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CONTENTS
The fault finding procedure 4 Heating circuit 9 Additional heating 17 Air conditioning 31 Questionnaire 50
ask the right questions to obtain an exact description of the customer complaint, if necessary, run checks and operation tests, identify the faulty system correctly, carry out the documentary search correctly.
If all of this information is precise, the cause of the fault can be identified more quickly.
the faults are recorded by the computers, the physical symptoms are detected by the user and checked by the repair technician but do not cause a fault to be recorded, the physical symptoms are detected by the user but not observed by the repair technician during the fault finding request.
approval request when replacing a part with mandatory approval, requests for technical assistance from the Techline (technical department in some countries).
IMPORTANT
This fault finding log is also attached to monitored parts for which return has been requested.
The fault finding log comes from either NT 3700A, or the Workshop Repair Manual or the CLIP tool (figure 1). The fault finding log should be photocopied or printed out and filled out by hand by the repair agent as they progress through the fault finding procedure.
NOTE
ACTIS solutions: operation reserved for authorised personnel.
HEATING CIRCUIT
Introduction to the hot loop. 10 The hot loop within the engine compartment 10 The hot loop in the passenger compartment 12 Fault finding on the coolant circuit 14 Maintenance of the hot loop 15
Heating circuit
10
Heating circuit
The thermostat
The thermostat (figure 5) regulates the circulation of the coolant according to the engine temperature.
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Heating circuit
Thanks to the thermostat, the rise in temperature of the engine is faster, which enables the heater matrix to heat up more quickly.
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Heating circuit
If regulation is in manual mode, the functions are switched on and adjusted by the user. If regulation is in automatic mode, the functions are switched on and adjusted by the system.
1. Evaporator 2. Heater matrix 3. Distribution flaps 4. Proportioning flaps 5. Recirculation flap The evaporator The evaporator allows the blown air to be cooled by the passage through it of the refrigerant fluid. The heater matrix The heater matrix assists heat exchange between the outside air and the engine to heat the air in the passenger compartment.
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Heating circuit
The mixing components The mixing flaps mix the air from the hot and cold loops to achieve the level of comfort requested. Depending on the temperature requested, the air is partially or fully directed towards the heater matrix, using the mixing flaps. Certain vehicles have two mixing flaps for separate right/left regulation. The distribution components The distribution flaps allow the flow of air to be directed to the different areas of the passenger compartment. Depending on the request, the distribution flaps direct the air in the vehicles ventilation circuit. The air recirculation components The recirculation flap allows the user to choose the source of the air entering the passenger compartment. Recirculation is the continual cooling or heating of the passenger compartment air to obtain the thermal comfort required quickly.
An emission of smoke may appear in the following places: from the exhaust pipe in the form of white smoke (engine hot), in the engine compartment, in the passenger compartment.
The dashboard warning indicators are the temperature warning light and the coolant temperature needle.
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Heating circuit
A malfunction may reveal itself in other forms: a bubbling noise under the dashboard, the level and colour of the coolant in the expansion tank, heavy condensation on the inside of the windscreen. The thermostat A thermostat malfunction may be revealed in the following forms:
the engine temperature climbs slowly and the radiator is warm, the engine heats up but the radiator remains cold.
note the level and check the colour of the coolant, check the condition and tension of the water pump drive belt, check that the fan, radiator and radiator grille are not obstructed, check that there is no trace of leakage in the engine compartment or passenger compartment.
Checking the thermostat To confirm correct operation of the thermostat, there should be a significant change in temperature between the heater matrix inlet hose and the radiator inlet hose as the engine warms up. When the engine is warm, the matrix inlet hose and the radiator inlet hose should be at the same temperature. When removed, the thermostat is checked visually.
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Heating circuit
IMPORTANT
Follow the safety instructions when working on the cooling circuit. The circuits are under pressure, and it is vital to be aware of the high temperatures (risk of serious burns). Never remove the expansion bottle plug when the engine is hot. When working under the bonnet, be aware of the possible sudden operation of the cooling fan(s).
conformity
IMPORTANT
On certain vehicles, when removing the thermostat, it is essential to note the position of the degassing hole. On thermostats not fitted with the hole, degassing is provided by a moulded bypass within the unit. Never flush out an engine when it is hot as this could create a thermal shock which could damage certain components. Consult the technical documentation before carrying out bleeding, flushing, refilling or bleeding of the cooling circuit. After connecting the battery, it is necessary to perform the required programming operations.
