Post on 23-Oct-2014
© Renault s.a.s. 2005
"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.
77 11 318 022 FEBRUARY 2003 Edition Anglaise
X84, and B84 or C84 or G84 or S84
1 Engine and peripherals
10A ENGINE AND LOWER ENGINE ASSEMBLY
11A TOP AND FRONT OF ENGINE
12A FUEL MIXTURE
12B TURBOCHARGING
13A FUEL SUPPLY
13B DIESEL INJECTION
13C PREHEATING
14A ANTIPOLLUTION
16A STARTING - LOAD
17A IGNITION
17B PETROL INJECTION
© Renault s.a.s. 2005
"The repair methods given by the manufacturer in this document are based on the technicalspecifications current when it was prepared.
The methods may be modified as a result of changes introduced by the manufacturer in theproduction of the various component units and accessories from which his vehicles areconstructed."
All copyrights reserved by Renault.
The reproduction or translation in part of whole of the present document, as well as the useof the spare parts reference numbering system, are prohibited without the prior writtenconsent of Renault.
77 11 318 022 FEBRUARY 2003 Edition Anglaise
X84, and B84 or C84 or G84 or S84
19A COOLING SYSTEM
19B EXHAUST
19C RESERVOIR
19D ENGINE MOUNTING
Mégane II - Section 1
Contents
Page
Mégane II - Section 1ContentsPage
10A ENGINE AND LOWER ENGINE ASSEMBLY
Engine identification 10A-1
Engine oil: Draining - Refilling 10A-2
Oil consumption Check 10A-3
Oil filter: Removal - Refitting 10A-4
Exchanger: Removal - Refitting 10A-10
Oil pressure 10A-16
Oil pressure sensor: Removal - Refitting 10A-17
Oil level sensor: Removal - Refitting 10A-20
Sump: Removal - Refitting 10A-21
Oil pump: Removal - Refitting 10A-42
Multifunction support: Removal - Refitting 10A-45
Engine/gearbox assembly: Removal - Refitting 10A-55
Engine speed and position sensor: Removal - Refitting 10A-131
Crankshaft seal at timing end Removal - Refitting 10A-132
11A TOP AND FRONT OF ENGINE
Accessories belt: Removal - Refitting 11A-1
Timing belt: Removal - Refitting 11A-11
Timing chain: Removal - Refitting 11A-116
Cylinder head gasket : Removal - Refitting 11A-117
Tightening the cylinder head 11A-199
Cylinder head: Removal - Refitting 11A-205
12A FUEL MIXTURE
Specifications 12A-1
Air inlet 12A-11
Air resonator: Removal - Refitting 12A-22
Air filter: Replacement 12A-23
Air filter: Removal - Refitting 12A-25
Air filter unit: Removal - Refitting 12A-26
Air flowmeter: Removal - Refitting 12A-39
Air inlet flap: Removal - Refitting 12A-41
Air inlet duct: Removal - Refitting 12A-49
Inlet manifold: Removal - Refitting 12A-52
Injector holder shim: Removal - Refitting 12A-58
Manifolds: Removal - Refitting 12A-64
11A TOP AND FRONT OF ENGINE
Contents
Exhaust manifold: Removal - Refitting 12A-67
Throttle valve: Removal - Refitting 12A-86
Throttle valve: Cleaning 12A-94
Engine stop device 12A-96
12B TURBOCHARGING
Turbocharging: Precautions for repair 12B-1
Turbocharger: Removal - Refitting 12B-6
Pressure regulator: Checking 12B-37
Turbocharging pressure regulation valve 12B-43
Intercooler: Removal - Refitting 12B-46
13A FUEL SUPPLY
Petrol supply circuit 13A-1
Diesel fuel supply circuit 13A-2
Petrol filter: General information 13A-6
Diesel filter: Removal - Refitting 13A-7
Injector rail - Injectors: Removal - Refitting 13A-14
Electric fuel: Checking 13A-20
13B DIESEL INJECTION
Specifications 13B-1
Diesel injection: Specifications 13B-11
12A FUEL MIXTURE
Diesel injection: Precautions for repair 13B-16
Description 13B-31
Operation 13B-33
Location of components 13B-36
Immobiliser function 13B-61
Injection warning light 13B-62
Injection / air conditioning programming 13B-64
Idling speed 13B-67
Centralised coolant temperature management 13B-69
Computer configuration 13B-71
High pressure pipe: Checking 13B-73
High pressure pipe: Replacement 13B-76
Diesel injector: check 13B-83
High pressure pump: Removal - Refitting 13B-84
Diesel injector: Removal - Refitting 13B-113
Injectors: Configuration 13B-130
High-pressure pipe between the rail and injector: Removal - Refitting 13B-132
Injector rail: Removal - Refitting 13B-143
Rail pressure sensor 13B-160
Rail pressure sensor: Removal - Refitting 13B-161
Fuel flow actuator: Removal - Refitting 13B-164
Leak flow from injectors: Check 13B-170
