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Kangoo Heating and Ventilation.pdf | Electrical Connector | Air Conditioning
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D7F - E7J - F8Q ENGINES
CANCELS AND REPLACES:
- Section n° 6 of M.R. 325 Part Number: 77 11 194 262 of JULY 1997,
- Technical Note n° 2871A Part Number: 77 11 197 147 of DECEMBER 1997.
77 11 198 230
Fan assembly (GMV)
Fault finding - XR25 fiche
Fault finding - Interpretation of XR25 bargraphs
Fault finding - Customer complaints
Fault finding - Associated checks
- the mounting screws.
- the two screws securing the control panel to the dashboard.
- control panel connector,
- the control cables for the rotator arms.
Refitting is carried out in reverse order to remo- val.
Check the adjustment of the air distribution and air mixing controls (refer to the section on "Control cables").
Route the cable through the control panel loca-
Push back the flap control to prevent the cable
from coming out of its location.
Fit securing clips (E) and (M).
Fit the complete control panel without screwing it
On the bottom right-hand side
Fit the cable on to the mark.
Place the air distribution control on position
, place the heater control on the maxi-
mum cold position (blue mark) and check that the
flaps are at their end stop.
The control cables can be removed without remo- ving the dashboard.
- the control unit.
In the bottom right-hand side of the passenger compartment
Remove the securing clip (E) (depending on which cable is to be replaced) :
from the hot/cold air flap control cable,
from the air distribution cable.
Refer to the Warranty and Servicing book for the vehicle.
- the air intake grille by freeing off the access flap clips,
- the water drainage channel,
- the nut (A) securing the particle filter to the bracket.
Refitting is carried out in reverse order to removal.
Check to make sure that the water drainage channel is correctly fit- ted in place.
HEATING Fan assembly (GMV)
- the windscreen wiper arms using tool Elé. 1294-01,
- the upper seal for the plenum chamber as well as the external air intake grille.
Disconnect the feed connector.
Remove the fan assembly mounting bolts.
Take out the fan assembly through the right-hand side of the plenum chamber.
Check the condition of the seal.
Fit a deflector and blow out the remaining liquid
Remove the heater pipe flange bolt on the bul-
khead.
Passenger compartment end
Unclip the four securing clips (E) and take out the
98816R
Refitting is carried out in reverse order to remo-
Fit two mounting bolts (F) onto the body of the
unit if the clips have broken.
The radiator is removed after first removing the air blower unit, the dashboard and the air distri- bution unit.
Engine compartment end
Fit a hose clamp and disconnect the quick-release clamps from the heater hoses.
Other type of quick-release hose clamps.
Using adhesive tape, immobilise the rotor for the
air bag switch.
- the two screws securing the heater control pa-
- the fuse holder plate securing screws (five
screws),
- the dashboard mounting nuts.
Unclip the wiring from the dashboard.
HEATING Air distribution unit
- the steering wheel bolt,
- the steering wheel after first placing the wheels in a straight line.
ATTENTION: Follow the recommendations contai- ned in section 88 relating to the AIR BAG system.
- the steering wheel half-shell cowlings,
- the visor and the instrument panel,
- the switch stalk block assembly.
- the flange bolt from the heater pipes,
- the windscreen wiper arms using tool
Elé. 1294-01,
- the upper seal for the plenum chamber as well
as the external air intake grille,
- the blown air unit,
- the air distribution unit mounting bolt.
Other type of quick-release clamps.
- the air distribution unit,
- the heater unit radiator.
- that the wiring is correctly routed behind the dashboard,
- that the air ducts are correctly secured to pre- vent noises developing.
Change the steering wheel bolt (pre-bonded bolt, tightening torque : 4.5 daN.m).
IMPORTANT : Before reconnecting the AIR BAG cushion it is necessary to apply the air bag system operational check procedure :
• Check that the AIR BAG warning light on the instrument panel is illuminated when the igni- tion is switched on.