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ADDITIONAL HEATING
Introduction to additional heating 18 The thermoplunger heating system 18 The auxiliary combustion heating system 20 The passenger compartment heating resistors 23 Fault finding on the additional heating systems 25 Maintenance of additional heating systems 27
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Additional heating
18
Additional heating
19
Additional heating
20
Additional heating
21
Additional heating
Start-up of the heating operation Using the information received and its own internal mapping, the control unit calculates the quantities of air and fuel to supply to the heater. Using this calculation, the control unit initiates start-up of the heater (figure 15).
Regulation of the heating Heating regulation is based on a two-phase cycle: full speed and low speed (figure 16). The control device manages the heater speed according to the information received from the coolant temperature sensor and the overheating switch.
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Additional heating
Switching the heating off The heater is switched off when the temperature reaches its limit threshold, when the engine stops or when a fault is detected.17
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Additional heating
24
Additional heating
25
Additional heating
Fault finding on the self-contained heater Malfunction of the self-contained heater is indicated by a lack of heating or no heating at all. The coolant circuit should be checked before assuming a heater fault. Check the airflow and air distribution. With the engine warm, and with the unit in the maximum heat position, the blown air should be warm. Operation of the self-contained heater, independent of user command, is managed by the heater control unit. The heater can be started or stopped using a command mode in the diagnostic tool. Operating safety is provided by a sensor within the self-contained heater (protection against overheating).
IMPORTANT
Certain vehicles may be fitted with a heater programming unit which is available as an accessory (see the TRAFFIC II - Leisure activities drivers handbook, Heating when stationary section).
IMPORTANT
Follow the safety instructions when working on the additional heating system. Disconnect the battery, starting with the negative terminal. Wait until the heating elements have cooled down (risk of burns). Before removing the dashboard or seats, always lock the airbag computer using the diagnostic tool.
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Additional heating
Checking the thermoplungers The thermoplungers are supplied with 12 V by two or three relays. One relay controls two thermoplungers, and the other relays each control one thermoplunger. The power of each thermoplunger is about 300 watts, therefore 1200 watts for all four. The current consumed by each thermoplunger is about 25 amperes, therefore 100 amperes for all four. The resistance of a thermoplunger is about 0.5 . The thermoplungers do not operate in the following cases: during preheating, during post heating, when the heated windscreen is activated, if the engine speed is less than 600 rpm. Checks possible: resistance, power supply and conformity of relay operation using the diagnostic tool. Checking the passenger compartment heating resistors The passenger compartment heating resistors are supplied with 12 volts by relays. The resistance of the passenger compartment heating resistors is about 0.3 . The power of a resistor is about 400 watts on the Renault ESPACE IV. The power of the passenger compartment heating resistors varies according to the vehicle model, year of manufacture and engine. The current consumed by a resistor is about 35 amperes on the Renault ESPACE IV, therefore 175 amperes for five resistors. Configuration of the Type of heating resistors (for example: None, 1600 watts or 2000 watts for the Renault ESPACE IV) is verified in the computer by reading the configuration. Depending on the registration year of the vehicle, the configuration of the heating resistor type may differ (refer to the technical documentation for the choice of configuration). The number of resistors is different depending on the vehicle. For example, on the Renault ESPACE IV, if the number of relays is 5, the computer will be configured to 2000 watts and if the number of relays is 4, the computer will be configured to 1600 watts.
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Additional heating
Verify correct operation of the system by carrying out a current consumption test using the ammeter. The conditions necessary for activation of the passenger compartment heating resistors are as follows: vehicle engine running, battery voltage greater than the reference value in the technical documentation, heating/ventilation blower in operation (at least at the lowest speed), exterior temperature lower than the reference value in the technical documentation, alternator "Alternator charge information" authorisation less than the reference value in the technical documentation, injection authorised, coolant temperature less than the reference value in the technical documentation, "hot" position selected on the control panel. Checks possible: current, resistance, power supply and conformity of relay operation using the diagnostic tool. Checking the self-contained heater The differences between the diesel and petrol heaters is the layout of the combustion chamber and the computer programming. After engine start-up, if the coolant temperature is less than 75C and the outside air temperature is less than 5C, the heater is switched on. The heater then operates at full power until a temperature of 80C is reached. At between 80C and 85C, the heater operates at half power. Above 85C, the heater is switched off and only restarts if the temperature falls below 75C. The maximum heating power applied to the coolant is 3300 watts. The maximum fuel consumption of a heater is about 0.4 litre/hour. The maximum electrical power consumption is about 23 watts. After start-up and in operation, the current consumption of the heater is about 2 amperes. The outside air temperature bimetallic contact is a temperature switch located on the outside of the heater. The fuel metering pump incorporates a filter which must be changed periodically.
