Mot. 1536 Top Dead Centre pin
Mot. 1548 G9T high pressure pump
extractor
Mot. 1566 Tool for removing the high
pressure pipes
ESSENTIAL SPECIAL TOOLING
Facom wrench for DM19 high pressure pipes

Facom "Crowfoot 18-17" jaws for tightening the
rail high pressure pipe "Low torque" torque
wrench
TIGHTENING TORQUES (in daN.m)
High pressure pipe 2.5±0.2

High pressure pump mounting 3.2± 0.3
High pressure pump pulley nut 5 ± 0.5
Suspended mounting cover bolt 6.2 ± 1
Engine tie-bar bolt 15
IMPORTANT: before any intervention, connect the

After-Sales diagnostic tool, query the injection
computer and check that the injection rail is not under
pressure.
Take note of the fuel temperature.
13-22
DIESEL EQUIPMENT
REMOVAL Remove:
– the damper unit mounting bolts (3),
YOU MUST OBSERVE THE CLEANLINESS
ADVICE GIVEN IN THIS SECTION
Disconnect:
– the battery,
– the air flow meter.
Remove:
– the air filter unit,
– the expansion bottle and release it,
– the air exchanger/damper unit pipe by disconnecting
the wastegate pipe,
– the stiffening bracket (1) between the damper unit
and the power assisted steering pump,
– the exhaust gas recirculation pipe (2) and the seals.
Plan for the replacement of the pipe and the seals
when refitting.
16030R
– the connection pipe (4) with the inlet manifold,

– the damper unit from underneath.
15853M1
Disconnect the exhaust gas recirculation control

solenoid valve connector.
15855R
13-23
DIESEL EQUIPMENT
Set the engine to top dead centre using pin Mot. 1536.
Disconnect:
– the pump pressure regulator (RSV),
– the diesel temperature sensor,
– the position sensor,
– the fuel return and supply pipe on the pump, and fit
the cleanliness plugs.
Remove the expansion bottle mounting.
Unclip:
– the rail cover and move as far away as possible,
– the pump outlet / rail inlet high pressure pipe and fit
the sealing plugs.
Fit tool Mot. 1548, using the central dowel, then

remove the central dowel once the tool is in place.
Remove:
– the position sensor (1) taking care not to drop the O-
ring into the timing gear assembly,
– the pump hub plug (2).
Remove the Top Dead Centre pin Mot. 1536.
Remove the pump hub central mounting nut, locking

the engine flywheel using a large screwdriver.
13-24
DIESEL EQUIPMENT
Loosen the three mounting bolts on the multifunction REFITTING
support pump by a few turns.
Proceed in the reverse order to removal using the
central nut to engage the new pump.
NOTE to correct position of the rear pump mounting

holes.
Refit a hub plug for the new pump using tool

Mot. 1503.
Drive out the pump by tightening the dowel on tool

Mot. 1548.
17950-4S
NOTE: be careful not to place the high pressure pipe

under stress. To do this:
– loosen the high pressure rail,
– offer up the high pressure pipe nuts to the pump and
rail before tightening them to torque,
– tighten the rail to the correct torque,
– tighten the pump end and rail end to torque.
You must replace the diesel return pipe if it has been

removed.
17950-3S
Remove the pump mounting bolts, then the high

pressure pump.
13-25
DIESEL EQUIPMENT
Reprime the circuit:
– close the fuel cock (R),
– start the low pressure pump by switching on the
ignition several times,
– start the engine,
– OPEN THE FUEL COCK (R) (the valve is open
when the two coloured lines are aligned).
After any intervention, check that there are no leaks

in the diesel circuit. Start the engine at idle speed until
the fan starts up, then accelerate several times under
no load.
Check that there are no stored faults using the fault

finding tool. Erase them if necessary.
13-26
DIESEL EQUIPMENT
Injectors 13
Mot. 1549 Injector extractor

pressure pipes
"Low torque" torque wrench

Flywheel end injector bracket nut 360±30 ˚

High pressure pipe nuts 2.5±0.2
Injection rail mounting bolt 2.3±0.3
Injector bracket bolt 5±0.5
Pump/rail pipe bracket bolt 2.5±0.2
Injector bracket studs 0.2±0.05
Injector bracket bolt pretightening 0.6±0.1
IMPORTANT: before any intervention, connect

