engine RENAULT KANGOO 1997 KC / 1.G Foult Finding - Injection Workshop Manual

Contents
BATTERIE PROJECTEURS
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Aid
Checking conformity
Customer complaints
Fault charts13-1
13-2
13-5
13-31
13-32
13-37
13-38Page Page
Fault finding
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Checking conformity
Aid
Customer complaints
Fault charts38-1
38-2
38-4
38-18
38-19
38-20
38-21
ELECTRONICALLY CONTROLLED
HYDRAULIC SYSTEMS
LUCAS DIESEL INJECTION13
38
BATTERIE PROJECTEURS
E7J 780 engine
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Status and parameter checks
Status and parameter
interpretation
Customer complaints
Fault charts
Aid
Checking conformity
D7F 710 engine - 35 tracks
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Status and parameter checks
Status and parameter interpretation
Customer complaints
Fault charts
Aid
Checking conformity17-1
17-6
17-9
17-30
17-36
17-56
17-57
17-62
17-63
17-75
17-80
17-83
17-103
17-109
17-128
17-129
17-134
17-135INJECTION17
BATTERIE PROJECTEURS
D7F 710 engine - 55 tracks
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Status and parameter checks
Status and parameter interpretation
Customer complaints
Fault charts
Aid
Checking conformity17-147
17-152
17-155
17-175
17-181
17-201
17-202
17-207
17-208INJECTION (cont)17

F8Q 630/662 ENGINE
LUCAS DIESEL INJECTION
FAULT FINDING
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01
XR25 fiche . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02
Interpretation of XR25 bargraphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checking conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Customer complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fault charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Page

BARGRAPH SYMBOLS
FAULTS
(always on a coloured background)
If illuminated, there is a fault with the product tested. The associated text
defines the fault.
The bargraph may be :
- Permanently illuminated : fault present.
- Flashing : fault memorised
- Extinguished : no fault or not diagnosed
STATUS (always on a white background)
Bargraph always at the top right hand side.
If illuminated dialogue has been established with the computer for the product.
If it remains extinguished:
- The code does not exist.
- There is a fault with the tool, the computer or the XR25 / computer connection.
The representation of the following bargraphs indicates their initial status:
Initial status: (ignition on, engine stopped, no operator action)
Indefinite
- illuminated when the function or condition on the fiche is met.
Extinguished
Illuminated - extinguishes when the function or condition on the fiche is no
longer met
ADDITIONAL NOTES
Certain bargraphs have a *. The *.. command, when the bargraph is illuminated,
allows additional information on the type of fault or status to be displayed.
DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - XR25 fiche
13
or
13-4

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIR
Fiche n° 60 1/2
Bargraph 1 RH extinguished
Code present
1
Use bornier Elé. 1332 for any operations on the computer connector.NOTES
When communication is established, deal with any fault bargraphs which may be
illuminated.
Ensure that the XR25 is not the cause of the fault by trying to communicate with the computer on ano-
ther vehicle. If the XR25 is not the cause of the fault and dialogue is not established with another compu-
ter on the same vehicle, a faulty computer may be causing interference on the K and L fault finding lines.
Disconnect connections successively to determine which computer is at fault.
Check the ISO selector is on position S8, that you are using the latest XR25 cassette and the correct access
code (D34).
Check the battery voltage and carry out any necessary operations to ensure the correct voltage (U battery
> 10.5 volts).
Check the 15 Amp fuses on the engine connection unit have not blown (positions 3 and 4).
Check the connection and condition of the connections on the computer connector and the connection
R67 engine / dashboard.
Check the computer is correctly fed:
- Earth on track 2 of the computer connector (check the condition and tightness of the engine earth
strap and the engine earth MH near to the gearbox housing).
- + after ignition feed on track 1 of the computer connector.
Check the diagnostic socket is correctly fed:
- Earth on track 5.
- + before ignition feed on track 16.
Check and ensure the continuity and insulation of the lines in the connection diagnostic socket/
computer:
- Between track 10 of the computer connector and track 15 of the diagnostic socket.
- Between track 13 of the computer connector and track 7 of the diagnostic socket.
If fault finding is not established after these operations, replace the computer (consult the "Aid" section
for this operation).
13-5