Fuel pressure regulator: Removal - Refitting 13B-174
13B DIESEL INJECTION
Contents
Diesel temperature sensor: Removal - Refitting 13B-179
Accelerometer: Removal - Refitting 13B-189
Venturi: Removal - Refitting 13B-190
Accelerator pedal potentiometer: General information 13B-194
Accelerator pedal potentiometer: Removal - Refitting 13B-195
Diesel injection computer: Removal - Refitting 13B-196
13C PREHEATING
Pre/postheating unit: Removal - Refitting 13C-1
Heater plugs Removal - Refitting 13C-2
Pre-postheating control 13C-11
14A ANTIPOLLUTION
Petrol vapour rebreathing: Operation 14A-1
Fuel vapour recirculation circuit: check 14A-3
Fuel vapour canister: Removal - Refitting 14A-4
Fuel vapour canister:Checking 14A-5
Oil vapour rebreathing 14A-6
Exhaust gas recirculation: Operating diagram
Exhaust gas recirculation: Description 14A-17
Exhaust gas recirculation unit 14A-23
13B DIESEL INJECTION
Exhaust gas recirculation solenoid valve: Removal - Refitting 14A-29
Intercooler: Removal - Refitting 14A-31
Exhaust gas recirculation mounting: Removal - Refitting 14A-36
Exhaust gas recirculation rigid pipe: Removal - Refitting 14A-37
16A STARTING - LOAD
Alternator: General information 16A-1
Alternator: Removal - Refitting 16A-2
Alternator pulley: Removal - Refitting 16A-20
Starter: Identification 16A-24
Starter: Removal - Refitting 16A-25
17A IGNITION
Coils Removal - Refitting 17A-1
Spark plugs 17A-5
17B PETROL INJECTION
Location of components 17B-1
Oxygen sensors: Removal - Refitting 17B-14
Accelerator pedal potentiometer: Removal - Refitting 17B-16
Position and speed sensor 17B-17
14A ANTIPOLLUTION
Contents
Petrol injection computer: Removal - Refitting 17B-19
Special notes 17B-21
Injection warning light 17B-24
Immobiliser function 17B-25
Injection - air conditioning programming 17B-26
Throttle valve: Operating 17B-30
Idle speed correction 17B-31
Adaptive idle speed correction 17B-34
Richness regulation 17B-35
Adaptive richness correction 17B-39
Central coolant temperature management 17B-41
Camshaft dephaser: Description 17B-42
Fault finding warning light activation conditions (when driving) 17B-44
Conditions for carrying out fault finding (when driving) 17B-45
Combustion misfire fault finding 17B-46
Catalytic converter fault finding 17B-47
Oxygen sensor fault finding 17B-48
Speed limiter: Operating principle 17B-49
19A COOLING SYSTEM
General information 19A-1
Specifications 19A-2
Checking 19A-3
Diagram 19A-4
17B PETROL INJECTION
Cooling circuit: Draining - Refilling 19A-12
Engine cooling circuit: Cleaning 19A-14
Cooling circuit: Bleeding 19A-15
Cooling radiator: Removal - Refitting 19A-16
Water pump: Removal - Refitting 19A-22
Plenum chamber: Removal - Refitting 19A-40
19B EXHAUST
General information 19B-1
Pipe assembly 19B-5
Catalytic pre-converter: Removal - Refitting 19B-10
Catalytic converter: Removal - Refitting 19B-15
Expansion chamber: Removal - Refitting 19B-29
Silencer: Removal - Refitting 19B-30
Particle filter: Function 19B-31
Particle filter: Removal - Refitting 19B-32
Particle filter pressure sensor: Removal - Refitting 19B-38
Particle filter temperature sensors: Removal - Refitting 19B-42
Connecting hose: Removal - Refitting 19B-45
Particle filter: Cleaning 19B-46
19A COOLING SYSTEM
Contents
19C RESERVOIR
Draining the fuel tank 19C-1
Fuel tank: Description 19C-6
Fuel tank: Removal - Refitting 19C-12
Filler neck: Removal - Refitting 19C-15
Sender unit: Removal - Refitting 19C-17
Pump-sender unit-filter: Removal - Refitting 19C-20
Petrol filter: General information 19C-22
Fuel level sensor: Checking 19C-23
19D ENGINE MOUNTING
Suspended engine mounting 19D-1
Suspended engine mounting: Tightening torque 19D-9
Left-hand suspended engine mounting: Removal - Refitting 19D-12
Right-hand suspended engine mounting: Removal - Refitting 19D-14
Rear suspended engine mounting: Removal - Refitting 19D-16
10A-1
ENGINE AND LOWER ENGINE ASSEMBLYEngine identification 10A
List of engine Workshop Repair Manuals to be consul-ted depending on the engine type:
- K4J and K4M engine, Technical Note 3784A,
- K9K engine, Technical note 6006A,
- F9Q engine, Technical Note 3652A,
- F4R engine, Technical Note 3783 A.