the After-Sales diagnostic tool, query the injection
computer and check that the injection rail is not 17533M2
under pressure.
Take note of the fuel temperature. Remove the pipe at the turbocharger inlet,
disconnecting the oil vapour rebreathing pipe.
Order the special injection circuit plugs kit, part no.
77 01 206 381 Unclip the side partitions of the rubber flap.
REMOVAL Unclip the rubber flap from the engine mounting, then
the cylinder head cover and push as far as possible to
the rear.
Remove the sealing cover attached by two nuts to the
cylinder head cover, holding the stud (on some
Disconnect the battery. versions), and remove the absorbent foam.
Remove:
– the air filter,
– the bulkhead soundproofing material.
IMPORTANT: to remove this you must remove the

turbocharger pressure regulation control solenoid
valve on the bulkhead, without disconnecting it.
13-27
DIESEL EQUIPMENT
Injectors 13
Blow underneath the engine. IMPORTANT: when loosening the connections (7) of
the injection harness on the injector holder, you must
Remove the oil filler funnel and the air filter mounting hold the filter-rod supporting bolts (8) with a lock
pad on the left-hand side of the engine. wrench.
Plug the oil filler hole using a clean cloth. Insert the plugs to maintain cleanness.
Disconnect the pressure sensor electrically (1). Loosen the injection rail bolts (5) without removing it.
Remove:
– the injector diesel return pipe (2) (to be replaced),
– the injection harness (3) between the high pressure
pump and the rail, NOTE that the cylinder mounting
bolt (6) is very fragile,
– the injector harnesses (4).
13-28
DIESEL EQUIPMENT
Injectors 13
REMOVE THE INJECTOR HOLDER Fit the extractor on an injector holder. Tighten the
(pipes removed) knurled ring to bring the two jaws together on the flat
surfaces without overtightening.
Loosen the mounting bolts for each injection holder.
A special extractor must be used to remove the

injectors. Never attempt to remove an injector holder
locked in its cylinder socket unless using the tool
described below.
Description of tool Mot. 1549
1 Extractor support chassis; this is fitted on the

cylinder head cover mounting bolts. Check that
it is fitted correctly before use.
2 Extractor
3 Extraction bolt
17554S
Fit the chassis of tool Mot. 1549 on the cylinder head

mounting bolts. Tighten the extraction bolt until the
injector is released from the cylinder head.
17549R
Apply releasing agent around the injector.
17555-1S
Remove the washer from the bottom of each injector

socket.
13-29
DIESEL EQUIPMENT
Injectors 13
REFITTING Torque tighten the:
– three rail mounting bolts to 2.3 daN.m,
Do not remove the protection plugs from any – the injection pipe connections on the injectors and
component until the last minute. the high pressure pump to 2.5 daN.m,
– the injection pipe connections on the rail to
Clean the injector sockets and the injector bodies, as 2.5 daN.m.
well as their brackets using a lint-free cloth (use the
wipes recommended for this purpose, part Clip the pump/rail pipes mounting clip and tighten the
no. 77 11 211 707) dipped in clean solvent. two mounting bolts.
Dry off using a different new wipe. Refit the sealing partition, attached to the cylinder
head cover by two nuts.
Clean one of the old injector mounting bolts and
tighten it to the end of the mounting hole thread to Refix the side partitions of the rail shield correctly.
clean the tappings.
Fold to the front and clip the rubber flap of the rail
Fit new studs and injector mounting spacers after protector.
coating them with oil on the thread and tighten them as
tightly as possible by hand (0.2 daN.m). The studs During any operations on the rail protector, you
and nuts must be replaced every time they are must ensure that the system components are fitted
removed. properly after refitting (see rail protector section).
Fit a new injector head washer on every injector. Non-observance of this advice may have serious
consequences.
Fit the injector equipped with its bracket and locking
spring ring. Carry out the rest of the refitting operation in the
reverse order to removal.
Oil the threads of the nuts.
Throw away the bag of plugs used during the
operation.
WARNING: tighten the nut at the timing end first
and then that at the flywheel end. Use the fault finding tool to erase any faults which may
be stored by the injection computer before restarting
the engine.
Tighten the mounting nuts (oiled) to 0.6 daN.m, first at
the timing end, then at the flywheel end.
After any intervention, check that there are no
Retighten only the flywheel end nut by 360˚±30˚. leaks in the diesel circuit.
Proceed as follows:
Loosen the three rail mounting bolts in order to release ● Run the engine at idle speed until the fan starts up.
it. ● Accelerate several times under no load.
● Carry out a road test.
● Switch the ignition off and check that there is no
Remove the rail plugs, the injector holders and the
injection pipes. leakage of diesel.
● Check that the foam is not soaked in diesel.
Fit the injection pipes between the rail and the
injectors and pretighten by hand until they touch.
13-30
DIESEL EQUIPMENT
Rail protector 13
GENERAL
The rail protector, comprising ten parts, ensures

