Technical Note 3364a

8/14/2019 Technical Note 3364a

http://slidepdf.com/reader/full/technical-note-3364a 1/81

TECHNICAL NOTE 3364A

C066 - C06C

Special featuresof the sequential gearbox

JH1/D7F and JH1/D4F

For parts not dealt with in this Technical Note,

refer to Repair Manual 305 and to Technical Note 2682.

77 11 294 022

"The repair methods given by the manufacturer in this document are based on thetechnical specifications current when it was prepared.

The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which hisvehicles are constructed."

DECEMBER 2000

All copyrights reserved by Renault.

EDITION ANGLAISE

Copying or translating, in part or in full, of this document or use of the service partreference numbering system is forbidden without the prior written authority of Renault.

© RENAULT 2000



Contents

Page

07

12

13

16

17

VALUES AND SETTINGS

Tyres and wheels 07-1

Brakes 07-2

FUEL MIXTURE

Technical specifications 12-1

Inlet manifold 12-5

Motorised throttle body 12-7

FUEL SUPPLY

Special features 13-1Injector rail/injectors 13-2

STARTING - CHARGING

Alternator 16-1

Starter 16-2

INJECTION

Special features 17-1

Location of components 17-2

Accelerator pedal potentiometer 17-3

Immobiliser function 17-4

Injection programming/air conditioning 17-5Motorised throttle body 17-7

Idle speed correction 17-8

Richness regulation 17-9

Adaptive richness correction 17-11

Centralised coolant temperaturemanagement (GCTE) 17-12

Antipollution 17-13

Computer 17-14

Page

20

21

37

CLUTCH

Identification 20-1

MANUAL GEARBOX

Gears 21-1

Capacity - lubricant 21-1

Consumables 21-2

Parts to be systematically replaced 21-2

Hydraulic unit oil 21-2

Layouts 21-3Description 21-4

Diagram 21-5

Operation 21-6

Hydraulic unit 21-7 Accumulator 21-11

Pump unit 21-12

Pump 21-13Tank 21-15

Clutch module 21-16

Actuator module 21-19

Solenoid valves 21-23

Engagement position sensor 21-25

Selected position sensor 21-26

Clutch position sensor 21-27

Pressure sensor 21-28Computer 21-29

Relays 21-31

Fuses 21-32

Wiring harness 21-33

Gear lever 21-34

Programming 21-36

MECHANICAL ELEMENTS CONTROL

Master cylinder 37-1Brake servo 37-3

Air filter - Brake servo non-return valve 37-5



VALUES AND SETTINGS

Tyres and wheels 07107VALUES AND SETTINGS

Tyres and wheels

(1) With full load and on motorways.

Tightening torque of the wheel nuts: 10.5 daNm

Rim run-out: 1.2 mm

Type Rim Tyres

Tyre pressure when

cold (in bar) (1)

Front Rear

C06 6

C06 C5.5 J 14 155/65 R14 T 2.2 2.0

07-1



VALUES AND SETTINGS

Brakes 07

07-2

Brakes

(1) Drum: maximum wear diameter

Type

Disc thickness (in mm)

Drum diameter or

Disc thickness

(in mm)

Max. disc

run-out (in mm)Front Rear

Normal Min. Normal Max. (1)

C06 6

C06 C20.6 17.7 203 204.45 0.07

Type

Lining thicknesses (in mm) (including backing)

Brake fluidFront Rear

New Min. New Min.

C06 6C06 C 18 6.5 6.5 4.5 SAE J1703DOT 4



FUEL MIXTURE

Specifications 12D7F ENGINE

112FUEL MIXTURE

Specifications

(1) at 2 500 rpm, the CO content should be 0. maximum.

Vehicles Gearbox

Engine

Depollution

standardType Index

Bore

(mm)

Stroke

(mm)

Capacity

(cm3 )

Compression

ratio

Catalytic

converter

C06 6 JH1 D7F 703 69 76.8 1149 9./1◊ C82

◊ C239

EU 00

(Euro 2000)

Tests at idle speed*

Fuel***

(minimum octane rating)Engine speed(rpm)

Pollutant emission **

CO (%) (1) CO2 (%) HC (ppm) Lambda (λ)

750 ± 50 0.5 max 14.5 min 100 max 0.97<λ<1.03 Super unleaded (95 RON)

*

*****

For a coolant temperature greater than 80 ˚C and after the speed has stabilised at 2 500 rpm for

approximately 30 seconds.

For legal values refer to your country specification.91 RON unleaded compatible.

Temperature in ˚C - 10 25 50 80 110

Air sensor

NTC type

Resistance in ohms

10 450 to 8 525 2 120 to 1 880 860 to 760 - -

Coolant sensor

NTC typeResistance in ohms

- 2 360 to 2 140 770 to 850 275 to 290 112 to 117

12-1



FUEL MIXTURE

Specifications 12

12-2

D4F ENGINE

Vehicle Gearbox

Engine

Depollution

standardType Index

Bore

(mm)

Stroke

(mm)

Capacity

(cm3 )

Compression

ratio

Catalytic

converter

C06C JH1 D4F 702 69 76.8 1149 9.8/1 C127 EU 00

Engine

Tests at idle speed*

Fuel***

(minimum octane

rating)

Engine

speed(rpm)

Pollutant emission **

Type Suffix CO (%) (1) CO2 (%) HC (ppm) Lambda (λ)

D4F 702 750 ± 50 0.5 max 14.5 min 100 max 0.97<λ<1.03Unleaded

(95 RON)

(1)*

**

***

at 2 500 rpm the CO content should be 0.3 maximum.For a coolant temperature greater than 80 ˚C and after the speed has stabilised at 2 500 rpm for

approximately 30 seconds.For legal values refer to your country specification.

91 RON unleaded compatible.

Temperature in ˚C - 10 25 50 80 110

Air temperature sensor

NTC typeResistance in ohms 10 450 to 8 625 2 065 to 2 040 815 to 805 - -

Coolant temperature sensor

NTC type

Resistance in ohms

- 2 360 to 2 140 850 to 770 290 to 275 117 to 112



FUEL MIXTURE

Specifications 12

12-3

D7F ENGINE

DESCRIPTION MARQUE/TYPE SPECIAL NOTES

Injection and ignition computer SAGEM S 2000112 tracksSequential multipoint injection

Static ignition

Motorised throttle body Ø 40 mm

(double track integrated

potentiometer)

MGI/VDOEngine resistance = 1.6 ± 0.3 Ω

Potentiometer resistance = 1 200 ± 240 Ω

Accelerator pedal sensor (mounted

on the sub-frame)CTS

Double track potentiometer

Track resistance = 1 700 ± 15 Ω

Ignition coils SAGEM

Two coils with two grouped outputs

Primary resistance ≈ 0.5 Ω

Secondary resistance: 11 ± 1 kΩ

Manifold pressure sensor DELCO Resistance ≈ 50 kΩ

Pinking sensor SAGEM Piezoelectric type

Magnetic sensor

(TDC and engine speed)ELECTRIFIL/SIEMENS

Variable reluctance type

Resistance = 200 to 270 Ω

Oxygen sensors (upstream and

downstream)NTK

Heater resistance = 6 ± 1 Ω at 23 ˚CInternal resistance = 5 kΩ maximum

Rich mixture > 750 mV ± 70

Lean mixture < 150 mV ± 50

Injector SIEMENS Resistance: 14.5 ± 0.7 Ω at 20 ˚C

Canister solenoid valve SAGEMIntegrated into the canister

Resistance: 26 ± 4 Ω at 23 ˚C

Coolant pressure sensor. TEXAS INSTRUMENTSFor the use of air conditioning without a cold

loop (omission of air conditioning computer)

Booster pump -Pressure: 3.5 bar ± 0.06 Minimum flow: 80 at 100 l/h

Spark plugs NGK BKR 5 EK

Idle speed manifold pressure - 340 ± 40 mbar

Exhaust counter-pressure -

Upstream of the pre-catalytic converter

1 500 rpm

3 000 rpm

4 500 rpm

5 500 rpm



FUEL MIXTURE

Specifications 12

12-4

D4F ENGINE

DESCRIPTION MARQUE/TYPE SPECIAL NOTES

Injection and ignition computer MAGNETI MARELLI 96 tracksSequential multipoint injection

Static ignition

Motorised throttle body (double

track integrated potentiometer)

MAGNETI MARELLI Ø 42 mm

Engine resistance: 2 ± 0,3 Ω

Potentiometer resistance: 2 500 ± 500 Ω

Accelerator sensor

(mounted on sub-frame)

CTS Double track potentiometer

Track 1 resistance = 1 700 ± 900 Ω

Track 2 resistance = 3000 ± 2200 Ω

Ignition coils ELECTRICFIL Two coils with two grouped outputs

Primary resistance = 0.4 ± 0.02 Ω

Secondary resistance = 11 ± 1 kΩ

Manifold pressure sensor DELCO

Pinking sensor SAGEM

Magnetic sensor

(TDC and engine speed)

SIEMENS Resistance = 200 to 270 Ω

Oxygen sensor (upstream and

downstream)

NTK Heater resistance = 3.3 ± 0.5 Ω at 23 ˚C

Internal resistance = 5 kΩ maximum

Rich mixture > 850 mvolts

Lean mixture < 100 mvolts

Injectors MAGNETI MARELLI"PICO"

Resistance: 14.5 ± 0.7 Ω at 20˚C

Canister solenoid valve SAGEM Integrated into the canister

Resistance: 26 ± 3 Ω at 23˚C

Coolant pressure sensor.TEXAS

INSTRUMENTS

Booster pump Pressure: 3.5 bar ± 0.06

Minimum flow: 80 to 100 l/h

Spark plugs CHAMPIONREA 8 MCL Gap: 0.9 mm

Idle speed manifold pressure 350 ± 50 mbars



FUEL MIXTURE

Inlet manifold 12

12-5

D4F ENGINE Inlet manifold

REMOVAL

Disconnect the battery.