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Additional heating
The resistance of the metering pump is about 10 ohms. The pressure of the metering pump is about 230 millibars. To measure the quantity of fuel, the self-contained heater must be operated. The supply of fuel begins about 40 seconds after the self-contained heater is switched on. Collect the fuel in a graduated measuring cylinder. The fuel supply is interrupted automatically after 90 seconds. The command mode in the diagnostic tool allows operation of the heater to be verified. If the heater does not start, check the following statuses: the level of fuel in the tank, the condition of the fuses, obstruction of the combustion and exhaust air ducts. The supply voltage of the turbine electric motor is 8 volts. The supply voltage of the glow plug is 8 volts, its current consumption is about 8.5 amperes and its resistance is about 0.9 ohms. The heater enters defect mode in the following cases: - if combustion has not started after two start-up attempts, - if the temperature read by the coolant temperature sensor differs from that read by the overheating switch by more than 15C, - the coolant temperature reaches 125C, - if the flame detector does not detect any combustion after the second start-up attempt, - if the battery voltage is greater than 16 volts or less than 10 volts. Note: defect mode is deactivated when the ignition is switched off. The self-contained heater will not make another start-up attempt until the vehicle ignition is switched on again. The fault is stored and can be consulted using the diagnostic tool. The setting of the level of CO discharged at the exhaust of the heater is set in the factory and cannot be changed in After-Sales. Checks possible: continuity and insulation, resistance, power supply and conformity of operation using the diagnostic tool.
IMPORTANT
29
Additional heating
After connecting the battery, it is necessary to perform programming operations on some of the vehicle systems.
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AIR CONDITIONING
Introduction to air conditioning 32 The components of the automatic regulation system 32 Switching on the air conditioning 39 Operation of the air conditioning system 40 Automatic regulation of the air conditioning 42 Switching off air conditioning and safety 44 Maintenance of the air conditioning system 45
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Air conditioning
The sensors send signals to the air conditioning computer. The air conditioning computer also receives information from other computers. The air conditioning computer controls the actuators to attain the level of comfort requested.
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Air conditioning
the toxicity sensor, the solar radiation sensor, the moisture sensor, the pressure sensor, the evaporator sensor.
Other sensors also take part in the automatic regulation operation, such as the outside air temperature sensor and the coolant temperature sensor. The toxicity sensor The toxicity sensor (figure 23) continuously analyses changes in the concentration of NOx and CO and sends the results to the air conditioning computer.
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Air conditioning
The solar radiation sensor The solar radiation sensor (figure 24) notifies the computer of the intensity of solar radiation, in order to adjust the flow of air to the air vents.
The humidity sensor The humidity sensor (figure 25) measures the variation in humidity in the air in the passenger compartment.
The humidity sensor consists of the following components: 1. a humidity sensor for the passenger compartment, 2. an internal temperature sensor, 3. a microturbine blowing air over the two sensors.
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Air conditioning
The pressure sensor The air conditioning computer uses the information from the pressure sensor (figure 26) to decide whether to turn on the air conditioning or not.
The evaporator sensor The evaporator sensor (figure 27) notifies the computer of the air temperature to prevent freezing of the evaporator.
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Air conditioning
36
Air conditioning
The electromagnetic coupling Once the injection computer has authorised start-up of the compressor, the injection computer or the UCH operates the electromagnetic coupling (figure 30).
The compressor output electrical control valve By controlling the position of the control valve (figure 31), the computer adjusts the capacity to adjust the refrigerating power to meet the users request for cold air.
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Air conditioning
The power modules The power modules (figure 32) are of the electronic or resistance type.
Depending on the vehicle type, the passenger compartment blower is supplied by one or two power modules. The control panel The control panel (figure 33) sends the users instructions to the air conditioning computer.
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Air conditioning
The air conditioning computer analyses the temperature inside the vehicle and the temperature requested in order to switch on the air conditioning system if necessary. The air conditioning computer requests authorisation from the injection computer to switch on the air conditioning. The engine cooling fan assembly is engaged at the same time as the compressor coupling.
