Logan X90 User manual

© Renault s.a.s. 2004
"The repair methods given by the manufacturer in this document are based on the technical
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 his vehicles are
constructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
APRIL 2004 Edition Anglaise
X90
1Engine and lower engine
assembly
10A ENGINE AND LOWER ENGINE ASSEMBLY
11A TOP AND FRONT OF ENGINE
12A FUEL MIXTURE
13A FUEL SUPPLY
14A ANTIPOLLUTION
16A STARTING - LOAD
17A IGNITION
17B PETROL INJECTION
19A COOLING SYSTEM
19B EXHAUST
19C RESERVOIR

© Renault s.a.s. 2004
"The repair methods given by the manufacturer in this document are based on the technical
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 his vehicles are
constructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the use
of the spare parts reference numbering system, are prohibited without the prior written
consent of Renault.
APRIL 2004 Edition Anglaise
X90
19D ENGINE MOUNTING

L90 - Section 1
Contents
L90 - Section 1 ContentsPage
10A ENGINE AND LOWER ENGINE ASSEMBLY
Engine identification
Oil filter 10A-1
Oil consumption 10A-3
Oil pressure 10A-4
Engine/gearbox assembly 10A-5
Sump 10A-31
Oil pump 10A-41
Multifunction support 10A-43
11A TOP AND FRONT OF ENGINE
Accessories belt 11A-1
Timing belt 11A-19
Cylinder head gasket 11A-29
12A FUEL MIXTURE
Specifications 12A-1
Air inlet 12A-7
Air filter: Replacement 12A-9
Air filter unit 12A-11
Inlet manifold 12A-13
Exhaust manifold 12A-19
Throttle valve 12A-23
Throttle body: Connection 12A-25
13A FUEL SUPPLY
Petrol supply circuit 13A-1
Injector rail - Injectors 13A-2
Fuel pressure
regulator:Checking 13A-6
Electric fuel: Checking 13A-7
14A ANTIPOLLUTION
Petrol vapour rebreathing:
Operation 14A-1
Fuel vapour rebreathing:
Checking 14A-2
Fuel vapour canister 14A-3
Fuel vapour
canister:Checking 14A-4
16A STARTING - LOAD
Alternator: General
information 16A-1
Alternator 16A-2
Starter: Identification 16A-12
Starter motor 16A-13
17A IGNITION
coils 17A-1
Spark plugs 17A-5

Contents
17B PETROL INJECTION
Location of components 17B-1
Oxygen sensors 17B-7
Position and speed sensor 17B-11
Fuel supply computer 17B-13
Computer: Connection 17B-19
Special notes 17B-21
Injection warning light 17B-23
Immobiliser function 17B-24
Injection - air conditioning
programming 17B-25
Throttle body potentiometer 17B-26
Idle speed correction 17B-28
Richness regulation 17B-29
Central coolant temperature
management 17B-30
Special notes on the system
(when driving) 17B-31
Conditions for carrying out
fault finding (when driving) 17B-32
Combustion misfire fault
finding 17B-33
Catalytic converter fault
finding 17B-34
Oxygen sensor fault finding 17B-35
19A COOLING SYSTEM
General information 19A-1
Specifications 19A-2
Checking 19A-3
Diagram 19A-4
Bleeding and filling the
cooling circuit. 19A-6
Bleeding the cooling circuit 19A-8
Cooling radiator 19A-9
Water pump 19A-14
Thermostat 19A-18
Engine cooling fan assembly 19A-19
19B EXHAUST
General information 19B-1
Pipe assembly 19B-3
Catalytic converter 19B-5
Expansion chamber 19B-9
Silencer 19B-10
19C RESERVOIR
Draining the fuel tank 19C-1
Fuel tank 19C-3
Pump / sender unit / filter 19C-7
Fuel level sensor: Distinctive 19C-10
19D ENGINE MOUNTING
Suspended engine mounting 19D-1
19A COOLING SYSTEM

10A-1
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter
L90, and K7J, and 710
10A
REPLACING THE OIL FILTER
Remove the oil filter using tool (Mot. 1329).
Coat the sealing ring of the new oil filter with engine
oil.
Tighten the oil filter by hand.
Essential special tooling
Mot. 1329 Oil filter cover - 76 mm
diameter
109223