Remove:

– the air filter unit, – the engine cover.

Disconnect:

– the injection computer connectors,

– interconnection (A) on the engine wiring harness, – the manifold pressure sensor (1).

Remove the anti-interference condenser located

behind the engine (arrow B).

Disconnect:

– the ignition coil connector and remove the anti-

interference condenser,

– the high voltage spark plug leads by pulling themthrough the extension cable,

– the pinking sensor and release the inlet manifold

wiring,

– the coolant temperature sensor (2).

Disconnect

– the brake servo vacuum pipe (manifold side),

– the fuel vapour rebreathing pipe,

– the fuel supply pipe,

– the starter cables.

Remove:

– the inlet manifold bolts,

– the inlet manifold by shifting it to the right while

disconnecting the motorised throttle body connector,

the air temperature sensor and the injectors.

TIGHTENING TORQUES (in daNm)

Inlet manifold/cylinder head (bolts 4 and 5) 0.6

then all the bolts 1

Inlet manifold/cylinder head cover 1

18445R

18444S



FUEL MIXTURE

Inlet manifold 12

12-6

D4F ENGINE

REFITTING

Replace the inlet manifold gasket, the cylinder head

cover/inlet manifold gasket and the oil vapour

rebreather pipe gasket.

Refit:

– the inlet manifold, reconnecting the injectors, the air

temperature sensor and the motorised throttle body,

– the eight bolts on the inlet manifold using Loctite

FRENETANCH and pre-tighten to 0.6 daNm on bolts(4) and (5).

Loosen bolts (4) and (5).

Tighten bolts (1) to (8) definitively, applying a torque of

1 daNm.

Refit and tighten the four upper mounting bolts on the

manifold in a cross-wise pattern to a torque of

1 daNm.

Continue the refitting procedure in the reverse order to

removal.

WARNING: the mounting bolts for the inlet

manifold on the cylinder head project into the

cylinder head. It is vital that you fit them usingLoctite FRENETANCH.

18444R1



FUEL MIXTURE

Motorised throttle body 12

12-7

D7F ENGINE Motorised throttle body

IMPORTANT:

Never:

– change the position of the stop screw (A),

– remove the support clip from the axis (B),

– remove the motor bolts from the motorised

throttle body (C).

Motorised throttle body connector:

1 Earth

2 Track 1 potentiometer signal

3 Motor supply

4 Motor earth

5 5 V supply


REMOVAL

Removing the motorised throttle body does not pose

any special problems.

17790R





FUEL MIXTURE


12-9

D4F ENGINE

ALLOCATION OF CONNECTOR TRACKS

MOTORIZED THROTTLE BODY CONNECTOR

18440S

TRACK Description1

2

3

4

5

6

Earth

Track 1 potentiometer signal

Motor supply

Motor earth

5 volt supply

Track 2 potentiometer signal



FUEL SUPPLY

Special notes 13113FUEL SUPPLY

Special notes

The petrol fuel supply system for the engine is a no-return circuit.

The petrol fuel pressure no longer varies depending on the engine load.

The circuit comprises:

– a rail (1) without a union to return piping and without a supply pressure regulator,

– a single pipe (2) coming from the tank, – a pump/feed gauge assembly (3) fitted with a pressure regulator (4) (located in the tank),

– a fuel filter (5) located under the car,

– a tank for reabsorbing fuel vapour (6).

OPERATING DIAGRAM OF THE PETROL CIRCUIT

15777R

13-1



FUEL SUPPLY

Injector rail/injectors 13

13-2

D7F ENGINE Injector rail/injectors

Removing the rail does not pose any special problems and can be done

without removing the inlet manifold.

REMOVAL

Remove:

– the wiring harness clips,

– the wiring harness,

– the injector mounting clips,

– the injectors.

Take note of the injection clips position on the injectors.

17791R

REFITTING

Replace the injector O-rings.

Listen for the click that indicates the fuel supply union is correctly fastened.

For the other operations, refitting is the reverse of removal.





STARTING - CHARGING

Starter 16116STARTING - CHARGING

Starter

REMOVAL

– Put the car on a two-post lift and disconnect the

battery.

– Remove the cooling fan,

– disconnect the starter electrical connections.

Remove the two starter mounting bolts.

REFITTING

Refitting is the reverse of removal.

10076R

16-1



INJECTION

Special features 17D7F ENGINE

117INJECTION

Special features

SPECIAL FEATURES OF THE SEQUENTIAL MULTIPOINT INJECTION

q A SAGEM "S 2000" 112 track computer controls the injection and ignition.

q Multipoint injection operating in sequential mode without a camshaft position sensor . This means that phasing is

controlled by software using the TDC sensor.

q Integrated OBD "On Board Diagnostic" indicator light on control panel (linked to an EOBD "European On Board

Diagnostic" system).

q Injection warning light on instrument panel.

q Motorised throttle body regulates airflow and idle speed.

q Use of two oxygen sensors (upstream and downstream of the catalytic converter).

q Injection computer controls the fan assemblies and the coolant temperature warning lights on the instrument panel.

q Idling speed correction depending on:

– battery voltage,

– air conditioning.

q Idle speeds:

– nominal idle speed

– idle speed with automatic transmission operation

752 rpm

848 rpm

q Maximum engine speeds: – when the coolant temperature is lower than 40˚ C

– for a temperature of > - 40 ˚ C in 1st and 2nd gear (depending on SRBCI) – for a temperature of > - 40 ˚ C in 3rd, 4th and 5th gear

– when reversing

6 100 rpm

6 100 rpm6 100 rpm

6 100 rpm

17-1



INJECTION

Special features 17

17-2

D4F ENGINE

SPECIAL FEATURES OF THE SEQUENTIAL MULTIPOINT INJECTION

q A MAGNETI MARELLI "5NR" 96 track computer controls the injection and ignition.

q Multipoint injection operating in sequential mode without a camshaft position sensor . This means that phasing is

controlled by software using the TDC sensor.

q Injection warning light on the instrument panel. Special injection warning light (OBD "On Board Diagnostic"

warning light) integrated as part of the EOBD "European On Board Diagnostic" system.

q Use of two oxygen sensors (upstream and downstream of the catalytic converter).

q Motorised throttle body to regulate the airflow and the idle speed.

q Fuel circuit without return to the tank (the pressure regulator is located on the pump/sender unit).

q Idling speed correction depending on:

– battery voltage,

– air conditioning.

q Canister drain solenoid valve controlled by Opening Cyclic Ratio (RCO).

q Injection computer controls the fan assemblies and the coolant temperature warning light on the instrument panel

(GCTE function).

q Injection computer controls the air conditioning (the air conditioning computer is no longer fitted).

q

Idle speeds: – nominal idle speed – idle speed with automatic transmission operation

750 rpm

750 rpm

q Maximum engine speeds:

– when the coolant temperature is lower than 40˚ C

– in 1st gear (depending on SRBCI) – in 2nd, 3rd, 4 th and 5th gears

– when reversing

6 300 rpm

6 100 rpm

6 300 rpm

6 300 rpm





INJECTION

Location of components 17

17-4

D4F ENGINE

PHOTO 19681

1

2

3

4

5

6

7

8

9

10

1112

13

Inertia switch

Monobloc coil with double output

Manifold pressure sensor Injection computer

Motorised throttle body with integrated temperature sensor

Accelerator pedal potentiometer

Supply relay

Fuel vapour tank (canister) with integrated solenoid valve

TDC sensor

Coolant temperature sensor

Pinking sensor Injector railSequential gearbox computer



INJECTION

Accelerator pedal potentiometer 17

17-5

ENGINES

D4F - D7F Accelerator pedal potentiometer

The accelerator pedal position potentiometer is

located on the front sub-frame.

To remove, place the car on a two-post lift. There are

no special instructions for removal.

Potentiometer connector:



3 Track 2 supply

4 Track 1 supply5 Track 2 earth6 Track 1 feed

17974-1S

15760S

15759R1



INJECTION

Immobiliser function 17

17-6

D7F ENGINE Immobiliser function

This vehicle is fitted with an engine immobiliser controlled by a random rolling code 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. When theignition is off, the engine immobiliser function will be activated after approximately 10 seconds (red engine

immobiliser warning light flashes).

IMPORTANT:

With this engine immobiliser, the computer keeps its immobiliser code for life.

In addition, this system does not have a security code.

Consequently, it is forbidden to perform tests with computers borrowed from the stores or from another

vehicle which must then be returned.

It will no longer be possible to decode them.



INJECTION

Injection/air conditioning management 17

17-7

D7F ENGINE Injection/air conditioning management

THE COMPRESSOR IS OF VARIABLE DISPLACEMENT TYPE

INJECTION COMPUTER / AIR CONDITIONING COMPUTER CONNECTION

The injection computer is linked to the air conditioning computer by two wires and to the coolant pressure sensor

by three wires:

– one injection computer wire leads to the air conditioning computer track C-F3. The instruction to authorise or

prohibit compressor operation is conveyed along this wire.