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Air conditioning
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Air conditioning
Depending on the blown air temperature chosen, the air conditioning computer operates the electric control valve to adjust the compressor flow. However, certain compressors are fitted with a pneumatic control valve which opens or closes according to the pressure in the low-pressure circuit. The system can regulate cold production more precisely when it is fitted with a variable capacity compressor. The computer controls the air mixing motors according to the initial position of the flaps and the blown air temperature instruction. Depending on the vehicle type, the passenger compartment fan is supplied by one or two power modules. The power modules are electronic or resistance type. The air conditioning computer controls the motors that operate the distribution flaps as a function of the internal temperature.
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Air conditioning
The computer adjusts the air conditioning according to the outside temperature, solar radiation, humidity level and the vehicle speed. The role of the air conditioning computer The air conditioning computer receives signals from various external sensors: The air conditioning computer performs several functions:
It regulates the production of cold air. Cold production and air mixing depend mainly on solar radiation and the outside temperature.
It regulates the ventilation speed. The air ventilation speed depends mainly on the vehicle speed and the intensity and direction of the suns rays.
It regulates the distribution of the air. The air conditioning computer regulates the distribution of the air. The air distribution depends principally on the humidity level and the intensity of the suns rays.
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Air conditioning
External conditions also affect the control of the recirculation flap. The recirculation flap and additional heating systems contribute to blown air heat processing performance. On some vehicles, if there is a high risk of misting, the air conditioning computer can engage the "See clear" function The heat insulating windscreen is used to reduce the influence of solar radiation in the passenger compartment in order to lower the temperature in the vehicle interior.
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Air conditioning
In automatic or manual mode, the injection computer can switch the air conditioning off to prevent the engine from overheating. The additional heating systems are switched off when the operating conditions are no longer fulfilled.
Sensor check
The air conditioning sensors can be checked using the diagnostic tool and the multimeter.
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Air conditioning
the toxicity sensor, the solar radiation sensor, the humidity sensor, the pressure sensor, the evaporator sensor.
Other more general sensors which take part in the automatic regulation procedure can be checked using the diagnostic tool. The toxicity sensor The toxicity sensor continuously analyses changes in the concentration of NOx and CO in the outside air. The toxicity sensor sends this information to the air conditioning computer which manages the operation of the recirculation flap. The toxicity sensor conformity check is performed using two parameters: CO inlet toxicity and NO inlet toxicity. These parameters, which represent the variation in the levels of carbon dioxide (CO) and nitrogen oxide (NOx) at the air mixing unit inlet, can be displayed using the diagnostic tool. The sensitive element of the toxicity sensor consists of a layer of metallic oxide. The semiconducting layer is heated by a filament to cause a surface absorption reaction with the volatile components contained in the ambient air. This absorption causes a variation in resistivity which is practically proportional to the concentration of the substances absorbed. The sensitive element of the toxicity sensor is protected by a membrane. This membrane allows the entry of gas molecules but prevents the entry of moisture and dust.
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Air conditioning
a positive feed, a negative feed, an NOx toxicity sensor signal, a CO toxicity sensor signal.
Each signal is sent separately by a modulated current pulsed at 39 Hertz. The concentration of NOx and CO in the air is expressed in parts per million (ppm). The value of the parameter corresponding to the concentration of CO varies between 0 and 510 ppm but is also measured as a percentage varying between 0 and 100%. The value of the parameter corresponding to the concentration of NOx varies between 0 and 1 ppm. When the concentration of CO reaches its maximum value (510 ppm) and does not fall, the ignition must be turned off several times until this value falls. Under these conditions, the filament in the sensor neutralises the CO products. The passenger compartment humidity and temperature sensors The unit consists of the following components: a relative humidity sensor, a passenger compartment temperature sensor, a micromotor and a turbine. The humidity sensor measures the variation in humidity of the air in the passenger compartment. The humidity sensor is of the capacitance type and delivers a signal at a frequency of between 5.8 kHz and 7.3 kHz, which is proportional to the humidity level. The passenger compartment temperature sensor is of the Negative Temperature Coefficient type. The micromotor is powered at APC and drives a turbine which blows air over the relative humidity sensor and the passenger compartment temperature sensor.
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Air conditioning
The solar radiation sensor The radiation sensor measures the brightness of the sun in order to adjust the flow of air to the air vents. Its resistance is proportional to the solar radiation. The radiation sensor is of the photoresistive type. When performing electrical checks, if the radiation sensor detects a source of light, it is possible to vary the radiation parameter by masking the sensor. The supply voltage of the sensor is 5 volts. The value of the corresponding parameter is expressed in watts on the diagnostic tool. The evaporator sensor The evaporator sensor notifies the computer of the air temperature to prevent freezing of the evaporator. The sensor is of the Negative Temperature Coefficient type. The value of the corresponding parameter is expressed in C on the diagnostic tool. The vehicle may be configured as WITH or WITHOUT the evaporator sensor using the diagnostic tool. The pressure sensor The air conditioning computer uses the information from the pressure sensor to decide whether to turn on the air conditioning or not. The pressure sensor is of the capacitance type. The value of the corresponding parameter is expressed in bar on the diagnostic tool. The pressure sensor may be replaced without bleeding the cooling circuit.