insulation of the high pressure injection system from
the engine compartment.
THIS RAIL PROTECTOR ENSURES SAFE

OPERATION AND REQUIRES SPECIAL
ATTENTION WHEN BEING FITTED.
To ensure its safety function, the rail protector must

consist of:
– two pieces of foam (1) to be replaced if they are
damaged or impregnated with diesel,
– a lower metal protector (2) fixed between the rail and
the cylinder head,
– a diesel drain pipe,
– a rubber flap fixed to the metal protector and to the
cylinder head cover (3), 19032R
– two side partitions (4),
– a partition fixed to the cylinder head cover (5),
– two clips (6).
During any operations on the rail protector, you must

ensure that the system components are fitted properly
after refitting.
NON-OBSERVANCE OF THIS ADVICE

MAY HAVE SERIOUS CONSEQUENCES
FOR SAFETY.
13-31
DIESEL EQUIPMENT
Rail protector 13

pressure pipes

Facom "Crowfoot 18-17" jaws for tightening the
rail high pressure pipe "Low torque" torque
wrench
Unclip the side partitions of the rubber flap.

Unclip the rubber flap from the engine mounting, then
High pressure pipe nut 2.5±0,2
the cylinder head cover and push as far as possible to
Injection rail mounting bolt 2.3±0.3
the rear.
Pump/rail pipe bracket bolt 2.5±0.2
Remove the sealing cover attached by two nuts to the
cylinder head cover, holding the stud (on some
IMPORTANT: before any intervention, connect versions), and remove the absorbent foam.
the After-Sales diagnostic tool, query the injection
computer and check that the injection rail is not
under pressure.
Order the special high pressure injection circuit

plugs kit
REMOVAL
YOU SHOULD FOLLOW THE CLEANNESS

ADVICE CLOSELY
Disconnect:
– the battery,
– the air flow meter.
Remove:
– the air filter unit,
– the bulkhead soundproofing material,
– the expansion bottle mounting by disconnecting the
pre-postheating unit,
– the pipe at the turbocharger inlet, disconnecting the
oil vapour rebreathing pipe.
13-32
DIESEL EQUIPMENT
Rail protector 13
Disconnect the pressure sensor (1) and the injectors
electrically.
Remove:
– the injector diesel return pipe (2) (to be replaced),
– the injection pipes (3) between the high pressure
pump and the rail. WARNING: the cylinder head
mounting clip (6) is very fragile,
– the injector pipes (4).
Insert the plugs to maintain cleanness.
WARNING: when loosening the injection pipe unions

(7) on the injector holders, you must hold the filter-rod
supporting nuts (8) with a lockwrench.
Loosen the injection rail bolts (5) and the mounting

clamp bolt for the rail on the lower metal protector,
then remove the rail with its side partition.
13-33
DIESEL EQUIPMENT
Rail protector 13
REMOVAL REFITTING
Disconnect the diesel drain pipe (1). Refit the rubber flap to the lower metal protector by
pulling on the five rubber wall staples (4). Check that
Remove: the wall staples are clipped correctly.
– the side partition mounting bolt (2),
– the lower metal protector mounting bolt (3), Refit the rubber flap/lower metal protector assembly
on the engine.
18838R
To refit the side partition on the lower metal protector it