• Connect an inert ignition unit to the AIR BAG cushion connector and check that the warning light extinguishes.
• Switch off the ignition, connect the AIR BAG cushion in place of the inert ignition unit and secure the cushion on to the steering wheel.
• Switch on the ignition, check that the air bag warning light illuminates for three seconds when the ignition is switched on and then ex- tinguishes and remains extinguished.
If the warning light does not operate as indicated above, please consult section 88 of the workshop repair manual.
B Engine compartment
C Exterior air
D To air mixing unit
E Scuttle panel grille
F Exterior or recirculated air
1 Compressor with variable capacity
3 Dehydration canister
5 High pressure valve
7 Evaporator
8 Low pressure valve
9 Heating/ventilation fan
11 Engine radiator
12 High pressure fluid
13 Low pressure vapour
14 High pressure vapour
SANDEN SP 10: 135 cm 3 ± 15
- Coolant R134a: 650 g ± 35
ESTABLISHING XR25 / HEATING-VENTILATION CONTROL UNIT DIALOGUE
- Connect the XR25 to the diagnostic socket.
- ISO selector on S8
- Enter D17
When carrying out checks using a multimeter, avoid using a contact tip on the connectors the size of which could damage the clips and result in poor contact.
After repairing the air conditioning system, enter G0** on the XR25 keypad to erase the fault stored.
AIR CONDITIONING Fault finding - XR25 fiche
PRESENTATION OF XR25 FICHE N° 61
FI21761
REPRESENTATION OF BARGRAPHS
REPRESENTATION OF FAULTS (always on a coloured background)
If illuminated, this indicates a fault on the component in question, the associated text defines
REPRESENTATION OF STATUS (always on a white background)
Illuminates when dialogue is established with the component computer, if it remains
- the code does not exist,
- there is an equipment, computer or line fault.
Engine stopped, ignition on, no operator action
The status bargraphs on the fiche are represented as they should appear with the engine stopped, ignition
on and no operator action.
- If on the fiche, the bargraph is represented
the XR25 should display
Extinguished when the function or condition described on the fiche is no longer carried out.
Illuminated when the function or condition described on the fiche is carried out.
Left-hand bargraph 1 illuminated
Fiche n° 61
Change the air conditioning control unit.
Enter G0** on the XR25. Check that the system operates correctly.
Right-hand bargraph 1 extinguished
XR25 / CONTROL UNIT COMMUNICATION
Before establishing communication between the XR25 and the control unit, check that you have switched on the ignition.
Ensure that the XR25 is not the cause of the fault by trying to communicate with a computer on another vehicle.
Check that the ISO interface is in position S8 and that you are using the latest version of the XR25 cassette and the correct access code (D 17).
Check the battery voltage (U > 10.5 volts). Recharge the battery if necessary.
Check that the control unit connectors are engaged correctly.
Check that the air conditioning control unit is supplied correctly:
- earth on track 4 of the red 15-way connector -+ after ignition on track 1 of the blue 30-way connector -+ after ignition on track 6 of the red 15-way connector -+ fuse board on track 5 of the red 15-way connector
Check that the diagnostic socket is supplied correctly:
of the air conditioning control unit
blue 30-way connector
If there is still no dialogue between the XR25 and the control unit, change the air conditioning control unit.
You may begin the fault finding procedure.
Left-hand bargraph 2 illuminated
XR 25 assistance:
: 2 def = low level 1 def = high level
Check that the coolant sensor connector is correctly engaged.
Engage the connector correctly if necessary.
Check the continuity and insulation from earth of the electrical wiring between tracks A, B and C of the sensor and tracks 9, 10 and 11 of the air conditioning control unit 30-way connector (sensor supplied with 5 V).
Repair the faulty electrical wiring.
Connect the XR25 and enter # 16. Measure the coolant pressure. The low pressure should be less than or equal to 2 bars.
Change the coolant pressure sensor.