– one air conditioning computer wire leads to the injection computer track C-A1. This consists of the absorbed

power information signal.

– three injection computer wires lead to the coolant pressure sensor. Track B-J3 for Freon pressure information.

When the air conditioning is switched on, the air conditioning computer authorises compressor operation.

The injection computer either authorises or blocks engagement of the compressor clutch, orders modified idle speed

and controls the fan unit. In this case, the engine speed can reach 880 rpm depending on how much power is

absorbed by the compressor.

COMPRESSOR OPERATION PROGRAMMING

During certain stages of operation, the injection computer stops the compressor from functioning.

Engine start programming

The compressor is prevented from operating for 12 seconds after the engine has started.

Heat protection

The compressor is not engaged in cases where the coolant temperature is greater than 115 °C .

Overspeed protection programming

The compressor is prevented from operating if the engine speed is greater than 6 200 rpm.



INJECTION

Injection/air conditioning management 17

17-8

D7F ENGINE

Recovery of performance

The compressor is disengaged for 8 seconds when the following conditions are combined:

Entry conditions

– throttle position potentiometer at full load

– and engine speed less than 3 000 rpm.

– and vehicle speed less than 55 mph (85 km/h).

Exit conditions

– Full load not recognised

– or delay of 8 seconds expired

– or engine speed greater than or equal to 3 500 rpm

– or vehicle speed greater than 55 mph (87 km/h).

Recovery of power at full load

When at full load the air conditioning compressor is disengaged for 15 seconds when the power absorbed by the air

conditioning compressor is significant:

Entry conditions

– engine speed less than 3 000 rpm.

– and vehicle speed less than 2.5 mph (4 km/h).

– and 1st or 2nd gear is engaged

– and the throttle section greater than 0 mm2

Exit conditions

– delay of 15 seconds expired

– or engine speed greater than or equal to 3 500 rpm

– or vehicle speed greater than 9 mph (15 km/h).

Recovery of power at full load when the vehicle starts moving

The air conditioning compressor is disengaged if the following conditions are met to help initial movement of the

vehicle:

Entry conditions

– engine speed greater than 2 208 rpm

– and vehicle speed less than 2.5 mph (4 km/h).

– and throttle section greater than 0 mm2

– and 1st or 2nd gear is engaged

Exit conditions

– vehicle speed greater than 15 mph (25 km/h).



INJECTION


17-9

ENGINES

D4F - D7F Motorised throttle body

MOTORISED THROTTLE BODY

The motorised throttle body carries out idle speed regulation and engine air intake modulation functions. It consists

of an electric motor and a throttle position potentiometer.

When the engine is idling, the throttle position is adjusted according to the idle speed setting. This setting takes into

account the major power consumers (air conditioning), operating conditions (air temperature and coolant

temperature) and acceleration request.

When the driver presses the accelerator pedal, his request is translated as the angle of the throttle opening.

However, to improve driving pleasure, the throttle opening is not directly proportional to the driver's request.

To eliminate misfires, facilitate gear changes and safety functions, the throttle body modulates the engine torque.

MOTORISED THROTTLE BODY DEFECT MODES

The motorised throttle body has three types of defect mode.

q Reduced Performance Mode: this mode covers electrical faults for which there is a viable backup solution for theinjection system (loss of one of the two tracks on the pedal or the throttle body).

This mode results in reduced acceleration and limits the maximum opening of the throttle.

q Driver Override Mode: this mode is also called Electrical Limp Home. This mode is applied when the accelerator

pedal signal disappears completely, but the injection computer still controls the intake of air to the engine (automatic

throttle control is still operational).

In this mode, the injection computer imposes a set engine speed for each gear ratio and imposes the idle speedwhen the brake pedal is pressed.

q Mechanical Limp Home Mode: this mode covers breakdowns which result in loss of the automatic throttle control(the throttle can no longer be controlled).

In this case the throttle is in the mechanical rest position and the injection computer limits the engine speed by

cutting off the injection.



INJECTION

Idle speed adjustment 17

17-10

D7F ENGINE Idle speed adjustment

ELECTRICAL CORRECTION AS A FUNCTION OF BATTERY VOLTAGE AND ELECTRIC POWER BALANCE

The lower the battery voltage, the greater the correction. Correction of the engine speed is therefore variable. It

begins when the voltage drops to below 12.7 Volts. The idling speed may reach 128 rpm maximum.

IDLING SPEED CORRECTION DEPENDING ON AIR CONDITIONING STATUS

If air conditioning is selected on the instrument panel, the idling speed is set to 880 rpm.

ADAPTIVE IDLE SPEED ADJUSTMENT

This adjustment only takes effect if the coolant temperature is above 70 ˚C, 30 seconds after the engine is started

and during the idle speed regulation phase.

VALUES OF THE IDLING OPENING CYCLIC RATIO AND ITS ADAPTIVE CORRECTION

Each time the ignition is switched off, the computer programs the minimum and maximum motorised throttle body

stops.

IMPORTANT: after erasing the computer memory, it is essential to start the engine then stop it to allow themotorised throttle body to be reset. Start it again and let it run at idle speed so that the adaptive correction can take

place.

PARAMETERS D7F 703 Engine

Nominal idle speed X = 752 rpm

Idling opening cyclic ratio 0 % ≤ # 12 ≤ 10 %

Adaptive idling opening cyclic ratio Stop:

minimum: - 3.9 %

maximum: 6.25 %



INJECTION

Mixture control 17

17-11

D7F ENGINE Mixture control

An engine using the SAGEM S 2000 computer is equipped with two oxygen sensors, called the upstream sensor

and the downstream sensor.

HEATING THE SENSORS

Heating the oxygen sensors is controlled by the computer:

– if the inlet manifold pressure is below a threshold which varies according to the engine speed,

– if the speed is below 150 mph (255 km/h),

– after the engine has been running for a certain length of time, programmed according to the top dead centre

(outside no load position) and the coolant temperature for the downstream sensor.

Heating the oxygen sensors stops:

– if vehicle speed is greater than 150 mph (255 km/h), (example),

– with the throttle potentiometer in the full load position.

UPSTREAM SENSOR VOLTAGE

The value read on the diagnostic equipment (except XR25) under the upstream sensor voltage parameter

represents the voltage supplied to the computer by the oxygen sensor located upstream of the catalytic converter. It

is expressed in millivolts.

The voltage should fluctuate between two values during richness regulation:

– 20 mV ± 50 for a lean mixture,

– 840 mV ± 70 for a rich mixture.

The smaller the difference between the minimum and maximum values, the poorer the signal from the sensor (the

difference is usually at least 500 mV).

NOTE: if the difference is small, check the sensor heater.

DOWNSTREAM SENSOR VOLTAGE

The value read on the diagnostic equipment (except XR25) under the downstream sensor voltage parameter

represents the voltage supplied to the computer by the oxygen sensor located downstream of the catalytic

converter. It is expressed in millivolts.

The function of this sensor is to locate faults on the catalytic converter and to perform a second more precise check

on the richness (slow regulation loop). This function does not operate at idle speed and only starts operating after

the engine has been running for a while.

When the engine is operating in a closed loop, at stabilised speed, the voltage should vary within the range600 mV ± 100.

When the engine is decelerating, the voltage should be less than 200 mV.

The voltage read on the diagnostic tools at idling speed should be ignored.



INJECTION

Mixture control 17

17-12

D7F ENGINE

MIXTURE ADJUSTMENT

The value read on the diagnostic tools (except XR25) under the richness correction parameter represents the

average of the richness corrections applied by the computer depending on the richness of the fuel mixture asdetermined by the oxygen sensor located upstream of the catalytic converter.

The correction value has a mid-point of 128 and limits of 0 and 255:

– value less than 128: leaner mixture required,

– value greater than 128: richer mixture required.

ENTRY INTO RICHNESS REGULATION MODE

Loop phase

Entry into richness regulation takes place after a time of 28 seconds to 210 seconds from the time the engine isstarted, if the coolant temperature is greater than 22 ˚C.

Unlooping phase

In mixture regulation mode, the phases of operation during which the computer ignores the value of the voltage from

the sensor are:

– at full load,

– during heavy acceleration, – during deceleration with a no load signal,

– when the oxygen sensor is faulty.

DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT

If the voltage from the oxygen sensor is incorrect (varies only slightly or not at all) during richness regulation, the

computer will only enter defect mode (value = 128) if the fault has been present for a period of time (at least

10 minutes' delay). Only in that case will the fault will be stored.

If an oxygen sensor fault is present and detected and if the fault has already been stored, the system goes directly to

the open loop mode. In this case, the richness correction parameter = 128.



INJECTION

Adaptive richness adjustment 17

17-13

D7F ENGINE Adaptive richness adjustment

PRINCIPLE

In looping phase, the richness regulation corrects the injection time to obtain fuel dosing as close as possible to a

richness of 1. The correction value is close to 128, with limits of 0 and 255.

Adaptive mixture adjustment makes it possible to of fset the injection mapping to reset the richness regulation to 128.

Adaptive adjustments take 128 as an average value after initialization (erasing the memory) and have the following

limit values:

ROAD TEST

Conditions:

– engine warm (coolant temperature above 75 ˚C),

– do not exceed an engine speed of 4 290 rpm

– disconnect the canister solenoid valve or block the inlet pipe on the engine.