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIRErase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
Bargraph 2 LH illuminated
Coolant temperature sensor circuit
XR25 aid:*02 :co.1 : Open circuit or short circuit to 12 volts
cc.0 : Short circuit or short circuit to earth
2
Use bornier Elé. 1332 for any operations on the computer connector.NOTES
Fiche n° 60 1/2
co.1
Ensure the continuity and insulation in relation to + 12 volts of the following connection :
- Between track 25 on the computer connector and track 2 on the coolant temperature sensor
connector.
Ensure the continuity of the following connection :
- Between track 3 on the computer connector and track 1 on the coolant temperature sensor connector.
Test the connections on the 2 connectors.
If bargraphs 2RH and 3LH are also illuminated, look for a CO of the sen-
sor earth (track 3 of the computer connector)
Also check the condition and tightness of the engine earth strap and
the gearbox engine earth.
NOTES
If the fault persists after these tests, replace the coolant temperature sensor then erase the computer me-
mory.
If the "coolant temperature sensor circuit" fault reappears, replace the computer (consult the "Aid"
section for this operation).
cc.0None NOTES
Ensure insulation from earth of the following connection :
- Between track 25 on the computer connector and track 2 on the coolant temperature sensor
connector.
Check to see if the sensor circuit (or the sensor) is in short circuit (resistance at 60°C = 1.2 Kohms).
Test the connections on the 2 connectors.
If the fault persists after these tests, replace the coolant temperature sensor then erase the computer me-
mory.
If the "coolant temperature sensor circuit" fault reappears, replace the computer (consult the "Aid"
section for this operation).
13-7

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIRErase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
Bargraph 3 RH flashing
Engine speed sensor circuit3
The engine speed sensor circuit fault is present if the bargraph illuminates when
the engine is running.
Use bornier Elé. 1332 for any operations on the computer connector.
NOTES
Measure the resistance of the flywheel signal sensor at its connector. Replace the sensor if the resistance
is not approximately 250 ohms.
Ensure the continuity and insulation of the following lines:
- Between track 8 on the computer connector and track B on the flywheel signal sensor connector.
- Between track 3 on the computer connector and track A on the flywheel signal sensor connector.
Also check the insulation between these two connections.
Test the connections on the 2 connectors.
Carry out a visual inspection of the general condition of the wiring and its routing for possible
interference.
Fiche n° 60 1/2
Check the positioning and condition of the sensor.
Check the condition of the target (deformation, mounting, noise....).
Check the conformity of the target: 2 gaps at 180°.
If the fault persists after these tests, replace the flywheel signal sensor.
If the "engine speed sensor circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
13-11

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIRErase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
Bargraph 5 LH flashing
Needle lift sensor circuit
5
The needle lift sensor circuit fault is present if the bargraph illuminates when the
engine is running. Use bornier Elé. 1332 for any operations on the computer
connector.
NOTES
Measure the resistance of the needle lift sensor at its connector.
Replace the injector with the sensor if the resistance is not approximately 105 ohms.
Ensure the continuity of the following connections:
- Between track 7 on the computer connector and track 1 on the needle lift sensor connector.
- Between track 3 on the computer connector and track 2 on the needle lift sensor connector.
Test the connections on the 2 connectors.
Fiche n° 60 1/2
Ensure the insulation of the connection between track 7 on the computer connector and track 1 on the
needle lift sensor connector .
Also ensure the insulation between the 2 lines on the needle lift sensor.
Also check the condition of the wiring between the sensor connector and the sensor.
If the fault persists after these tests, replace the injector with the sensor.
If the "needle lift sensor circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
The "needle lift sensor circuit" fault may be connected to absence of injection at the cylinder with the
sensor.
Check the condition of the injector and its fuel supply.
13-14