Check the condition of the electrical wiring between tracks A, B and C of the sensor and tracks 9, 10 and 11 of the air conditioning control unit 30-way connector (sensor supplied with 5 V).
Connect the XR25 and enter # 16. Measure the coolant pressure. The high pressure should be less than or equal to 28 bars.
Left-hand bargraph 4 illuminated
XR25 assistance :
short circuit to 12 volts
Before any removal, enter G0** on the XR25 and reinitialise the system.
Enter G21* on the XR25 to control the compressor.
Does the compressor cut in?
Using the XR25, check the pressure of the circuit (# 16). At an ambient temperature of approximately 20 °C, a pressure of between 2 and 28 bars should be measured.
Is the pressure between these values?
Top up the coolant circuit. Repair the circuit if necessary.
If left-hand bargraph 4 remains permanently illuminated, change the clutch.
If left-hand bargraph 4 still remains permanently illuminated, change the compressor.
Refer to Left-hand bargraph 4 illuminated, CONT 1.
Check that 12 volts is present on track 1 of the clutch connector.
Is 12 volts present?
Check the condition of the compressor earth.
Is the compressor earth in good condition?
Check the continuity and absence of short circuits of the electrical wiring between the clutch and the compressor.
If the electrical wiring is faulty, repair it.
If the electrical wiring is in good condition, change the compressor.
Repair the compressor earth.
Check the continuity and absence of short circuits of the electrical wiring between track 1 of the clutch and tracks 2 and 17 of the air conditioning control unit 30-way connector.
Repair the electrical wiring if necessary.
Use the XR25 fiche which corresponds to the vehicle. With the engine running, operate the AC then check on the XR25 fiche whether the "Compression authorised or prohibited" status bargraph is illuminated.
Is the bargraph illuminated?
Check and repair the electrical wiring.
Refer to Left-hand bargraph 4 illuminated, cont 2.
Use the XR25 injection fiche which corresponds to the vehicle. With the engine running, operate the AC then check on the XR25 fiche whether the " AC authorisation" status bargraph is illuminated.
There is a problem at the injection end. Refer to the injection fault finding procedure which corresponds to the vehicle.
Check the continuity and absence of short circuits of the electrical wiring.
Check that 12 volts is present on tracks 2 and 17 of the air conditioning control unit 30-way connector.
Check whether the evaporator temperature sensor is in place. Check its resistance: disconnect the evaporator temperature sensor and measure the resistance at its terminals. The resistance measured should be between 90 ohms and 13.7 kohms.
If the evaporator temperature sensor is in good condition, change the air conditioning control unit.
If the evaporator temperature sensor is not in good condition, change it.
Right-hand bargraph 4 illuminated
AIR RECIRCULATION MOTOR
This fault only appears on the XR25 if air recirculation is selected.
Check the condition of the air recirculation flap control motor.
On the motor connector, measure the resistance between the two tracks.
Change the recirculation motor if necessary.
Check the condition of the electrical wiring between tracks:
red 15-way connector
Check the continuity and insulation from earth and from 12 volts of the electrical wiring between tracks:
If the fault persists, change the air conditioning control unit.
Left-hand bargraph 6 illuminated
FAN ASSEMBLY (2) CONTROL
Check that the air conditioning has been selected. Check that right-hand bargraph 6 is extinguished, if it is not, deal with right-hand bargraph 6 first. Enter G0** on the XR25. If left-hand bargraph 6 remains illuminated, you can begin the fault finding procedure.
Check the condition of the earth of fan assembly (2) (the relay is controlled by 0 volt). Repair the fan assembly earth if necessary.
Connect the XR25 and enter # 16. Check that the coolant pressure is approximately 20 bars.
If it is not, top up the coolant (operation of the cooling fan assembly is dependent on the coolant pressure).
Check the condition of the wiring between the relay of fan assembly (2) and track 10 of the injection computer.
Check the operating status of the relay by entering G23* on the XR25. The fan assembly should be heard to knock.
Is the fan assembly heard to knock?