Pressure zones which must be passed through during the test

Following this test the adjustments will be operational.

The test must then be continued by driving normally, in a varied manner for 3 to 6 miles (5 to 10 km).

After the test, record the values of the adaptive programs. Initially 128, they may have changed. If not, repeat thetest ensuring that the test conditions are observed.

INTERPRETATION OF VALUES OBTAINED FROM A ROAD TEST'

In the case of a lack of fuel, the richness regulation (in #35) increases to obtain a richness as close as possible to 1

and the adaptive richness correction increases until the richness correction again fluctuates at around 128.

In the event of an excessive amount of fuel, the logic is reversed: the richness regulation decreases and the

adaptive richness correction also decreases to realign the richness correction at around 128.

PARAMETERS D7F 703 Engine

Mixture adjustment 89 ≤ #35 ≤ 166

Operating adaptive richness 64 ≤ #30 ≤ 192

Idle adaptive richness 64 ≤ #31 ≤ 192

Zone no. 1

(mbars)

Zone no. 2

(mbars)

Zone no. 3

(mbars)

Zone no. 4

(mbars)

Zone no. 5

(mbars)

D7F 703 259 381 529 677 825 873



INJECTION

Coolant temperature management (GCTE) 17

17-14

D7F ENGINECoolant temperature management (GCTE)

The fan unit is controlled by the injection computer.

ANTIPERCOLATION FUNCTION

The antipercolation system is controlled by the injection computer.

The coolant temperature signal used is the one from the injection system.

After the engine is switched off the system enters monitoring mode. If the coolant temperature exceeds the limit of

101 ˚C during the 35 seconds after the engine is switched off, the fan unit is controlled at slow speed.

If the coolant temperature falls below 95 ˚C, the fan unit relay is cut off (the fan unit cannot be controlled for more

than 3 minutes).

OPERATION OF THE FAN UNITS

– The fan unit is controlled at slow speed if the coolant temperature exceeds 98 ˚C and is switched off when thetemperature falls below 96 ˚C.

– The fan unit is controlled at high speed if the coolant temperature exceeds 103 ˚C and is switched off when the

temperature falls below 100 ˚C.

– The fan unit is controlled when the air conditioning function is selected on the instrument panel.

OPERATION OF THE TEMPERATURE LIGHT

The coolant temperature warning light comes on if the coolant temperature exceeds 118 ˚C and goes out when the

temperature falls below 115 ˚C.



INJECTION

Antipollution 17

17-15

D7F ENGINE Antipollution

ANTIPOLLUTION

CANISTER PURGE CONDITIONS

The canister purge solenoid valve is controlled by RCO (Opening Cyclic Ratio) signals:

– when the coolant temperature is greater than 20˚ C,

– when the temperature is greater than 10˚ C,

– with the accelerator pedal position at no load,

– when the engine speed is greater than 1 470 rpm,

– when the manifold pressure is greater than 990 mbar ,

IMPORTANT:

The valve of the closed solenoid valve is never equal to 0. The minimum read value is approximately 1.20 %.



INJECTION

Computer 17

17-16

D7F ENGINE Computer

INJECTION COMPUTER TRACK ASSIGNMENTS

CONNECTOR A

H2

H3

H4

G2

G4

F2

F3

F4

E4

B2

B3

B4

←

---

------

---

---

←

---

←

→

→

→←

LOAD POTENTIOMETER SIGNAL (TRACK 1)

LOAD POTENTIOMETER EARTH (TRACK 1)

POWER EARTHLOAD POTENTIOMETER SUPPLY (TRACK 1)

POWER EARTH

LOAD POTENTIOMETER SUPPLY (TRACK 2)

LOAD POTENTIOMETER SIGNAL (TRACK 2)

LOAD POTENTIOMETER EARTH (TRACK 2)

BRAKE SIGNAL

COOLANT TEMPERATURE WARNING LIGHT CONTROL

ON BOARD DIAGNOSTIC WARNING LIGHT CONTROL

FAULT FINDING

CONNECTOR B

M2

M3M4

L2L3

L4K3

K4J3

H2

H3

H4

G2

G3

G4

F2

F3

F4

E2

E3

E4

D2

D3

D4

C2

C3

B2

A2

A4

→

→ →

→ →

→

→←

→←

←

---

←

---

---

←

---

←

←

---

←

---

←

←

←

→

---

←

---

←

---

INJECTOR 4 CONTROL

(-) MOTORISED THROTTLE CONTROL(+) MOTORISED THROTTLE CONTROL

INJECTOR 3 CONTROLINJECTOR 2 CONTROL

INJECTOR 1 CONTROLMULTIPLEXING (ENGINE/GEARBOX)

MULTIPLEXING (ENGINE/GEARBOX)REFRIGERANT PRESSURE SENSOR SIGNAL

REFRIGERANT SENSOR AND MANIFOLD PRESSURESENSORS SUPPLY

MANIFOLD PRESSURE SENSOR SIGNAL

REFRIGERANT SENSOR AND MANIFOLD PRESSURE

SENSOR SUPPLY

MOTORISED THROTTLE BODY POTENTIOMETER FEED

MOTORISED THROTTLE BODY POTENTIOMETER

SIGNAL (TRACK 1)

MOTORISED THROTTLE BODY POTENTIOMETER

EARTH (TRACK 1)

COOLANT TEMPERATURE SIGNAL

ENGINE SPEED SENSOR SIGNAL

COOLANT TEMPERATURE SENSOR EARTH

AIR TEMPERATURE SIGNAL

AIR TEMPERATURE SENSOR EARTH

ENGINE SPEED SENSOR SIGNAL

IMMOBILISER

MOTORISED THROTTLE POTENTIOMETER SIGNAL

(TRACK 2)

ACTUATOR CONTROL RELAY

PINKING SENSOR SCREENING

VEHICLE SPEED INFORMATION

PINKING SENSOR EARTH

PINKING SENSOR SIGNAL

+ AFTER IGNITION



INJECTION

Computer 17

17-17

D7F ENGINE

INJECTION COMPUTER TRACK ASSIGNMENTS (CONT)

CONNECTOR C

A2

A1

B3B2

B1

C2

C1

D1

E1

F3

F2

F1

G3

G2

G1

H3

H2

H1

←

←

→ ---

←

→

---

→

→

→

→

→

→

---

→

→

→

---

DOWNSTREAM OXYGEN SENSOR SIGNAL

AIR CONDITIONING INFORMATION

ENGINE SPEED INFORMATIONDOWNSTREAM OXYGEN SENSOR SIGNAL EARTH

UPSTREAM OXYGEN SENSOR SIGNAL

INJECTION FAULT WARNING LIGHT CONTROL

DOWNSTREAM OXYGEN SENSOR SIGNAL EARTH

PUMP/COIL CONTROL RELAY

CANISTER BLEED SOLENOID VALVE

AIR CONDITIONING COMPRESSOR CLUTCH RELAY

HIGH SPEED FAN UNIT CONTROL RELAY

LOW SPEED FAN UNIT CONTROL RELAY

UPSTREAM OXYGEN SENSOR HEATER CONTROL

+ AFTER RELAY FEED


IGNITION COIL CONTROL CYLINDERS 2 AND 3 (opposite

track H3)IGNITION COIL CONTROL CYLINDERS 1 AND 4 (opposite

track H3)

POWER EARTH



INJECTION

Computer 17

17-18

D4F ENGINE

INJECTION COMPUTER TRACK ASSIGNMENTS

CONNECTOR A (BLACK)

A1A3

A4

B1

B3

B4

C1

C2

C3

C4

D2

D3D4

E1

E3E4

F1

F4

G1

H1

H2

H3

J1

J4

K1K2

K4

L3

L4

M1

M2

M3

L4

→ →

→

---

←

---

---

→

←

---

←

← →

---

→ →

---

←

→

←

←

---

←

---

← ---

---

---

---

→

→

→

---

INJECTION FAULT WARNING LIGHT CONTROLON BOARD DIAGNOSTIC WARNING LIGHT CONTROL

AIR CONDITIONING COMPRESSOR CONTROL

ACCELERATOR PEDAL POTENTIOMETER SUPPLY

(TRACK 1)

BRAKE SWITCH (CLOSURE)


(TRACK 2)

REFRIGERANT PRESSURE SENSOR SUPPLY

HIGH SPEED FAN CONTROL

BRAKE SWITCH (OPENING)


(TRACK 1)

AIR CONDITIONING CYCLE INFORMATION

IMMOBILISER SYSTEMLOW SPEED FAN CONTROL

DOWNSTREAM OXYGEN SENSOR EARTH

COOLANT TEMPERATURE WARNING LIGHT CONTROLSPEED INFORMATION

ACCELERATOR PEDAL POTENTIOMETER SUPPLY(TRACK 2)

VEHICLE SPEED

FUEL PUMP CONTROL RELAY

ACCELERATOR PEDAL POTENTIOMETER SIGNAL 1

DOWNSTREAM OXYGEN SENSOR SIGNAL

MULTIPLEX CONNECTION (UCH)

REFRIGERANT PRESSURE SENSOR SIGNAL

MULTIPLEX CONNECTION (UCH)

ACCELERATOR PEDAL POTENTIOMETER SIGNAL 2REFRIGERANT PRESSURE SENSOR EARTH

DIAGNOSTIC (LINE K)