is essential that you follow the method below:
● Fit the lower strap (5).
● Fit the rubber ring (6) of the partition onto the lower
– the rail protector with the side partition, then remove
metal protector.
the partition of the central section.
● Then fit the upper section of the partition to the metal
Separate the rubber flap from the lower metal
protector.
protector.
13-34
DIESEL EQUIPMENT
Rail protector 13
● Fit the upper strap (7).
● Refit the partition mounting bolts (8).
● Reconnect the diesel drain pipe (9), checking that it

is not plugged.
18838R1
– the sealing partition, attached to the cylinder head
cover by two nuts.
Refit the injection rail with its partition without
tightening the rail mounting bolts. Check that the mark (10) on the rail partition is
positioned correctly (in the axis of the high
Remove the plugs from the rail, the injector holders, pressure rail outlets).
the pump and the injection pipes.
Fit the injection pipes between the rail and the

injectors and between the pump and the rail, then
pretighten by hand until they touch.
Torque tighten the:

– three rail mounting bolts to 2.3 daN.m,
– the injection pipe connections on the injectors and
the high pressure pump to 2.5 daN.m,
– the injection pipe connections on the rail to
2.5 daN.m.
Refit:
– the absorbent foam, replacing it if it is damaged or
impregnated with diesel,
13-35
DIESEL EQUIPMENT
Rail protector 13
Reconnect the injectors and the rail pressure sensor.
Refit a new diesel return pipe ensuring that the

mounting clips are properly fitted at the injectors
and at the end of the rail at the overpressure valve.
Fold the rubber flap to the front and clip the side
sealing partitions to it.
Check that the clip buttons are correctly welded to

the partitions and that the rubber flap skirts are
correctly fitted.
IMPORTANT: check that the diesel drain pipe is

correctly reconnected.
18839S
Reclip the rubber flap to the cylinder head cover and

the engine mountings.
Check that the rubber flap is correctly clipped to

the cylinder head cover and engine mountings
studs.
Use the fault finding tool to erase any faults which may
be stored by the injection computer before restarting
the engine.
18838S
After any intervention, check that there are no

leaks in the diesel circuit.
Proceed as follows:
● Run the engine at idle speed until the fan starts up.
● Accelerate several times under no load.
● Carry out a road test.
● Switch the ignition off and check that there is no
leakage of diesel.
● Check that the foam is not soaked in diesel.
13-36
DIESEL EQUIPMENT
Injector rail 13
PAY STRICT ATTENTION TO THE RULES REGARDING CLEANLINESS.
IMPORTANT: before any intervention, connect the After-Sales diagnostic

tool, query the injection computer and check that the injection rail is not under
pressure.
Removal of the common rail requires the removal of the harnesses (3), (4)
and disconnection of the pressure sensor (1). Refer to the "High pressure
injection circuit" section above
Remove the bolts (5) and remove the rail
NOTE: it is imperative that you replace the fuel return pipe (5) placed on the
injectors during removal.
13-37
DIESEL EQUIPMENT
Injector rail 13
Reprime the circuit using the fuel cock (R) mounted on
the diesel filter.
After any intervention, check that there are no leaks

in the diesel circuit.
Proceed as follows:
– run the engine at idle speed until the fan starts up,
– accelerate several times under no load,
– switch the ignition off and check that there is no
leakage of diesel.
It is forbidden to check for diesel leaks from the high

pressure circuit visually when the engine is running.
13-38
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 delivered by the supercharging pump (electric pump located under the diesel filter designed to
feed the high pressure pump).
Mot. 1311-01
or Pressure gauge
Mot. 1328
Mot. 1311-08 Pressure measuring
connector
Graduated 2000 ml test tube
CHECK LOW PRESSURE CHECK THE FLOW (SUPERCHARGING PUMP)

(SUPERCHARGING PUMP)
Make the pump flow into a 2000 ml graduated test
Fit a "T" connection Mot. 1311-08, to position the tube. Turn on the ignition to run the pump. The pump is
pressure gauge Mot. 1311-01 or Mot. 1328 at outlet supplied for 30 seconds if the engine is not started.
(S) of the fuel filter or at the inlet of the high pressure
pump. The flow measured should be 130 litres/hour.
Turn the fuel pump using the diagnostic tool or by

directly feeding the pump (each time the ignition is
switched on, the low pressure pump is supplied for IMPORTANT: it is forbidden to measure the
30 seconds). pressure and the flow of the high pressure pump.
Measure the pressure which should be between