Check the continuity and insulation from 12 volts of the electrical wiring between track F2 and track 23 of the air conditioning control unit 30-way connector.
Change the relay of fan assembly (2).
Right-hand bargraph 6 illuminated
FAN ASSEMBLY (1) CONTROL
XR25 assistance:
Check that the air conditioning has been selected. Enter G0** on the XR25. If right-hand bargraph 6 remains illuminated, you can begin the fault finding procedure.
Check that the air conditioning is operating.
Fan assembly (1) is controlled from the time the air conditioning is switched on.
Check the condition of the earth of fan assembly (1) (the relay is controlled by 0 volt). Repair the fan assembly earth if necessary.
Connect the XR25 and enter #16. Check that the coolant pressure is approximately 10 bars. If it is not, top up the coolant (operation of the cooling fan assembly is dependent on the coolant pressure).
Check the operating status of the relay by entering G22* on the XR25. The fan assembly should be heard to knock.
Check the continuity and insulation from 12 volts of the electrical wiring between track M2 and track 22 of the air conditioning control unit 30-way connector.
Change the relay of fan assembly (1).
Incorrect illumination of left-hand bargraph 7
This bargraph is illuminated outside the starting phase. If it is not illuminated, the compressor and the fan assemblies will not be controlled.
Check the condition of the + fuse board fuse.
Check the condition of the electrical wiring between track A26 of the fuse box and track B1 of the air conditioning control panel.
Repair the faulty wiring if necessary.
Check that the system operates correctly.
Left-hand bargraph 13 illuminated
AIR CONDITIONING PROHIBITED BY INJECTION
This bargraph should be extinguished when the engine is running. If it is illuminated, you can begin the fault finding procedure.
First check that the air conditioning has been selected (selection on the control panel).
Check the continuity of the electrical wiring between track 5 of the injection computer and track 13 of the air conditioning control unit 30-way connector (P.A. information).
Check the continuity of the electrical wiring between:
- track 51 of the injection computer and track 18 of the AC computer 30-way connector for D7F and E7J engines,
- track 19 of the injection computer and track 18 of the AC computer 30-way connector for F8Q engines.
If the problem persists, check the injection fault finding procedure, as it is a problem related to the injection.
Heater performance poor
Heating inadequate in the rear
Deicing/demisting performance poor
PASSENGER COMPARTMENT FAN DOES NOT OPERATE
PASSENGER COMPARTMENT INCONVENIENCE
RECIRCULATION FLAP DOES NOT OPERATE
COOLING FAN ASSEMBLY DOES NOT OPERATE
AIR CONDITIONING Fault finding charts
Before carrying out any work, check that the customer uses the air conditioning correctly. Non regulated air conditioning.
Place the passenger compartment fan on full, temperature control on maximum heat or maximum cold, and move the air distribution control. Check that the air output corresponds to the selection. Is it correct?
Check visually or by touch, on the right-hand
side of the air distribution unit,
that moving the control
moves the sprockets
Check the connection of the cable
to the air distribution unit
and check the condition of the cable and its
retainer. Is it correct?
The air distribution is correct.
If necessary, explain how the system works to the customer again.
Check the adjustment of the air distribution
flap control cable.
In the case of a ventilation problem, check the ventilation ducts and the vents. Repair if necessary.
If the fault persists, remove the air distribution unit and check the distribution flaps. Repair or change the assembly.
Change the control cable or repair the connection of the cable (clip)
or change the faulty part (control panel or distribution unit).
Check the condition of the kinematic
(sprockets, levers
on the air distribution
unit and the control panel. Is it correct?
Remove the air distribution unit and check the distribution flaps. Repair or change the unit.
Repair if possible, otherwise change the distribution unit or the control panel.
Does the passenger compartment fan operate?
Check the air intake circuit, scuttle panel grille, particle filter, rain shield. Are they correct?
Check that the air extraction circuit
Is it a passenger compartment air distribution problem?