10A-2
ENGINE AND LOWER ENGINE ASSEMBLY
Oil filter
L90, and K7M, and 710
10A
REPLACING THE OIL FILTER
Remove the oil filter using tool (Mot. 1329).
Coat the sealing ring of the new oil filter with engine
oil.
Tighten the oil filter by hand.
Essential special tooling
Mot. 1329 Oil filter cover - 76 mm
diameter
109223

10A-3
ENGINE AND LOWER ENGINE ASSEMBLY
Oil consumption
L90, and K7J or K7M
10A
PROCEDURE FOR MEASURING OIL
CONSUMPTION
1 - Filling to the maximum level
Turn the engine off.
Wait 2 minutes for all the oil to flow into the oil sump.
Carry out a visual inspection using the dipstick.
Top up to the "MAX" mark.
Make a paint mark on both the filler plug and the
sump drain plug in order to be able to check later that
it has not been removed.
2 - Customer driving
Ask the customer to drive approximately 1240 miles
(2000 km) in the vehicle without letting the oil level
reach the "MIN" mark.
3 - Topping up
Turn the engine off.
Wait 2 minutes for all the oil to flow into the oil sump.
Carry out a visual inspection using the dipstick.
Top up to the "MAX" mark.
Note the quantity of oil added and the mileage cove-
red since the last top-up to maximum level.
4 - Measurement of the oil consumption
Oil consumption= Quantity of topping up oil (in
litres) / number of kilometres (in thousands).
Note:
The operation should be carried out with the
engine warm after the fan assembly has cut in
once.
Note:
The operation should be carried out with the
engine warm after the fan assembly has cut in
once.

10A-4
ENGINE AND LOWER ENGINE ASSEMBLY
Oil pressure
L90, and K7J or K7M
10A
I -CHECKING
Ensure that the engine oil level is between the "MIN"
and "MAX" marks.
Use the tool (Mot. 836-05) and a long dowel of 22 mm.
The oil pressure check must be carried out with the en-
gine warm (approximately 80˚C).
II - USE
Connect the pressure gauge in place of the oil pressure
switch.
III - ENGINE MANAGEMENT
K7J/K7M engine:
- Idling : 1 bar
- 3000 rpm: 3 bar
Torque tighten the oil switch (3.5 daNm).
Special tooling required
Mot. 36-05 Oil pressure gauge kit
87363
K7J
engine K7M engine
C + E + F
H
F
E
G
D
C
B
A

10A-5
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
REMOVAL
Place the vehicle on a two-post lift.
Essential special tooling
Mot. 1202-01 Clip pliers for cooling
system hose clips
(large model)
Mot. 1202-02 Clip pliers for cooling
system hose clips
(small model)
Mot. 1448 Remote operation
pliers for cooling sys-
tem hose clips
Mot. 1453 Multiple-adjusting
engine mounting sup-
port with retaining
straps
Mot. 1159-03 Engine mounting on
right-hand side mem-
ber for operations not
requiring removal of
the engine
Mot. 1390 Support for removing
and refitting the engine
and gearbox assembly
Tav. 1747 Threaded rods for
removing the sub-
frame
Essential equipment
filling station
Tightening torquesm
gearbox rubber moun-
ting mounting bolts 10.5 daNm
gearbox cover moun-
ting nut on the gearbox
rubber mounting
6.2 daNm
sub-frame mounting
bolts 10.5 daNm
sub-frame tie-rod upper
mounting bolts 2.1 daNm
sub-frame tie-rod lower
mounting bolts 6.2 daNm
steering rack mounting
bolts 10.5 daNm
shock absorber base
bolts 10,5 daNm
brake calliper mounting
bolts 10.5 daNm
track rod end nuts 3.7 daNm
engine tie-bar mounting
bolts 10.5 daNm
wheel bolts 10.5 daNm
Note:
The « engine and gearbox» assembly can be
removed by removing the « engine and gearbox/
driveshafts/half-axles/sub-frame » assembly.
IMPORTANT
During this operation, use a strap to secure the
vehicle to the lift to prevent it from becoming
unbalanced.
For the strap fitting procedure, (see 02A, Lifting
equipment, Underbody lift).
Tightening torquesm