Vehicle type Engine type Engine suf-fix
Cubic capa-city (cc)
Bore (mm) Stroke (mm) Compressionratio
XM0B
XM0H
XM1AK4J
730
1390 79.5 70 10/1
XM08 732
XM0C
XM0J
XM1B
K4M
760
1598 79.5 80.5 9.8/1761
XM05
XM0U
XM1M
XM1N
F4R
770
1998 82.7 939.8/1771
XNOW 776 9.5/1
XM0F
XM0T
K9K
722
1461 76 80.517.9/1XM02
XM13
728
XM02 729
XM1E 732 15.3/1
XM0G
XM1G
F9Q
800
1870 80 93
18.4/1
XM0L
XM1D
804 17/1
XM00 808 18.4/1
10A-2
ENGINE AND LOWER ENGINE ASSEMBLYEngine oil: Draining - Refilling
M9R, and 700
10A
I - OIL SERVICE
Remove the oil filler plug and the dipstick.
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Remove the engine undertray.
Remove the drain plug (1) .
Let the oil run into a drain tray.
Copper seal
Refit the new seal on the plug, positioning the groo-ve (2) towards the plug.
Tighten to torque the drain plug ( 44 Nm ) .
II - FILLING
When filling up the engine oil, always leave at least10 minutes for the oil to drain down before checkingwith a dipstick.
Fill up the engine with oil.
Refit the engine undertray.
Tightening torquesm
drain plug 44 Nm
Engine
Average oil capacity (check and adjust with
dipstick) (l)
Draining Oil changewith oil filterreplace-ment
M9R 6.4 6.7
114651
113764
WARNING
Always check the oil level using the dipstick.
Do not exceed the maximum level on the dipstick(as this could damage the engine).
Correct the engine oil level if necessary beforedelivering the vehicle to the customer.
10A-3
ENGINE AND LOWER ENGINE ASSEMBLYOil consumption Check 10A
PROCEDURE FOR MEASURING OIL CONSUMPTION
1 - Filling to the maximum level
Turn the engine off.
Wait two minutes for all of the oil to flow into the oilsump.
Check the level on the dipstick.
Top up to the "MAX" mark.
Make a paint mark on both the fuel filler cap and thesump drain plug in order to be able to check laterthat they have not been removed.
2 - Customer driving
Ask the customer to drive approximately 1,200 mi-les (2,000 km) in the vehicle without letting the oil le-vel reach the "MIN" mark.
3 - Topping up
Turn the engine off.
Wait two minutes for all of the oil to flow into the oilsump.
Check the level on 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 (inlitres) / number of kilometres (in thousands).
Note:
The operation should be carried out with theengine warm after the fan unit has started opera-ting.
Note:
The operation should be carried out with theengine warm after the fan assembly has startedoperating.
10A-4
ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove the engine undertray.
Position (Mot. 1329) (1) on the oil filter.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the oil filter.
REFITTING
I - REFITTING PREPARATION OPERATION
Lubricate the oil filter seal with new engine oil.
II - REFITTING OPERATION FOR PART CONCERNED
Tighten the oil filter until it comes into contact withthe oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
III - FINAL OPERATION
Top up the engine oil.