2.5 and 3 bar.
15773R1
13-39
DIESEL EQUIPMENT
Pressure sensor 13
TIGHTENING TORQUES (In daN.m or/and°)
Pressure sensor 3.5 ± 0.5

pressure. Take note of the fuel temperature.
PRESSURE SENSOR (1) REFITTING
Replace the seal.

Screw in the sensor then tighten it to torque.
REMOVAL Connect the connector.
Disconnect the battery.
Remove the sensor connector (1).
Unscrew the pressure sensor.
After any intervention, check that there are no leaks in the diesel circuit.
Start the engine at idle speed until the fan starts up, then accelerate several
times under no load.
13-40
DIESEL EQUIPMENT
Pressure regulator 13
TIGHTENING TORQUES (In daN.m or/and°)
Regulator bolt 0.9 ± 0.1

pressure.
PRESSURE REGULATOR (1) REFITTING
Change the seals.

Moisten the seals with clean diesel.
REMOVAL Replace the regulator in the pump by turning it in an

anticlockwise direction (do not use any tools as a lever
Disconnect the battery. when replacing the pump regulator).
Remove the regulator connector. Fit the mounting bolts then tighten to torque.
Unscrew the regulator mounting bolts. Connect the connector.
Remove the regulator by turning in an anticlockwise

direction (do not use any tools as a lever when After any intervention, check that there are no
removing the pump regulator). leaks in the diesel circuit. Start the engine at idle
speed until the fan starts up, then accelerate several
times under no load.
13-41
INJECTION
F3R ENGINE Fault finding - Introduction
17
INJECTION
F3R ENGINE Fault finding - XR25 fiche
17
INJECTION
F3R ENGINE Fault finding - Interpretation of XR25 bargraphs
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
F3R ENGINE Fault finding - Customer complaints without OPTIMA station
17
INJECTION
F3R ENGINE Fault finding - Fault chart without OPTIMA station
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
F3R ENGINE Fault finding - Checking conformity
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
Z7X ENGINE Fault finding - Introduction
17
INJECTION
Z7X ENGINE Fault finding - Introduction
17
INJECTION
Z7X ENGINE Fault finding - XR25 Fiche
17
INJECTION
17
INJECTION
17
INJECTION
Z7X ENGINE Fault finding - Interpretation of XR25 bargraphs
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
Z7X ENGINE Fault finding - Customer complaints without OPTIMA station
17
INJECTION
Z7X ENGINE Fault finding - Fault chart without OPTIMA station
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
Z7X ENGINE Fault finding - Checking conformity
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
G8T ENGINE Fault finding - Introduction
17
INJECTION
G8T ENGINE Fault finding - XR25 fiche
17
INJECTION
G8T ENGINE Fault finding - XR25 fiche
17
INJECTION
G8T ENGINE Fault finding - Interpretacion of XR25 bargraphs
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
G8T ENGINE Fault finding - Customer complaints
17
INJECTION
G8T ENGINE Fault finding - Fault charts
17
INJECTION
17
INJECTION
17
INJECTION
17
INJECTION
G8T ENGINE Fault finding - Checking conformity
17
INJECTION
G8T ENGINE Fault finding - Aid
17
INJECTION
G8T ENGINE Fault finding - Aid
17
BOSCH ABS - SELF LEVELLING SUSPENSION
Fault finding - Introduction
38
Fault finding - XR25 fiche
38
Fault finding - Interpretacion of XR25 bargraphs
38
38
38
38
38
38
38
38
38
38
Fault finding - Customers complaints
38
Fault finding - Fault charts
38
38
38
38
38
38
38
38
38
38
Fault finding - Checking conformity
38
Fault finding - Customer complaints
38
38
38
38
38
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
HEATING
61
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
AIR CONDITIONING
62
HEATING - AIR CONDITIONING
Fault finding - Aid
62
Fault finding - Aid
62
Fault finding - Aid
62
CODED KEY ENGINE IMMOBILISER
J66 Fault finding - Introduction
82
J66 Fault finding - XR25 fiche
82
J66 Fault finding - Interpretation of XR25 bargraphs
82
82
82
82
82
82
82
82
82
82
82
82
82
82
82
82
82
J66 Fault finding - Customer complaints
82
J66 Fault finding - Fault charts
82
82
82
J66 Fault finding - Chacking conformity
82
INSTRUMENT PANEL - CRUISE CONTROL
83
83
Fault finding - Introduction of XR25 bargraphs
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
Fault finding - Interpretation of XR25 bargraphs
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
83
Fault finding -Checking conformity
83
83
83
83
83
83
83
83
83
83
83
83
83
83
RADIO
Fault finding -Introduction
86
RADIO
Fault finding -Customer complaints
86
RADIO
Fault finding -Fault charts
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
86
RADIO
Summary
86
AIRBAG - SEAT BELT PRETENSIONERS
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
88
Fault finding - Aid
88
Fault finding - Aid
88
Fault finding - Aid
88
Fault finding - Aid
88
Summary
88