10A-6
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Disconnect the battery, starting with the negative ter-
minal.
Remove:
- fuse and relay cover (1),
- the fuse holders and relays from their supports (2),
- battery mounting clamp (3),
- the battery.
107846
107845
3
1
2
109184

10A-7
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Remove:
-the injection computer protector in (4),
-the injection computer in (5),
-the fuse and relay supports,
-the electrolyte recovery tray under the battery,
-the air suction sleeve on the body,
-the front wheels,
-the engine undertray,
-the bumper mounting bolts under the sub-frame.
Drain:
- the engine oil if necessary,
- the gearbox oil if necessary,
-the cooling circuit via the bottom hose, using tool
(Mot. 1202-01), tool (Mot. 1202-02) or tool (Mot.
1448).
Disconnect fan assembly connector (6).
Unclip the electrical harness from fan assembly (7).
108564
108562
4
4
5
DIRECTION MANUELLE, and BASIC HEATING
109398
7
6

10A-8
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Disconnect fan assembly connector (8).
Unhook the electrical harness from fan assembly (9).
Disconnect connector (10) of the power assisted
steering pressure switch.
Remove the power assisted steering pipe mounting
bolts:
- from the top of sub-frame (11),
- on the multifunction support,
- on the rear of the cylinder block.
Disconnect:
-the low pressure hose on the power assisted stee-
ring pump and drain the circuit,
-the high-pressure pipe from the power assisted
steering pump,
- the high-pressure pipe from the steering rack.
Remove the power assisted steering high-pressure
pipe.
DIRECTION ASSISTEE, and BASIC HEATING
109398
109397
9
8
10
107924
11

10A-9
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Disconnect fan assembly connectors (12).
Disconnect connector (13) from the refrigerant pres-
sure sensor.
Drain the air conditioning circuit using filling station.
Disconnect the air conditioning pipe unions on the air
conditioning compressor.
Disconnect connectors (14) of the fan assembly.
Disconnect connector (15) of the power assisted
steering pressure switch.
DIRECTION MANUELLE, and AIR CONDITIONING
109396
108107
WARNING
Protective plugs must be inserted into the pipe
and air conditioning compressor openings to pre-
vent moisture from getting into the circuit.
12
13
DIRECTION ASSISTEE, and AIR CONDITIONING
109396
109397
14
15

10A-10
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Remove the power assisted steering pipe mounting
bolts:
- from the top of sub-frame (16),
- on the multifunction support,
- on the rear of the cylinder block.
Disconnect:
-the low pressure hose on the power assisted stee-
ring pump and drain the circuit,
-the high-pressure pipe from the power assisted
steering pump,
-the high-pressure pipe from the steering rack.
Remove the power assisted steering high-pressure
pipe.
Disconnect connector (17) of the refrigerant pressu-
re sensor.
Drain the air conditioning circuit using the filling sta-
tion.
Disconnect the air conditioning pipe unions on the air
conditioning compressor.
Disconnect:
- ball joint (18) of the throttle valve control cable,
-cable sleeve stop (19) of the throttle valve control
cable.
107924
108107
16
17
WARNING
Protective plugs must be inserted into the pipe
and air conditioning compressor openings to pre-
vent moisture from getting into the circuit.
107356
19
18

10A-11
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Disconnect:
-the petrol vapour absorber bleeding solenoid valve
connector,
-the brake servo pipe from the inlet manifold,
-petrol vapour rebreather pipe (20) from the inlet
manifold.
-the fuel supply pipe (21) from the injection rail.
Disconnect cooling hoses (22).
Remove cooling hoses (23) from their support.
107357
IMPORTANT
Be careful of petrol splashing out when discon-
necting the fuel supply union.
Wear gloves during the operation.
21
20
108565
109493
2222
22
23