Wipe any oil run-off with a cloth.
Refit the engine undertray.
Special tooling required
Mot. 1329 76 mm diameter oil fil-ter removing tool
111850
10A-5
ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting
F4R, and 770 or 771 or 776
10A
REMOVAL
Position the vehicle on the two-post lift (see 02A,Lifting equipment, Underbody lift ).
Remove the engine undertray.
Remove:
- the mounting bolts (1) from the air conditioningcompressor stay.
- the air conditioning compressor stay.
Position the (Mot. 1329) (2) on the oil filter.
Remove the oil filter.
REFITTING
Lubricate the oil filter seal with new engine oil.
Tighten the oil filter until it comes into contact withthe oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
Refit the air conditioning compressor stay.
Tighten to torque the air conditioning compressorstay mounting bolts ( 44 Nm ) .
Top up the engine oil.
Wipe any oil run-off with a cloth.
Refit the engine undertray.
Special tooling required
Mot. 1329 76 mm diameter oil fil-ter removing tool
Tightening torquesm
air conditioning com-pressor stay mountingbolts
44 Nm
111851
11
111852
2
10A-6
ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting
K4M, and 760 or 761 – K4J, and 730 or 732
10A
REMOVAL
Position the vehicle on the two-post lift (see 02A,Lifting equipment, Underbody lift ).
Remove the engine undertray.
Position tool (Mot. 1329) (1) on the oil filter.
Remove the oil filter.
REFITTINGApply new engine oil to the oil filter seal.
Tighten the oil filter until it comes into contact withthe oil filter seal on the engine.
Tighten the oil filter three-quarters of a turn by hand.
Top up the engine oil.
Refit the engine undertray.
Special tooling required
Mot. 1329 76 mm diameter oil fil-ter removing tool
110385
10A-7
ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Remove the engine undertray.
Loosen the cover (1) slightly.
Let the engine oil flow out before removing the filterelement - cover assembly.
Remove the filter element - cover assembly.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the filter element (2) from the cover (3) ,
- the O-ring (4) from the cover (3) .
Tightening torquesm
cover 25 Nm
114653
114779
113320
10A-8
ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting
M9R, and 700
10AREFITTING
I - REFITTING PREPARATION OPERATION
Clean the cover.
Position the new O-ring (5) correctly on the cover.
Apply new engine oil to the O-ring.
II - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the new filter element (6) in the cover (7) ,
- the filter element - cover assembly.
Tighten to torque the cover ( 25 Nm ) .
III - FINAL OPERATION
Top up the engine oil.
Refit the engine undertray.
113869
114780
10A-9
ENGINE AND LOWER ENGINE ASSEMBLYOil filter: Removal - Refitting
F9Q
10A
If the AC pipe is significantly deformed when the oil fil-ter is removed, there may be a refrigerant leak.
To reduce the risk of a leak in the MEGANE II andSCENIC II equipped with F9Q engine, the ADVICE inthis Technical Note relating to the removal of the oil fil-ter from the TOP OF THE ENGINE must be strictly fol-lowed.
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Drain the engine oil (see 05A, Draining/Filling-up ).
II - REMOVING THE OIL FILTER
From the top of the engine, position the (Mot. 1329)on the oil filter using an open-jawed spanner 27 mmin width.
Remove the oil filter.
REFITTING
I - REFITTING PREPARATION OPERATION
Lubricate the new oil filter seal.
II - REFITTING THE OIL FILTER
Tighten the oil filter until it makes contact.
Tighten the oil filter three-quarters of a turn by hand.
III - FINAL OPERATION
Top up the engine oil (see 05A, Draining - Filling-up ).
Refit:
- the engine undertray,
- the engine covers.
Special tooling required
Mot. 1329 76 mm diameter oil fil-ter removing tool
115078
10A-10
ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting
M9R, and 700
10AREMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal and Refitting )
Remove:
- the engine protectors,
- the engine undertray,
- the oil filter (see 10A, Engine and peripherals, Oilfilter: Removal - Refitting ).
- the front bumper (see MR365 Bodywork, 55A Ex-terior protection, Front bumper )
Drain the coolant circuit using filling station (see62A, Air conditioning, Maintenance ).
Remove:
- the mounting bolts (1) from the Protection andSwitching Unit,
- the Protection and Switching Unit cover.