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIRErase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
Bargraph 5 RH illuminated (co.0) or flashing (cc.1)
Altimetric corrector control circuit
XR25 aid:*25 :co.0 : Open circuit or short circuit to earth
cc.1 : Short circuit to 12 volts
5
Use bornier Elé. 1332 for any operations on the computer connector.NOTES
Fiche n° 60 1/2
co.0
Measure the resistance of the altimetric corrector relay coil (position H on engine connection unit).
Ensure the continuity and the insulation from earth of the connection between track 15 of the computer
connector and terminal 2 of the corrector relay mounting.
Ensure the presence of + after ignition feed on track 1 of the corrector relay mounting.
Test the connections on the computer connector and the relay mounting.
None NOTES
cc.1
Measure the resistance of the altimetric corrector relay coil (position H on engine connection unit).
Replace the relay if the resistance is not approximately 85 ohms.
Ensure the insulation from +12 volts of the connection between track 15 on the computer connector
and terminal 2 on the corrector relay mounting.
Even if present at the moment of testing, this fault is declared by a
flashing BG 5RH side. To confirm its presence and the necessity of
following the fault finding below, erase the computer memory
then start command mode G19*.
The fault is present if the bargraph flashes again.
NOTES
If the fault persists after these tests, replace the altimetric corrector relay.
If the "altimetric corrector circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
If the fault persists after these tests, replace the altimetric corrector relay.
If the "altimetric corrector circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
13-15

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIRErase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
1.dEF
This fault indicates that the advance corrector is seized, the injection pump has been incorrectly set or
there is a fuel supply fault.
It is taken into account when the advance noted by the needle lift sensor differs by more than 5° from the
advance value requested by the computer.
NOTE : If there is a fault where the advance corrector is seized, there will be a characteristic noise when
the ignition is switched on (irregular clicking of the corrector).
The fault is present if the bargraph is illuminated when the engine is
running.NOTES
6
CONT
- Check the condition of the fuel supply to the pump and the injectors (filter blocked, pipe kinked, air
leak, ...).
Check the type of diesel fuel used in extreme cold weather (a "summer " type diesel fuel may cause
this fault at -15 °C).
- Check the pump timing and check the tightness of the pump pulley.
- If the fuel supply and the pump timing are correct, replace the advance corrector.
13-17

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Interpretation of XR25 bargraphs13
AFTER REPAIRErase the computer memory (G0**), switch the ignition off, then carry out a road
test.
Finish the operation by checking using the XR25.
Bargraph 7 RH illuminated (co.0) or flashing (cc.1)
EGR solenoid valve circuit
XR25 aid:*27 :co.0 : Open circuit or short circuit to earth
cc.1 : Short circuit to 12 volts
7
Use bornier Elé. 1332 for any operations on the computer connector.NOTES
Fiche n° 60 1/2
co.0
Measure the resistance of the EGR solenoid valve at its connector. Replace the EGR solenoid valve if the
resistance is not approximately 45 ohms.
Ensure continuity of the connection between track 5 on the computer connector and track 1 of the EGR
solenoid valve connector.
Ensure the presence of + after ignition feed on track 2 of the EGR solenoid valve connector, wiring side.
Ensure the insulation from earth of the connection between track 5 on the computer connector and track 1
of the EGR solenoid valve connector.
Test the connections on the 2 connectors.
None NOTES
If the fault persists after these tests, replace the EGR solenoid valve.
If the "EGR solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
cc.1
Measure the resistance of the EGR solenoid valve at its connector. Replace the EGR solenoid valve if the
resistance is not approximately 45 ohms.
Ensure insulation in relation to +12 volts of the connection between track 5 on the computer connector and
track 2 of the EGR solenoid valve connector.
Even if present at the moment of testing, this fault is still declared
by a flashing BG 7RH side. To confirm its presence and the necessity
of following the fault finding below, start the engine.
The fault is present if the bargraph illuminates when the engine is
running.
NOTES
If the fault persists after these tests, replace the EGR solenoid valve.
If the "EGR solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for this
operation).
13-19