+ AFTER IGNITION

+ BEFORE IGNITION

DOWNSTREAM OXYGEN SENSOR HEATER CONTROL

ACTUATOR CONTROL RELAY

CANISTER BLEED CONTROL

+ AFTER IGNITION



INJECTION

Computer 17

17-19

D4F ENGINE

INJECTION COMPUTER TRACK ASSIGNMENTS (CONT)

CONNECTOR B (BROWN)

A1A2

B2

C1

C2

C3

D1

D2

D3

D4

E3

E4

F1

F2F3

F4

G1

G3

J1

K1

K3

K4

L1

L2

L3

L4M1

M2

M3

M4

← ←

---

---

←

←

---

---

---

←

←

←

---

---←

←

---

←

→

→

→

→

→

---

---

---→

→

→

→

SPEED SENSORSPEED SENSOR

MANIFOLD PRESSURE SENSOR FEED

MOTORISED THROTTLE BODY POTENTIOMETERS

SUPPLY (5V)

PINKING SENSOR

PINKING SENSOR

UPSTREAM OXYGEN SENSOR EARTH

PINKING SENSOR SHIELDING

AIR TEMPERATURE SENSOR SUPPLY

AIR TEMPERATURE SENSOR SIGNAL

UPSTREAM OXYGEN SENSOR SIGNAL

AIR TEMPERATURE SENSOR SIGNAL

COOLANT TEMPERATURE SENSOR SUPPLY

MANIFOLD PRESSURE SENSOR EARTHMANIFOLD PRESSURE SENSOR SIGNAL

THROTTLE BODY POSITION POTENTIOMETER

SIGNAL 2THROTTLE BODY POSITION POTENTIOMETER EARTH

THROTTLE BODY POSITION POTENTIOMETERSIGNAL 1

INJECTOR 1 CONTROL

INJECTOR 2 CONTROL

INJECTOR 3 CONTROL

INJECTOR 4 CONTROL

MOTORISED THROTTLE BODY CONTROL

POWER EARTH

POWER EARTH

POWER EARTHMOTORISED THROTTLE BODY CONTROL

IGNITION COIL 2-3 CONTROL

IGNITION COIL 1 CONTROL




CLUTCH

Identification 20120CLUTCH

Identification

VEHICLE

TYPE

GEARBOX

TYPE

ENGINE

MODELMECHANISM PLATE

C06 6

C06 C

JH1 003JH1 002

JH1 007

D7F

D4F

180 DST 3500

26 splines

E = 7.6 mmD = 181.5 mm

BL: Blue

W : WhiteB : Black

R : Red

20-1



MANUAL GEARBOX

Ratios 21

21-1

121MANUAL GEARBOX

Ratios

Capacity - Lubricants

CAPACITY

JH1 5 speed gearbox: 3.40 l.

VISCOSITY GRADE

TRX 75W 80W

CHECKING THE LEVEL

Filling is by overflow

JH1

Index TypeDifferential

ratio

Speedometer

gear 1st 2nd 3rd 4th 5th Reverse

gear

002 C06 61556

2119

1137

2241

2837

3029

4131

1139

003 C06 615

58

21

19

11

37

22

41

28

37

30

29

39

32

11

39

007 C06 C1561

2119

1137

2241

2837

3435

3932

1139

92081R



MANUAL GEARBOX

Consumables 21

21-2

Consumables

Parts which must always be replaced

Hydraulic unit oil

Check the oil level every time the car is serviced. For information on levels see the Tank section.

Oil specified:

ELF RENAULTMATIC D3 SYN (to be ordered from ELF) Standard DEXRON III.

Capacity in litres

DESCRIPTION COMPONENT CONCERNED

MOLYKOTE 33 Medium

Part No.: 77 01 028 179Control axis half-moons

Loctite FRENBLOC Brake caliper mounting bolt

Parts to be replaced when they have been removed:

– self-locking nuts,

– gaskets,

– rubber seals.

Hydraulic unit

Total volume 0.6



MANUAL GEARBOX

Introduction 21

21-3

Introduction

A sequential gearbox is an automated manual gearbox. Clutch engaging and disengaging and gear changing are

computer controlled.

Thus the clutch pedal disappears, gear selection is controlled by an electric switch lever and the accelerator pedal iselectrically linked to the engine via the engine computer.

Gear change times are reduced and the driver and passengers are assured a comfortable journey.

MAINTENANCE: (to be carried out during every workshop visit).

Check:

– the hydraulic fluid level (see Tank section),

– operation of horn:

q apply the handbrake,

q start the vehicle,q select a gear (indicated by the letter "A" on the control panel),

q open the driver's door,the horn should sound.

– the start lock system:

q apply the handbrake,

q select a gear (do not depress the brake pedal),

q attempt to start the engine,

the starter should not work.

TOWING:

If the gearbox is stuck in gear:

– switch on the ignition,

– depress the brake pedal,

– select neutral,

– check that the car is in neutral (e.g. by pushing the car a little).

If neutral gear cannot be engaged, the car will have to be towed with the front wheels raised.

Always switch the engine off before towing a vehicle.



MANUAL GEARBOX

Instructions 21

21-4

Instructions

IMPORTANT:

SEQUENTIAL GEARBOX

Clean the hydraulic unit using a compressed air cleaning product before attempting any operations.

NEVER LEAVE THE CIRCUIT OPEN

NEVER USE A HIGH PRESSURE CLEANER

THROTTLE

Under no circumstances should the throttle body be opened or removed.

HYDRAULIC UNIT

Dump the pressure in the accumulator before attempting any operations.

Always use the hydraulic unit handling frame when carrying out removal operations.

SEQUENTIAL GEARBOX COMPUTER

Switch off the ignition and wait one minute before disconnecting the computer.

18278S





MANUAL GEARBOX

Operating principle 21

21-6

Operating principle

The hydraulic unit installed in the gearbox is made up of two actuators:

→ one to select and change gear,

→ and one to control the clutch and the hydraulic power unit.

The assembly is linked to the sequential gearbox computer and the engine computer.

The gear is selected at the gear lever:

→ in automatic mode, gear changes are controlled by the computer according to autoadaptive rules,

→ in manual mode, the driver shifts the lever to send a signal to the computer, which then implements

the gear change.

When changing gear, the sequential gearbox computer controls the engine torque so as to reduce jolts, leaving the

driver free to leave his foot on the accelerator.

The automatic mode used by the sequential gearbox is based on the design of the DP0 automatic gearbox which

uses rules which adapt themselves automatically to the driving style and road conditions.

The sequential gearbox is a manual gearbox with a hydraulic control. It has, thus, become possible to automate a

5 speed manual gearbox.



MANUAL GEARBOX

Hydraulic unit 21

21-7

Hydraulic unit

GENERAL

18119R

1 Clutch actuator

2 Pump

3 Reservoir

4 Accumulator

5 Actuator module

6 Low pressure pipe

7 High pressure pipe



MANUAL GEARBOX

Hydraulic unit 21

21-8

N.B.: DUMP THE ACCUMULATOR PRESSURE

USING THE DIAGNOSTIC TOOL BEFORE

ATTEMPTING ANY OPERATIONS ON THE

SEQUENTIAL SYSTEM.

The accumulator pressure is dumped using theaccumulator pressure dump command.

The buzzer sounds to indicate that procedure hasbeen completed.

To confirm that the system is depressurised, go to the

PR018 hydraulic pressure parameter to read the

value.

If there is still pressure in the system, repeat theaccumulator pressure dump procedure until the

pressure is negligible and will not pose a risk when thehigh pressure pipes are removed.

REMOVAL

The sub-frame and gearbox must be removed in order

to remove the hydraulic unit.

For information on removing the sub-frame, consult

Workshop Repair Manual 305 Section 21.

Remove the gearbox without damaging the hydraulic

unit.

Remove the gearbox hydraulic unit

Disconnect the clutch fork cable.

Disconnect the primary speed sensor connector.

Unscrew the gear change control shaft by turning it 1/4

of a turn with a screwdriver.

Locked control shaft.

The shaft grooves should be facing the mark.

Unlocked control shaft.

The shaft groove should be at a 90˚ angle to the mark.


Pump assembly M8 bolts 2.4


Actuator module nuts 2.1

Actuator module studs 0.8

High pressure pipe unions 1.4

17970S

17969R



MANUAL GEARBOX

Hydraulic unit 21

21-9

Fit the hydraulic unit handling frame.

Undo the six mounting bolts and remove the hydraulic

unit.

REFITTING

Check that the half-moons are positioned correctly.

Position the half-moons and the circlips in the control

shaft groove.

Grease the two MOLYKOTE 33 Medium half-moons

Place the control shaft on the actuator modules in a

raised and locked position.

The screwdriver slot and the shaft finger should be

facing the mark.

Fit the gasket.

Refit the hydraulic unit on the gearbox.

17968S

18011S

17972S

17970S



MANUAL GEARBOX

Hydraulic unit 21

21-10

Remove the hydraulic unit handling frame.

Tighten the hydraulic unit mounting bolts to tightening

torque.

Using a screwdriver, press on the control shaft to clip it

onto the actuator module.

Refit the control shaft closure plate (oil the seal).

Refitting the gearbox does not pose any special

problems; refitting is the reverse of the removalprocedure.

Remove the fuel refill tank breather.

Refill the oil tank with ELF RENAULTMATIC D3 SYN

Dexron III between 32 and 38 mm above the MIN

mark.

Reprogram using the diagnostic tool, (consult theSpecial notes after replacing components in the

Hydraulic unit kit section, pages 21-36)

Topping up the reservoir

The reservoir marker is at MIN.

