B3FD3FK1 - 406D9

CHECK : VACUUM CIRCUIT

1 - SPECIAL TOOLS

[1] Kit DIAL 2000 :

• [1a] unit DIAL 2000 (reference 1A)
• [1b] DIAL 2000 supply lead (reference 1B)

[2] Kit DEBI 2000 :

• [2a] flow/pressure sensor (reference 2A)
• [2b] 2 valve union (reference 2N)
• [2c] union (reference 2G)

2 - CONNECTIONS

2 - 1 - CLICK-ON UNION OF THE PIPE (1) ACCESSIBLE ON THE MANIFOLD OR VACUUM PUMP

Fit the union 2 with [2b] valves at the vacuum pump or intake manifold outlet and at the brake servo pipe (1) .

Position :

• the flow sensor [2a]
• the unit : DIAL 2000 [1a]
• the supply lead [1b]

2 - 2 - CLICK-ON UNION OF THE PIPE NOT ACCESSIBLE ON THE MANIFOLD OR VACUUM PUMP (NON CLICK-ON UNION ON THE VALVE (2))

Disconnect the servo pipe (1) from the non-return valve (2) .

Position :

• the union 2 with [2b] valves at the brake servo pipe outlet (1)
• the tool [2c] between the outlet of the tool [2b] and the non-return valve (2)
• the tool [2a]
• the tools [1a] + [1b]

2 - 3 - CLICK-ON UNION OF THE PIPE (1) NOT ACCESSIBLE ON THE MANIFOLD OR VACUUM PUMP (CLICK-ON UNION ON THE VALVE (2))

Disconnect the servo pipe (1) from the non-return valve (2) .

Position :

• the 2 valves connector [2b] between the non-return valve (2) and the power steering pipe outlet
• the tool [2a]
• the tools [1a] + [1b]

3 - PRELIMINARY OPERATIONS

Check :

• the condition of the pipes and unions
• tightening of the clips

WARNING : in order to isolate the power steering circuit, pinch the pipes connected to the attached equipment (solenoid valves) .

NOTE : the values indicated are relative pressures; the check must be carried out with the engine warm .

Stop the engine .

Ensure that the 2 valves of the union [2b] are open .

Press the brake pedal approximately ten times to establish the atmospheric pressure in the servo .

Select the menu : Brake servo on the tool [1a] : Confirm (See instructions for use) .

4 - CHECK OF THE SEALING OF THE SERVO

Engine at idle : Wait until the pressure stabilises .

Simultaneously :

• close the valve (A)
• set the time base of the tool [1a] to zero

IMPERATIVE : do not press the brake pedal .

Stop the engine .

XU/XUD ENGINE ES ENGINE DIESEL DW EW7J4 ENGINE EW10J4 ENGINE EW12J4 ENGINE

Checking value :

• variation in pressure : less than or equal to 0.03 bar(s) in 15 seconds

If the value is correct :

• diesel engine(s) : check the vacuum pump
• petrol engine(s) : system correct

NOTE : if the value is correct and the vehicle presents symptoms of malfunction, replace the pipe (1) .

If the value is incorrect :

• check : the presence of the seal (3)
• check : tightening of the master cylinder on the servo ( tightening torque : 2 da.Nm)
• replace the non-return valve (2) and the pipe (1)

Carry out the check again .

If the value is incorrect :

• replace the brake servo unit

EW10D ENGINE

The level of vacuum in the servo is controlled by the engine management ecu .

Description :

• (1) : pipe connected to the source of the vacuum (pipes)
• (4) : interface + vacuum sensor assembly
• (5) : vacuum valve
• (A) : black section towards the source of the vacuum
• (B) : white section towards the servo

If the value is correct (Pressure variation less than or equal to 0.03 bars in 15 seconds) .

System correct .

NOTE : if the pedal is stiff and the sealing of the servo is correct, connect the diagnostic equipment DIAG 2000 to the diagnostic socket and read the engine management ecu faults ; if there is a vacuum monitoring fault, rectify the fault .

If the value is incorrect (Pressure variation greater than 0.03 bars in 15 seconds) :

• check : the presence of the seal (3) on the master cylinder
• tightening of the master cylinder on the servo ; tightening torque : 2 da.Nm
• replace the vacuum valve (5) and the pipe (1)

Carry out the check again .

If the value is incorrect :

• replace the brake servo unit

ALL MODELS

5 - VACUUM PUMP PRESSURE CHECK

Open the valves (A) + (B) .

Press the brake pedal approximately ten times to establish the atmospheric pressure in the servo .

Close the valve (A) .

Set the time base of the tool [1a] to zero .

Start the engine (Idling speed) .

Open the valves (A) .

Checking value :

• - 1 ≤ pressure (bars) ≤ - 0.8 in less than 30 seconds

If the value is incorrect :

• replace the pipe (1)

Carry out the check again .

If the value is incorrect :

• replace the vacuum pump

Rectify the circuit .

NOTE : if the control values are correct and the vehicle continues to exhibit symptoms of malfunction, check the sealing of the attached equipment connected to the vacuum circuit (use a NAUDER T 7050 type manual pump) .