Espace III Service Repair Manual

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SPECIFICATIONS

Engine - Clutch - Gearbox

SPECIAL FEATURES OF THE ESPACE

77 11 297 982 AUGUST 2000 EDITION ANGLAISE

JE0 K PK1 G9T 718 87 92 2 188 18/1 ◊ C93 Euro 2000

ENGINE SPEED (rpm) SMOKE DENSITY

800 ± 10 4500 4250 ± 100 0.44 m-1 2.5 m-1

DESCRIPTION BRAND/TYPE SPECIAL NOTES

Supercharging pump (low

Diesel temperature sensor ELTH Resistance ≈ 2050 Ω at 25˚ C ± 123 Ω

Engine speed sensor MGI Resistance: 200 to 270 Ω at 23˚

Integrated in the computer

Atmospheric pressure sensor BOSCH track 1 controlled earth

Camshaft sensor ELECTRIFIL Hall effect sensor

track A controlled earth

Turbocharger operating BITRON/

Flow meter with integrated air temperature sensor

Solenoid valve resistance: 8 ±0.5 Ω at 20˚ C (tracks 1 and 5)

Thermoplungers EUROPALU Resistance: 0.45 ± 0.05 Ω at 20˚ C - 4 x 300 Watts

NTC C type sensor

Coolant temperature sensor ELTH track 2 controlled earth

Damper flap solenoid valve EATON Resistance: 43 to 49 Ω at 25˚ C

Turbulator flap solenoid valve

The system consists of:

The volume injected into the engine is determined as a function of:

Reprime the circuit using the priming bulb.

It is absolutely vital that you observe the tightening torque:

WARNING: ALL PIPES REMOVED MUST BE REPLACED.

It is prohibited to remove the interior of the pump.

Risks relating to contamination

WHAT ARE THE POLLUTING ELEMENTS?

The elements which contaminate are:

● Use a brush and thinner to clean the connections to be opened.

● Wash your hands before and during the operation if necessary.

INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION

193 injector control

8 Cylinder marking sensor

WARNING LIGHT PRINCIPLE

(1) In this case, the injection system cuts out.

REPLACING AN INJECTION COMPUTER

The compressor is of the variable capacity type.

Engine start programming

Recovery of output when the vehicle starts moving

Thermal protection programming

CORRECTION AS A FUNCTION OF THE ELECTRICAL CAPACITY

IDLE SPEED CORRECTION WHEN THE POTENTIOMETER IS FAULTY

IDLE SPEED CORRECTION WHEN DRIVING

PRE-POST HEATING 2) Starting the engine

For idle speed without

In all cases the injection warning light lighting time

TIGHTENING TORQUE (in daN.m)

Heater plug 1.1

Plugs may be removed without the need to open the

Unclip the plug connector.

Clean around the plug to prevent any dirt entering the

Unscrew and then remove the plugs.

Proceed in the reverse order to removal.

Ensure that no impurities can enter the cylinder during

Unshaded zone: Thermoplunger not supplied

If the battery voltage is > 13.5 volts