At rest: carry out the accumulator pressure dump

procedure. The oil level is between 32 and 38 mm

above the MIN mark.

IMPORTANT:

After the accumulator has been fully pressurised

(15 seconds after the ignition is switched on): The

oil level will be at the MIN mark.

17970R



MANUAL GEARBOX

Accumulator 21

21-11

Accumulator

OPERATION

The accumulator allows the pump to work

intermittently.When it is fully pressurised, it allows

three gear changes with clutch engagement/

disengagement.

Nominal operating pressures: at 20˚C: 45 bar to 55 bar

at -30˚C: 35 bar to 44 bar

N.B.:DUMP THE ACCUMULATOR PRESSURE USING

THE DIAGNOSTIC TOOL BEFORE ATTEMPTING

ANY OPERATIONS ON THE SEQUENTIALSYSTEM.

Dump the pressure in the accumulator using the

accumulator dump command (AC081).

To confirm pressure loss, go to the PR018 hydraulic

pressure parameter to read the value.

If there is still pressure in the accumulator, repeat the

accumulator dump procedure until the pressure is

negligible and will not pose a risk when the high

pressure pipes are removed.

The pressure reading should be almost zero.

REMOVAL


Drain the reservoir using a syringe.

Remove:

– the upper mountings of the gearbox,

– the accumulator.

REFITTING

Stick the safety label on the accumulator.

Proceed in the reverse order.

Refill the oil tank with ELFRENAULTMATIC D3 SYN Dexron III between 32 and

38 mm above the MIN mark.

Reprogram using the diagnostic tool (consult theSpecial notes after replacing components in the

Accumulator system).




procedure. The oil level is between 32 and 38 mmabove the MIN mark.

IMPORTANT:

After the accumulator has been fully pressurised(15 seconds after the ignition has been switched

on): The oil level will be at the MIN mark.


Accumulator 4

Lifting eye 2.1

18118S



MANUAL GEARBOX

Pump unit 21

21-12

Pump unit

N.B.:

DUMP THE ACCUMULATOR PRESSURE USING


ANY OPERATIONS ON THE SEQUENTIAL

SYSTEM. (Consult the Accumulator section)

REMOVAL



Remove:

– the battery, – the air filter hose.

Disconnect the clutch cable.

Disconnect the injection computer.

Remove:

– the high pressure pipes,

– the low pressure pipes,

– disconnect the wiring,


– the accumulator,

– Remove the three mounting bolts (C) from the pump

unit.

REFITTING


Refill the oil reservoir with ELF

RENAULTMATIC D3 SYN Dexron III between 32 and


Reprogram using the diagnostic tool (consult the

Special notes on reprogramming after replacing

components in the system).



At rest: carry out the accumulator pressure dumpprocedure. The oil level is between 32 and 38 mm

above the MIN mark.

IMPORTANT:

After the accumulator has been fully pressurised(15 seconds after the ignition is switched on): The






Accumulator 4

18012R



MANUAL GEARBOX

Pump 21

21-13

Pump

N.B.:





REMOVAL



Remove:

– the battery, – the air filter hose.

Disconnect the clutch cable.

Remove:

– the injection computer,

– the high pressure pipes, – the low pressure pipes,

– disconnect the wiring,


– the accumulator, – remove the three mounting bolts (C) from the pump

unit (see previous page),

– the reservoir,

– the pump, by removing the three bolts (B).

REFITTING




38 mm above the MINmark.

A PressureB Suction





Accumulator 4

M6 pump bolts 1

17981R1

DI2172



MANUAL GEARBOX

Pump 21

21-14

WARNING:

The sequential gearbox pump unit relays MUST be replaced when the pump unit is replaced.

The relay may have been damaged by excessive friction.Therefore the relays must be changed in order to avoid

damaging the new pump unit.

The pump relay (A) is located in the connection unit in the engine compartment.

Re-program using the diagnostic tool, consult the Pump only in the programming section.

Topping up the reservoir.


At rest: carry out the accumulator pressure dump procedure. The oil level is between 32 and 38 mm above the MIN mark.

IMPORTANT:After the accumulator has been fully pressurised (15 seconds after the ignition is switched on): The oil level

will be at the MIN mark.

18228R



MANUAL GEARBOX

Reservoir 21

21-15

Reservoir

N.B.:





REMOVAL



Remove:


– the high pressure pipes, – the gearbox mounting bracket,

– the accumulator,

– the reservoir mounting bolts (A).

A Suction

B Return

REFITTING


Refill the oil tank with ELF




Special notes after replacing components in thereservoir system).





IMPORTANT:





Accumulator 4


Lifting ring mounting nut 2.1

18012R1

DI2173



MANUAL GEARBOX

Clutch module 21

21-16

Clutch module

N.B.:



ANY OPERATIONS ON THE SEQUENTIALSYSTEM. (Consult the Accumulator) section

REMOVAL

The pump unit must be removed in order to remove

the clutch module.

For information on removing the pump unit, consultpage 21-12.

Remove:

– the reservoir,

– the pump, by removing the three bolts (B).

Remove:

– the sleeve stop,

– the dust seal,

– the clutch position sensor, taking care not to displace

the clutch cylinder.

Remove: – the piston spring assembly,

– the potentiometer control (A),

– the piston brace (B) using a screwdriver,

– the clutch cable (C).


Accumulator 4





M6 pump bolts 1

17981R1

17980S

17983R



MANUAL GEARBOX

Clutch module 21

21-17

Remove the clutch module sleeve with the seal.

REFITTING

IMPORTANT:

The piston seals have special lips and must be fitted

the right way round.

Check that the piston seals are in good condition.

Refit:

– the clutch cable in the piston (C),

– the brace (B),

– the potentiometer control (A).

Refit:

– the spring, – the sleeve (A) by pressing the spring and observing

the direction of fitting so as not to cut the piston seal.

18007S

17982S

17985R

17986R



MANUAL GEARBOX

Clutch module 21

21-18

Refit the sleeve (B) ensuring you observe the direction

of fitting so as not to damage the lip seal.

Refit:

– the cylinder liner-piston assembly in the clutch

module.

– the seal.

Clip the potentiometer to its control.

Screw the potentiometer to the clutch module,

compressing the spring.

Refit:

– the dust seal,

– the sleeve stop.

Proceed in the reverse order to removal to complete

the operation.





Special notes after replacing components in the clutch

cylinder system).





IMPORTANT:



17983-1R

17984S1

17980S



MANUAL GEARBOX

Actuator module 21

21-19

Actuator module

KEY

1 Clutch operation solenoid valve

2 Engagement solenoid valve

3 Selection solenoid valve

4 Engagement position sensor

5 Selection position sensor

6 Pressure sensor

7 High pressure filter

17979R



MANUAL GEARBOX

Actuator module 21

21-20

N.B.:




SYSTEM. (Consult the Accumulator) section

REMOVAL



Remove:

– the battery,

– the air filter hose, – the injection computer,

– the clutch cylinder connections, – the connector mounting plate (A).

Remove:

– the lifting ring mounting bracket (B),

– the accumulator (C),

– the high pressure pipes,


– the reservoir,

– the left headlight,

– the wheel,

– the left wheel arch liner,

– the earth strap on the gearbox.

Fit the engine support Mot. 1453.

Uncouple the gearbox mounting from its housing.

Lower the gearbox as far as possible.

Remove the control shaft closure panel.


Actuator module studs 0.8

Actuator module nut 2.1

Solenoid valve bolts 0.4

Control shaft closure panel bolts 0.6


Accumulator 4

18118R

96107R

17975S



MANUAL GEARBOX

Actuator module 21

21-21

Unscrew the gear change control shaft by turning it 1/4

of a turn with a screwdriver.

Remove the hydraulic unit.

REFITTING

Check that the half-moons are positioned correctly.

Position the half-moons and the circlips in the controlshaft groove.

Grease the two MOLYKOTE 33 Medium half-moons

Place the control shaft on the actuator modules in a

raised and locked position.

The screwdriver slot and the shaft finger should befacing the mark.

Fit the gasket.

Refit the actuator module on the gearbox.

17969R

18011S

17972S

17970S



MANUAL GEARBOX

Actuator module 21

21-22

Tighten the actuator module on the gearbox to the

correct tightening torque.

Using a screwdriver, press on the control shaft to clip it

onto the actuator module.

Connect: – the actuator earth wire,

– the connections.

Refit: – the control shaft closure panel (oil the seal).

– the gearbox mounting on its housing.

Remove the engine support tool Mot. 1453.

Refitting does not present any specific problems and

should be performed in the reverse order to removal.




Reprogram using the diagnostic tool, (consult the

Special notes after replacing components in the

selection cylinder, engagement cylinder system

section).




above the MIN mark.

IMPORTANT:




17970R



MANUAL GEARBOX

Solenoid valves 21

21-23

Solenoid valves

N.B.:





Follow the instructions on pages 21-4.

REMOVAL

Disconnect:

– the battery, – the hydraulic unit wiring harness connector.

Remove: – the air filter sleeve,

– the sleeve mounting,

– the computer,

– the gearbox mounting (B), – the accumulator (C),

– the hydraulic unit wiring harness connector (A).

Disconnect the connectors of the solenoid valves

concerned.

Disconnect the solenoid valves in order of removal.