Test options Using the diagnostic tool:
conformity
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Air conditioning
The conformity check involves the computer managing the air conditioning system. The electrical check of the air conditioning computers is carried out using the "continuity test" function, which at the same time measures the resistance and checks for the presence of interference resistance.
Test options Using the diagnostic tool:
conformity
the mixing components, the distribution components, the recirculation components, the electromagnetic coupling, the compressor output electrical control valve, the power modules, the switches on the control panel.
The mixing components The mixing flaps mix the warm and cool air. Certain vehicles have two mixing flaps for separate right/left regulation. The distribution components Calculations of the risk of misting control the start-up or switching off of the automatic demisting system.
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Air conditioning
the exterior temperature, the level of humidity in the passenger compartment, the level of solar radiation.
Depending on the risk of misting, the computer may switch on the air conditioning system, adjust the cooling performance of the evaporator, increase the air flow at the demisting outlets, restrict the use of automatic recirculation and automatically initiate electrical demisting of the windows. The recirculation components The strategy for controlling the recirculation components is applied using two detection methods: - detection of rapid changes in pollution (cars, motorcycles, buses, lorries), - detection of an average level of high pollution (driving in an urban area). The cylinder output electrical control valve The cylinder output electrical control valve cannot be checked visually. The control panel The control panel can be checked visually by pressing the various buttons.
Test options Using the diagnostic tool:
conformity
49
QUESTIONNAIRE
QUESTIONNAIRE
1. Which components prevent outside air from entering the passenger compartment?
A B C D The air mixing motor and flap. The recirculation motor and flap. The distribution motor and flap. The proportioning motor and flap.
2. What does the AC indicator mean when it is lit on an automatically regulated air-conditioning system?
A B C D Fault in the cold loop. Air conditioning compressor is running. Fault in the air conditioning compressor. Request for air conditioning.
3. Which components allow mixing of air from the cold loop and air from the hot loop?
A B C D The ventilation motor and flap. The distribution motor and flap. The proportioning motor and flap. The recirculation motor and flap.
4. Which component speeds up heating of the air in the passenger compartment when the engine is cold?
A B C D The evaporator. The thermostat. The passenger compartment blower. The passenger compartment heating resistors.
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QUESTIONNAIRE
5. What system allows the passenger compartment heating resistors to be activated when the correct driving conditions are not satisfied?
A B C D Automatic demisting. Heater control. A long press on the AC button. The diagnostic tool command mode.
8. Which component participates in the conditions for switching on the passenger compartment heating resistors?
A B C D The passenger compartment heating resistor switch on button. The solar radiation sensor. The alternator. The air temperature bimetallic contact.
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QUESTIONNAIRE
10. Which safety instruction must you observe before replacing the thermoplungers?
A B C D Switch off engine Check faults using the diagnostic tool. Lock the airbag. Disconnect the battery.
12. Which operations must you carry out after replacing the thermostat?
A B C D Flushing, refilling and bleeding. Topping up and bleeding. Bleeding and topping up. Degassing and topping up.
14. How much current is being consumed by a passenger compartment heating resistor when the system is supplying 2000 W?
A B C D 30 A. 2 A. 2000 A. 170 A.
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QUESTIONNAIRE
15. How much heat energy is generated by the heater at maximum output?
A B C D 400 W. 3300 W. 2000 W. 1600 W.
16. What information is sent by the air temperature bimetallic contact to the heater
A B C D Impact detected. Outside air temperature threshold. Coolant temperature threshold. Battery voltage threshold.
17. Which sensor controls the opening and closing of the recirculation flap in a regulated air conditioning system?
A B C D Solar radiation. Evaporator temperature. Electric control valve. Toxicity.
19. If the evaporator sensor is not working, what fault could this cause?
A B C D The compressor control valve is always operated at maximum. The coolant circuit pressure is increasing. No risk. The compressor will not be switched off if the evaporator freezes up.
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QUESTIONNAIRE
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Renault Reproduction ou traduction mme partielle interdite sans lautorisation de Renault 12/2002
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