10A-12
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Remove mounting bolt (24) from the earth strap on
the gearbox.
Remove:
-brake callipers (25) and attach them to the shock
absorbers,
- track rod ends (26),
- bolts (27) from the shock absorber bases,
-upper mounting bolts (28) of the sub-frame tie rods,
- the two mounting bolts from the steering rack.
Attach the steering rack to the body.
107934
24
107935
99070
26
25
27
28

10A-13
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Remove:
-the clutch control cable from clutch fork (29),
-the clutch control cable from sleeve stop (30).
Remove rubber protection (31) from the gear lever.
Remove mounting bolt (32) from the gear lever fork.
Attach the gearbox control linkage to the body.
Remove the engine tie-bar.
Remove the catalytic converter (see 19B, Exhaust,
Catalytic converter).
109494
109213
30
29
31
109214
108648
32

10A-14
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the timing end lifting eye as an ancho-
ring point.
Remove:
-the suspended engine mounting cover mounting
bolts,
-the suspended mounting from engine (33).
Put a shim under the engine on the right-hand side
of the sub-frame:
-put a rubber shim under multifunction support (34),
- fit tool (Mot. 1159-03) to the rear of engine (35),
-lower the engine to fix it in place on the right-hand
side of the sub-frame.
Fit engine support tool (Mot. 1453) with the retaining
belt, by taking the flywheel end lifting eye as an an-
choring point.
109495
108649
33
109229
107930
35 34

10A-15
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
Remove mounting nut (36) of the gearbox cover on
the gearbox rubber mounting.
Strike the gearbox mounting stud with a copper ham-
mer to uncouple « engine and gearbox » assembly
from the body.
Remove gearbox rubber mounting (37).
Put a shim under the gearbox on the left-hand side
of the sub-frame:
-put a rubber shim under gearbox (38),
-lower the gearbox to fix it in place on the left-hand
side of the sub-frame.
Place tool (Mot. 1390) under the sub-frame.
Lower the vehicle down onto the four pads of tool
(Mot. 1390).
Adjust the pad position to ensure the sub-frame is
stable on tool (Mot. 1390).
Bring the pads into contact with the underside of the
sub-frame in (39).
Lift the vehicle to separate « engine and gearbox/dri-
veshafts/half-axle/sub-frame» assembly from the
body.
107929
109230
36
37
38
17765
108574
WARNING
Ensure that no component obstructs the move-
ment of the body around the «engine and
gearbox » assembly.
3939

10A-16
ENGINE AND LOWER ENGINE ASSEMBLY
Engine/gearbox assembly
L90, and K7J, and 710
10A
REFITTING
Use two threaded rods of tool (Tav. 1747) on the
sub-frame front mountings to guide the sub-frame
when fitting the « engine and gearbox » assembly.
Use tool (Mot. 1453) to fit the suspended engine
mounting of the « engine and gearbox» assembly.
Coat the brake calliper mounting bolts with LOCTITE
FRENBLOC.
Torque tighten:
-the gearbox rubber mounting mounting bolts
(10.5 daNm),
-the gearbox cover mounting nut on the gearbox
rubber mounting (6.2 daNm),
- the sub-frame mounting bolts (10.5 daNm),
-thesub-frame tie-rod upper mounting bolts (2.1
daNm),
-thesub-frame tie-rod lower mounting bolts (6.2
daNm),
- the steering rack mounting bolts (10.5 daNm)
- the shock absorber base bolts (10,5 daNm),
- the brake calliper mounting bolts (10.5 daNm),
- the track rod end nuts (3.7 daNm),
- the engine tie-bar mounting bolts (10.5 daNm),
- the wheel bolts (10.5 daNm).
Refit the catalytic converter (see 19B, Exhaust, Ca-
talytic converter).
Perform the following operations:
- top up the engine oil if necessary,
- top up the gearbox oil if necessary,
-fill up and bleed the cooling circuit (see 19A, Coo-
ling, Draining - Filling the cooling circuit).
Fill up the power assisted steering circuit.
Bleed the power assisted steering circuit by turning
the steering wheel fully in one direction then the
other with the engine running.
Fill up the air conditioning circuit with filling station.
107927
109495
107930
DIRECTION ASSISTEE, and BASIC HEATING
DIRECTION MANUELLE, and AIR CONDITIONING