Remove the heater radiator. It must be blocked, clean or change it (only valid for vehicles which have been driven without the particle filter).
See CHART 9.
Repair or clean or change the particle filter.
Carry out a road test to observe the customer complaints. Is the test satisfactory?
Visually check that
the action of the control moves
the mixing flap.
Does the flap move?
whether the flap travel is complete.
(correct filling and bleeding),
the condition of the circuit (pipes,
connections, conformity
Advise the customer how to use the heating system correctly
(eg. : Do not place the passenger compartment fan on full when starting from cold, turn it up gradually instead).
Readjust the control cable
(cable which controls the sprockets to the right of the air distribution unit).
With the engine cold, remove the engine coolant thermostat and check that it is not jammed in the open position. Is it correct?
Check that there is no unwanted intake of cold air into the passenger compartment
(seals, grommets, cables Repair if necessary Does the fault persist?
Check the air inlets (particle filter)
Partially blocked air inlets or outlets
reduce the flow of heated air
The heater radiator must be blocked. Remove the radiator and clean or change it (only valid for vehicles which have been driven without the particle filter).
Check that the components which were removed are connected correctly. Check that the system operates correctly.
Is it an air flow problem?
Check the level of coolant in the cooling circuit. NOTE: if the coolant level is too low, the cir- cuit may become unprimed when driving at low load and at idle. Repair if necessary. Does the fault persist?
Visually check that moving the control
moves the mixing flap.
Check the coolant circuit.
NOTE: fitting an oil, water or air cooler which
has not been approved by the research centre
and which is incorrectly connected may re-
duce or even stop the flow of coolant in the
heater radiator.
Repair the coolant circuit if necessary.
Remove the heater radiator. Clean or change it if necessary.
Visually check that moving the control moves the mixing flap. Does it move?
Check that the flap travel is complete. Is the travel complete?
Check the operation of the recirculation flap. Is it jammed in the recirculation position?
Check the operation of the engine coolant thermostat. Change the thermostat if necessary.
Readjust the cable (to the right of the air distribution unit).
Check that the air inlets at the rear of the centre console are not blocked.
(floor carpet
Remove the centre console and check that the connection and sealing between the air distribution unit and the heating duct to the rear seats is correct. Repair if necessary.
Free the air outlets.
Check that the windows are clean on the inside.
Check that the air extractors are not blocked. Repair if necessary. Does the fault persist?
Ensure that there are no water leaks into the
passenger compartment which would
significantly increase the humidity level and
reduce the effectiveness of the demisting.
Is it an air distribution problem?
Is it a heater performance problem?
Check that the recirculation flap is not jammed in the recirculated air position (see CHART 11). Repair if necessary.
Check that the mixing flap travel is complete. Is is correct?
Readjust the cable.
Check fuses +battery, +fuse board, +side lights. Are the fuses in good condition?
Check the connections between the fuses and the instrument panel connector. Repair if necessary. Does the fault persist?
With the ignition on and the air conditioning selected, position the ventilation at the various speeds and check that 12 V is present on the tracks of the control panel connector:
- B5 in position 1,
- B4 in position 2,
- B2 in position 3,
- B3 in position 4. Is 12 V present?
Check the condition of the wiring between:
Change the faulty fuse(s).
Change the control panel.
Supply the fan with 0 and 12 V. Does the fan operate?
Check the condition of the electrical wiring between the the fan and tracks A1 and A2 of the resistor unit connector at the fan end. Is the wiring in good condition?
Change the resistor unit.
Repair the electrical wiring.
CONTROLS STIFF (passenger compartment inconvenience)
Check the travel of the control cable. Remove any constraints on it:
- cable clamped with plastic clips. Change it if necessary. Does the fault persist?
Unclip the cable from the side of the unit and check the stiffness of movement of each component, control button and flap control on the air distribution unit. Is it correct?
Change the flap control cable.
Change the control panel or repair the
kinematic of the flap or change the air distribution unit.