A Clutch operation solenoid valveB Selection solenoid valve 4

C Selection solenoid valve 3D Engagement solenoid valve 1

REFITTING



RENAULTMATIC D3 SYN Dexron III between 32 and38 mm above the MIN mark.

Reprogram using the diagnostic tool, (consult theSpecial notes after replacing components in the

solenoid valves operations section).





IMPORTANT:




Accumulator 4



Solenoid valve bolts 0.4

18118R

17978R



MANUAL GEARBOX

Solenoid valves 21

21-24

Engagement solenoid valve 2:

REMOVAL

The gearbox must be lowered in order to remove

engagement solenoid valve 2.

Remove:

– the battery,

– the air filter sleeve,

– the injection computer,

– the left headlight,

– the wheel,

– the left wheel arch liner,

– the earth strap on the gearbox.

Fit the engine support Mot. 1453.

Uncouple the gearbox mounting from its housing.

Lower the gearbox as far as possible.

Disconnect the engagement solenoid valve 2

connector (D).

Remove the engagement solenoid valve 2 (D).

REFITTING







solenoid valves operations section).





IMPORTANT:After the accumulator has been fully pressurised



17975S

17978R5



MANUAL GEARBOX

Engagement position sensor 21

21-25

Engagement position sensor

N.B.:





Removal of the engagement position sensor does notrequire removal of the actuator module.

REMOVAL

Operating from underneath, remove the accelerator

pedal potentiometer and its mounting.

Disconnect the engagement position connector (A).

Remove the engagement position sensor (A).

REFITTING




engagement position sensor operations section).





above the MIN mark.

IMPORTANT:




Engagement position sensor bolts 0.4

Actuator module nuts 2.1



Accumulator 4

17974-1S

17978R2



MANUAL GEARBOX

Selection position sensor 21

21-26

Selection position sensor

N.B.:





The car must be in 1st gear before the selection

position sensor is removed.

REMOVAL


Remove:

– the air filter sleeve, – the sleeve mounting.

Disconnect the hydraulic unit wiring harness

connector (A).

Remove the hydraulic unit wiring harness connector mounting (A).

Disconnect the selection position connector (B).

Remove the selection position connector (B).

REFITTING

Check that the selection sensor can rotate freely.

Proceed in the reverse order to removal to complete

the operation.



selection position sensor operations section).




above the MIN mark.

IMPORTANT:




Engagement position sensor bolts 0.4

Solenoid valves 0.4



Accumulator 4

18118R1

17978R3



MANUAL GEARBOX

Clutch position sensor 21

21-27

Clutch position sensor

N.B.:




REMOVAL

Remove:

– the gearbox mounting.

Disconnect the clutch position sensor connector.

Remove the clutch position sensor (A).

REFITTING




"clutch position sensor operations" section).





above the MIN mark.

IMPORTANT:




Clutch position sensor bolts 0.4





Accumulator 4

17980R



MANUAL GEARBOX

Pressure sensor 21

21-28

Pressure sensor

N.B.:




REMOVAL


Disconnect the pressure connector (C).

Remove the pressure sensor (C) using a thin 14 mm

spanner.

REFITTING


Refill the oil tank with ELF RENAULTMATIC D3 SYN

Dexron III oil.



"pressure sensor" system).





above the MIN mark.

IMPORTANT:





Position sensor bolts 0.4

Actuator module nut 4.4



Accumulator 4

17978R4



MANUAL GEARBOX

Speed sensor 21

21-29

Speed sensor

After the gearbox speed sensor has been replaced, the car must be driven to switch off the fault warning light and

erase the computer memory.

The computer will only erase the fault if it receives a speed signal from the sensor.



MANUAL GEARBOX

Computer 21

21-30

Computer

LOCATION

It is located in the engine compartment on the front

right wheel arch.

The connector is split into two sections (52 track

+ 28 track).

REMOVAL - REFITTING

Switch off the ignition and disconnect the battery

before operating on the computer.

IMPORTANT:

Reprogram the computer after it has been replaced.

17976S



MANUAL GEARBOX

Computer 21

21-31

TRACK ASSIGNMENT

52 track connector

1

2

3

26

27

28

29

31

32

33

36

38

39

4041

42

43

44

45

49

50

51

52

---

---

→

←

---

---

→

→

→

→←

←

←

←

← →

→

→

→

→←

→←

←

←

←

POWER EARTH 1

POWER EARTH 2

SELECTION SOLENOID VALVE 4 CONTROLCHANGING UP SIGNAL

+ BATTERY

+ AFTER IGNITION

SELECTION SOLENOID VALVE 3 CONTROL

PUMP UNIT SOLENOID RELAY

ENGAGEMENT SOLENOID VALVE 1 CONTROL

DIAGNOSTIC SOCKET: CAN L

VEHICLE SPEED SIGNAL

INPUT BOX SPEED SENSORENGAGEMENT POSITION SENSOR SIGNAL

PRESSURE SENSOR SIGNALFAULT WARNING LIGHT

STARTER SOLENOID VALVE RELAY

CLUTCH SOLENOID VALVE CONTROL

ENGAGEMENT SOLENOID VALVE 2 CONTROL

DIAGNOSTIC SOCKET: CAN H

DIAGNOSTIC LINE K

INPUT BOX SPEED SENSOR

SELECTION POSITION SENSOR SIGNALENGAGEMENT POSITION SENSOR SIGNAL

28 track connector

65

66

67

68

69

71

7273

7476

7778

80

---

---

←

←

←

←

→

---

←

←

←

←

→

GEAR LEVER EARTH

SENSORS EARTH

STABLE POSITION SIGNAL (STAND-BY)

CHANGING DOWN SIGNAL

BRAKE PEDAL SWITCH

HANDBRAKE SWITCH

INSTRUMENT PANEL SIGNALSENSORS SUPPLY

CHANGING TO NEUTRAL SIGNALKEY AFTER STARTING SIGNAL

AUTO MODE CONTACTDOOR SWITCH

HORN CONTROL

←

→

INPUT

OUTPUT



MANUAL GEARBOX

Relay 21

21-32

Relay

LOCATION

The system activates two relays:

– the starter authorisation relay (A), located near to buzzer (B) under the dashboard,

– The pump relay (C), located in the connection unit in the engine compartment.

REMOVAL - REFITTING

Switch off the ignition and disconnect the battery before operating on the system.

18228-1R



MANUAL GEARBOX

Fuses 21

21-33

Fuses

LOCATION

The system is supplied via three fuses:

– the + after ignition 3A fuse (A), located on the passenger compartment fuse plate, connected to pin 28 on the

sequential gearbox computer connector.

– the + battery 20A fuse (B), located on the engine compartment connection unit, connected to pin 27 on thesequential gearbox computer connector.

– the + battery 30A fuse (C), located on the engine compartment connection unit supplying the system pump unit.

REMOVAL - REFITTING

Switch off the ignition and disconnect the battery before operating on the system.

18228-2R



MANUAL GEARBOX

Harness 21

21-34

Harness

It is integrated to the hydraulic unit and unites the eleven connectors of the various system components.

The earths of the five solenoid valves are united on one terminal, a fixed plate on the hydraulic unit.

The pump unit earth is fixed to the clutch cylinder body.

The connection to the car wiring harness is made through a 24 track SICMA connector located on top of the system.

ALLOCATION OF CONNECTOR TRACKS

A8

B2

B3

B4

B5

B6

C1

C2

C3

C4

C5

C6

C7

C8

→

→

→

→

→

→

---

←

←

←

←

---

←

→

PUMP UNIT CONTROL +

CLUTCH SOLENOID VALVE CONTROL+

ENGAGEMENT SOLENOID VALVE 2 CONTROL +

SELECTION SOLENOID VALVE 3 CONTROL +

ENGAGEMENT SOLENOID VALVE 1 CONTROL +

SELECTION SOLENOID VALVE 4 CONTROL +EARTHS FOR:

- ENGAGEMENT SENSOR

- SELECTION SENSOR- CLUTCH SENSOR

- PRESSURE SENSOR

ENGAGEMENT SENSOR SIGNAL

SELECTION SENSOR SIGNAL

CLUTCH SENSOR SIGNAL

PRESSURE SENSOR SIGNAL

GEARBOX INPUT SPEED SENSOR EARTH -

GEARBOX INPUT SPEED SENSOR SIGNAL+CONTROL+:- ENGAGEMENT SENSOR

- SELECTION SENSOR

- CLUTCH SENSOR

- PRESSURE SENSOR

←

→

INPUTOUTPUT



MANUAL GEARBOX

Gear lever 21

21-35

Gear lever

USING THE GEAR LEVER

JoyStick gear levers have only one stable position.

All manoeuvres start from this position, also called

STAND-BY.

– move the lever forwards (+): to change to a higher gear,

– move backwards (-): to change to a lower gear,

– move right (N): to change to neutral,

– move right and then backwards (R): to change to

reverse.

Button (A) switches the automatic mode on or off,

according to the driver's requirements.

The gear selected is displayed on the instrument

panel. The R symbol on the gear lever base remindsthe driver that reverse gear has been selected.

OPERATION

The sequential gearbox is electrically controlled.

Contacts at the bottom of the control module sendelectronic signals to the gearbox computer when the

gear lever positions is changed.

16671S

17977R



MANUAL GEARBOX

Gear lever 21

21-36

REMOVAL


Remove:

– the gear lever console cover,

– the gear lever console.

Disconnect the gear lever electrical connection.

Remove the two LED supply wires for display R on the

gear lever electrical connector (tracks 6 and 7).

