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

Contents
Page
Fault finding
BATTERIE PROJECTEURS
Introduction
XR25 fiche
Interpretation of XR25 bargraphs
Customer complaints (petrol
version)
Fault charts (petrol version)
Customer complaints (diesel
version)
Fault charts (diesel version)
Checking conformity
Aid82-1
82-2
82-4
82-14
82-15
82-25
82-26
82-34
82-39IMMOBILISER82
Introduction
Wiring
XR25 fiche
Interpretation of XR25 bargraphs
Checking conformity
Checking the pretensioners
Aid88-1
88-2
88-5
88-7
88-22
88-23
88-24
AIRBAG - PRETENSIONERS88

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Introduction
13
F8Q
630 / 662
CONDITIONS FOR APPLYING THE TESTS DESCRIBED IN THIS FAULT FINDING DOCUMENT
The tests described in this fault finding section should only be applied to the vehicle if the title of the fault
treated corresponds exactly to the display noted on the XR25 when the ignition is switched on.
If a bargraph is interpreted when flashing, the conditions for confirming the presence of an actual fault (and
the necessity of applying the fault finding) are shown in the "Notes" section or at the start of the bargraph
interpretation.
If a bargraph is only interpreted if it is permanently illuminated, the application of these tests recommended
in the fault finding document when the bargraph is flashing will not allow the cause of the memorised fault
to be determined. In this case, only checking of the wiring and connections of the faulty component should
be carried out (the fault is simply memorised as it was not present at the moment of testing).
NOTE: The ignition should be switched off before the XR25 is used.
SPECIAL TOOLING REQUIRED FOR OPERATIONS ON THE DPC DIGITAL INJECTION SYSTEM
- XR25 test kit.
- XR25 cassette N° 17 minimum.
- 25 track bornier Elé. 1332 for testing using the computer connector.
13-1

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 6 LH illuminated (co.0/cc.1) or flashing (1.dEF)
Advance corrector circuit
XR25 aid:*06 :co.0 : Open circuit or short circuit to earth
cc.1 : Short circuit to 12 volts
1.dEF : Pump hydraulic control
6
Use bornier Elé. 1332 for any operations on the computer connector.NOTES
Fiche n° 60 1/2
co.0
Measure the resistance of the advance corrector at the 10 track pump connector (between tracks 2 and
7). Replace the advance corrector if the resistance is not approximately 12 ohms.
Ensure the continuity of the connection between track 6 on the computer connector and track 7 on the
pump connector.
Ensure the presence of + after ignition feed on track 2 of the corrector connector, wiring side.
Ensure the insulation from earth of the connection between track 6 on the computer connector and track 7
on the pump connector.
Test the connections on the 2 connectors.
None NOTES
If the fault persists after these tests, replace the advance corrector .
If the "advance solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
Measure the resistance of the advance corrector at the 10 track pump connector (between tracks 2 and
7). Replace the advance corrector if the resistance is not approximately 12 ohms.
Ensure the insulation from +12 volts of the connection between track 6 on the computer connector and
track 7 on the pump connector.
None NOTES
If the fault persists after these tests, replace the advance corrector .
If the "advance solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
13-16

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 6 RH illuminated (co.0) or flashing (cc.1)
Fast idle solenoid valve circuit
XR25 aid:*26 :co.0 : Open circuit or short circuit to earth
cc.1 : Short circuit to 12 volts
6
Use bornier Elé. 1332 for any operations on the computer connector.NOTES
Fiche n° 60 1/2
co.0None NOTES
If the fault persists after these tests, replace the fast idle solenoid valve.
If the "fast idle solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
cc.1
Measure the resistance of the fast idle solenoid valve at its connector. Replace the fast idle solenoid valve
if the resistance is not approximately 45 ohms.
Ensure insulation from +12 volts of the connection between track 16 on the computer connector and
track 1 on the fast idle solenoid valve connector.
Even if present at the moment of testing, this fault is still declared
by a flashing BG 6RH side. To confirm its presence and the necessity
of following the fault finding below, erase the computer memory
then start command mode G16*.
The fault is present if the bargraph flashes again.
NOTES
If the fault persists after these tests, replace the fast idle solenoid valve.
If the "fast idle solenoid valve circuit" fault reappears, replace the computer (consult the "Aid" section for
this operation).
Measure the resistance of the fast idle solenoid valve at its connector. Replace the fast idle solenoid valve
if the resistance is not approximately 45 ohms.
Ensure continuity of the connection between track 16 on the computer connector and track 1 on the fast
idle solenoid valve connector.
Ensure the presence of + after ignition feed on track 2 on the fast idle solenoid valve connector, wiring side.
Ensure the insulation from earth of the connection between track 16 on the computer connector and track 1
on the fast idle solenoid valve connector.
Test the connections on the 2 connectors.
13-18

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

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Fault charts
13
Carry out a road test then check using the XR25.AFTER REPAIR
NOTES
Chart 5WARNING LIGHT ILLUMINATES WITH NO FAULT SHOWN BY THE
XR25.
Only consult this customer complaint after a complete check using the XR25.
If no fault is shown by the XR25, look for a short circuit to earth of the heater plug feed wiring or a plug
short circuit fault.
13-42

DPCF01 1.0
LUCAS DIESEL INJECTION
Fault finding - Fault charts
13
Carry out a road test then check using the XR25.AFTER REPAIR
NOTES
Chart 6VEHICLE PRODUCES BLACK SMOKE AT ALTITUDE
Only consult this customer complaint after a complete check using the XR25.
Measure the resistance of the altimetric corrector at the 10 track pump connector (between tracks 1 and
6).
Replace the altimetric corrector if the resistance is not approximately 15 ohms.
Ensure the continuity of the connection between track 1 on the pump connector, wiring side, and track 5
on the altimetric connector control relay (position H on the relay plate in the engine connection unit).
Ensure the presence of earth on track 6 of the pump connector, wiring side.
13-43

JF5111.0
INJECTION
Fault finding - Introduction
17
E7J 780
engine
If the information obtained by the XR25 requires electrical continuities to be checked, connect bornier Sus.
1228.
Bornier Sus. 1228 is a 55 track base with a printed circuit on which are 55 copper coated surfaces, numbered
from 1 to 55.
Using the wiring diagrams, the tracks connecting the components to be tested can be easily identified.
IMPORTANT :
• All tests using bornier Sus. 1228 must be carried out with the battery disconnected.
• The bornier is only designed to operate with an ohmmeter. Under no circumstances should 12 Volts be
applied to the test points.
97434S
17-2