First of all check the condition of fuses +battery, + fuse board, +after ignition. Change them if necessary.
Check the condition of the electrical wiring between:
With the ignition on and air recirculation selected, check that 12 V is present on track A2 of the control panel. Is 12 V present?
Check the insulation and continuity of the electrical wiring between:
blue 30-way
Repair the faulty wiring.
Check the electrical wiring between the recirculation motor and the resistor unit. Is it in good condition?
Check that the recirculation flap control sprockets are in good condition and that the flap is not jammed. Repair if necessary. Does the fault persist?
Change the recirculation motor.
AIR CONDITIONING PROBLEMS No cold air
Non regulated air conditioning. The passenger compartment fan operates.
With the heating and ventilation selected, check that there is a voltage on track A1 of the control panel. Is there a voltage?
Check the connections between track A1 of the control panel and track 2 of the air conditioning computer. Is the wiring in good condition?
Check the electrical wiring between:
Is the wiring on good condition?
Using the XR25, enter G21* (compressor clutch control). Does the compressor cut in?
Change the air conditioning computer.
Repair the wiring.
Check that left-hand bargraph 13 is
extinguished. This relates to the inhibiting of
heating/ventilation/air conditioning by the
injection or the automatic gearbox.
Is this bargraph extinguished?
Using the XR25, measure the pressures of the
coolant circuit by entering #16 or use
The pressures should be:
28 bars,
Check the connections between:
Change the pressure sensor.
Refer to left-hand bargraph 13.
Top up the coolant circuit.
Check that the components which were removed are connected correctly.
AIR CONDITIONING PROBLEMS Too cold
Is the fan assembly always operating? (normal if high pressure ≥ 20 bars)
Check that the recirculation flap does not remain in the recirculated air position. Operate the control button and check that the flap moves. Does it move?
Check that the action of the heater control moves the flap. Does it move?
Visually check that the flap travel is complete. Is it correct?
Change the fan assembly.
Check the coolant circuit pressures using the XR25 or pressure gauges. The fan assembly operates if the high
pressure ≥ 20 bars and stops if the pressure ≤15 bars. If the pressures are correct, change the pressure sensor, otherwise, top up the coolant circuit.
AIR CONDITIONING PROBLEMS Performance poor
Check that the compressor operates, with the
air conditioning on, passenger compartment
ventilation on maximum in recirculation
mode, engine running at idle.
Check the tension of the compressor belt, the
clutch air gap and its condition.
Retension the belt or change
the compressor clutch.
Ensure that the recirculation flap is in the
recirculation position in air conditioning
recirculation mode.
Is it in this position?
Check that the flap travel is complete,
readjust the cable if necessary.
See CHART 14A.
See CHART 2 or CHART 9.
CONDITIONING Fault finding charts
With the vehicle stationary, engine running at idle, air conditioning on maximum, measure the pressure of the coolant circuit. If the pressure is > 28 bars, there is :
- or the operation of the fan assembly is ab- normal,
- or the condenser is clogged,
- or the engine heats up too much. Is the pressure < 28 bars ?
too much fluid,
Check the cleanness of the condenser wiring harness. Clean or change the condenser.
If the fault persists, check the operation of the cooling fan assembly at high speed (ventilation and air conditioning
on maximum). It should be:
- operating if high pressure
- stopped if high pressure
≥ 20 bars
≤ 15 bars
Is the operation of the fan assembly normal?
See CHART 15.
CHART 14A
With the air conditioning and ventilation on maximum and the engine running at idle, check that the compressor operates. Does the compressor operate?
Connect the XR25 and enter G21* (direct compressor control). Does the compressor operate?
Check the pressure of the coolant circuit. The compressor should cut in for:
28 bars.
Check the electrical wiring:
and between the connector and the sensor. Is the wiring in good condition?
See CHART 14.
Check the wiring between the heating and ventilation computer
and the compressor clutch. Repair if necessary.
If the fault persists, change the compressor.