Remove the supply wires for the automatic or

sequential selector push button on the gear lever

electrical connector (tracks 8 and 9).

Allocation of the connector pins (ten tracks):

Unclip the washer from the gear lever base.

Pull upwards to remove the gear lever knob (follow the

direction of the arrow).

Remove the four mounting bolts from the gear lever

base plate.

Change the faulty part.

REFITTING

Refitting does not present any specific problems and

should be performed in the reverse order to removal.

18006R

Track 1

Track 2Track 3

Track 4

Track 5Track 6

Track 7Track 8

Track 9

Track 10

:

::

:

::

::

:

:

Gear lever earth

Change up signalChange down signal

Stable position signal (STAND-BY)

Change to neutral signalEarth

Change to reverse signalEarth

Change to automatic mode signal

Not connected

SE2037

18006-1R



MANUAL GEARBOX

Special notes for replacing system components 21

21-37

Special notes for replacing system components

HYDRAULIC UNIT KIT/COMPUTER/GEARBOX/REPROGRAMMING

A)

B)

C)

D)

E)

F)

G)

Switch on the ignition

Restart all programming procedures: RZ002 Programming.

Command name: VP008 Programming selection zone/engagement.Wait until the end of the procedure

Switch off the ignition.Wait 1 minute

Switch on the ignition (the buzzer sounds if there is a fault)

Check programming OK: status ET061 Range good; if Range complete or status ET063 Solenoid valve

point zero are displayed, repeat procedure (B).

Engagement of all gear positions (signal OK on control panel display)

Shift the gear lever to neutral

Start the engineWait 10 seconds (until clutch biting point is programmed) without changing gear.

Check programming OK: status ET062 Biting point done if not, repeat procedure D.

Start the engine at half load 5 or 6 times until clutch temperature status PR095 is below 180 ˚C (for clutchprogression programming)

Switch off the ignition.

Wait 1 minute


Check programming OK: status ET065 Progression done and check again if the Progression signal varies.If not, repeat procedure E.

Command name: CF321 Gearbox type, options: short or long gearbox.

Check that the Gearbox type information is correct.


ENGAGEMENT POSITION SENSOR/SELECTION POSITION SENSOR

A)

B)

C)D)


Ensure there is no fault

Command name: VP008 programming selection zone/engagement.

Wait until the end of the procedure


Switch on the ignition (the buzzer sounds if there is a fault)

Check programming OK: status ET061 Range good; if Range zone or status ET063 Solenoid valve point

zero are displayed, repeat procedure (B).

Engagement of all gear positions (signal OK on control panel display)Switch off the ignition.

CLUTCH POSITION SENSOR/CLUTCH

A)

B)C)

D)



Command name: RZ003 Biting point programming.Put the gear lever in neutral

Start the engine

Wait 10 seconds (until clutch biting point is programmed) without changing gear.

Check programming OK: status ET062 biting point done if not, repeat procedure C.Start the engine at half load 5 or 6 times until the "clutch temperature" status PR095 is below 180 ˚C (for

progression clutch programming).





MANUAL GEARBOX


21-38

E)

Check programming OK: status ET065 Progression done and check again if the Progression signal

varies. If not, repeat procedure D.


PRESSURE SENSOR

A)

B)



Command name: AC011 bleed hydraulic pressure unit.



SELECTION SOLENOID VALVE/ENGAGEMENT SOLENOID VALVE

A)

B)

C)

D)


Ensure there is no faultCommand name: AC011 bleed hydraulic pressure unit.Wait until the end of the procedure


Engagement of all gear positions (signal OK on control panel display)


CLUTCH SOLENOID VALVE

A)

B)

C)

D)



Open the hydraulic unit bleed screwCommand name: AC008 bleed clutch circuit phase 1.

Close the bleed screw as soon as the fluid is running clear air bubblesWait until the end of the procedure (duration 6 minutes)

Command name: AC008 bleed clutch circuit phase 2.

Wait until the end of the procedure (duration 8 minutes)

Command name: AC011 bleed hydraulic pressure unit.



SELECTION CYLINDER/ENGAGEMENT CYLINDER/TANK/ACCUMULATOR/PUMP ONLY

A)

B)

C)

D)

E)


Ensure there is no faultCommand name: AC011 bleed hydraulic pressure unit.


Command name: VP008 Programming selection zone/engagement.Wait until the end of the procedure


Wait 1 minute

Switch on the ignition (the buzzer sounds if there is a fault)Check programming OK: status ET061 Range good; if Range done or status ET063 Solenoid valve point

zero are displayed, repeat procedure C.Engagement of all gear positions (signal OK on control panel display)




MANUAL GEARBOX


21-39

CLUTCH CYLINDER/FLUID LEAK DURING CLUTCH CABLE REPLACEMENT

A)

B)

C)

D)

E)

F)


Ensure there is no faultOpen the hydraulic unit bleed screw


Close the bleed screw as soon as the fluid runs clear of air bubbles




Command name: RZ003 Biting point programming.

Put the gear lever in neutralStart the engine

Wait 10 seconds (until clutch biting point is programmed) without changing gear

Check programming OK: status ET062 biting point done if not, repeat procedure E.


HIGH PRESSURE PIPE

A)

B)

3)



Open the hydraulic unit bleed screw

Command name: AC008 bleed clutch circuit phase 1 Close the bleed screw as soon as the fluid runs clear of air bubbles


Command name: AC009 bleed clutch circuit phase 2

Wait until the end of the procedure (duration 8 minutes)Switch off the ignition.



MECHANICAL ELEMENT CONTROLS

Master cylinder 37

37-1

137MECHANICAL ELEMENT CONTROLS

Master cylinder

REMOVAL


Remove:

– the battery mounting,

– the battery,

– the plastic protector for the computer,

Disconnect and remove the computer.

Drain the brake reservoir using a syringe.

Remove the reservoir, taking care to not spill any

brake fluid. Use a cloth.

Remove:

– the two brake pipes, (mark them).

– the master cylinder mountings.

In the passenger compartment, unscrew the 4 brakeservo mountings.

Pivot the brake servo downwards to release the

master cylinder.

REFITTING

Check the length of the pushrod.

Dimension X = 22.3 mm.

Depending on model, adjust using pin (P).


M 10 X 100 1.3

Master cylinder bolts 1.5

Brake servo bolts 2

94693S




Master cylinder 37

37-2

N.B.: these vehicles have a master cylinder which is

integral to the brake servo. Sealing of the brake servo

is directly linked to that of the master cylinder. During

any operation, a new seal (A) must be fitted.

Fit the master cylinder in alignment with the brake

servo so that pushrod pin (P) enters the master

cylinder housing correctly.

Reconnect:

– the pipes, ensuring they are in the positions

marked before removal,

– the compensation reservoir by pressing down on it to

click it into the master cylinder,

Bleed the brake circuit.




Brake servo 37

37-3

Brake servo

The brake servo cannot be repaired. Operations are

only allowed on: – the air filter,

– the non-return valve.


REMOVAL

Remove the master cylinder (follow the proceduredescribed on the previous page).

Using tool Elé. 1294-01 remove the two windscreenwiper mounting nuts.

Remove:

– the air inlet pipe,

– the three wiper motor mounting bolts.

– the wiper motor, – the non-return valve on the brake servo,

– the front left lens unit.

Fit the engine support tool Mot. 1453.

Remove the gearbox mounting bolts.

Fit the two Tav. 1233-01 8 mm diameter tools.

SPECIAL TOOLING REQUIRED

Elé. 1294 -01 Windscreen wiper arm

removing tool

Mot. 1453 Engine support

2 x Tav. 1233-01 Front subframe holding screw


M 10 X 100 1.3

Master cylinder bolts 1.5

Brake servo bolts 2

Gearbox mounting nuts 4.5

Sub-frame bolt 6.5

Upper windscreen wiper nut 1.6

Lower windscreen wiper nut 1.2

17975S

17967S




Brake servo 37

37-4

Remove:

– the shaft from the yoke connecting the brake pedal to

the push rod after having removed the clip,

– the brake servo mounting bolts,

– the steering shaft yoke nut,

– the two engine tie-bar bolts.

Gradually lower the engine and transmission assembly

and the sub-frame, to allow the release of the brake

servo.

REFITTING

Proceed in the reverse order to removal.

Before refitting, check that:

Dimension L = 94.5 mm

can be adjusted using pushrod C (see diagram)

Dimension X = 22.3 mm

can be adjusted using pushrod P (see diagram)

Fit the master cylinder in place (consult the advice in

the relevant section).

Bleed the brake circuit.

94692R

94693S




Air filter - Brake servo non-return valve 37Air filter - Brake servo non-return valve

REPLACING THE AIR FILTER

There is no need to remove the brake servo to replace

the air filter (F).

Under the pedal mounting, use a screwdriver or a

metal hook to remove the worn filter (F).

Cut the new filter at A (see diagram) and fit it aroundthe rod, then press it into position, checking that it fills

the opening completely to prevent any non-filtered air

from passing through

REPLACING THE NON-RETURN VALVE

This operation may be carried out on the vehicle.

REMOVAL

Disconnect the brake servo vacuum inlet pipe.

Pull and turn the non-return valve to release it from the

rubber sealing washer.

REFITTING

Check the condition of the rubber sealing washer and

the non-return valve.

Replace any faulty parts.

Refit the assembly into position.

75564G

74883S

Documents

Technical Note 3364a