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Equipment required
filling station
Tightening torquesm
oil cooler mountingbolts
25 Nm
coolant inlet unionmounting bolts
24 Nm
oil pressure sensor 44 Nm
intercooler downs-tream duct clip on theintercooler
5.5 Nm
intercooler downs-tream duct clip on thedamper valve
5.5 Nm
intercooler upstreamhose clip
5.5 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
112658
10A-11
ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting
M9R, and 700
10A
Disconnect the connectors (2) from the Protectionand Switching Unit.
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Disconnect the screen washer tubes.
Unclip the air inlet scoop.
Remove:
- front end panel mounting bolts (7) ,
- the front end panel,
- the air inlet scoop.
Drain the engine cooling system (see 19A, Cooling,Engine cooling system: Draining-refilling ).
Loosen the clip (8) from the intercooler upstream ho-se.
Disconnect the intercooler upstream hose.
102504
114933
102365
102473
10A-12
ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting
M9R, and 700
10A
Remove the bolt (9) mounting the intercooler downs-tream duct on the cooling radiator.
Loosen:
- the clip (10) on the intercooler downstream duct onthe intercooler,
- the intercooler downstream duct clip on the dampervalve.
Move the downstream duct away from the intercoo-ler.
Disconnect:
- the cooling radiator top and bottom hose using(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the fan unit resistor connector (11) ,
- the fan unit connector.
Unclip the wiring harness from the fan unit.
114649 112661
10A-13
ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting
M9R, and 700
10A
Disconnect:
- the hoses from the expansion bottle on the coolingradiator side (12) ,
- the pressure switch connector on the condenserlower air conditioning pipe (13) .
Unpick the wiring harness from the pressure switchconnector on the fan unit.
Remove the air conditioning pipes from the conden-ser (14) .
Remove the cooling assembly.
Disconnect the hose (15) from the oil cooler coolantoutlet union.
Remove:
- the oil pressure sensor using the (Mot. 1495-01) ,
- the mounting bolts (16) from the coolant inlet union,
- the coolant inlet union.
Disconnect, using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) :
- the hose (17) from the coolant inlet union on theunion,
- the hose (18) from the cylinder block coolant inletpipe,
Remove the hose from the coolant inlet union.
109537
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
114929
10A-14
ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting
M9R, and 700
10AII - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the mounting bolts (19) from the oil cooler,
- the oil cooler.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the oil cooler,
- the oil cooler mounting bolts.
Tighten to torque and in the order (1) - (3) - (2) - (4)the oil cooler mounting bolts ( 25 Nm ) .
114928
114928
10A-15
ENGINE AND LOWER ENGINE ASSEMBLYExchanger: Removal - Refitting
M9R, and 700
10AII - FINAL OPERATION
Connect, using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) :
- the coolant inlet union hose on the cylinder block,
- the coolant inlet pipe hose on the union,
- the coolant outlet union hose to the oil cooler.
Refit:
- the coolant inlet union,
- the coolant inlet union mounting bolts,
- the oil pressure sensor.
Tighten to torque:
- the coolant inlet union mounting bolts ( 24 Nm ),
- using (Mot. 1495-01) the oil pressure sensor ( 44Nm ) .
Refit the cooling assembly.
Refit the air conditioning pipes to the condenser.
Attach the pressure switch connector wiring harnessto the fan unit.
Connect, using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) :
- the expansion bottle hoses on the cooling radiatorside,
- the cooling radiator top and bottom hose.
Connect:
- the pressure switch connector on the condenserlower air conditioning pipe,
- the fan unit connector,
- the fan unit resistor connector,
Clip the fan unit wiring harness into place.
Refit:
- the intercooler downstream duct clip to the inter-cooler,
- the intercooler downstream duct clip on the dampervalve.
Tighten to torque:
- the intercooler downstream duct clip on the in-tercooler ( 5.5 Nm ) ,
- the intercooler downstream duct clip on thedamper valve ( 5.5 Nm ) .
Tighten the bolt mounting the intercooler downs-tream duct on the cooling radiator.
Connect the intercooler upstream hose.
Tighten to torque the intercooler upstream hoseclip ( 5.5 Nm ) .
Refit:
- the air inlet scoop,
- the front end panel,
- the clips,
- the front end panel mounting bolts.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) .
Connect the Protection and Switching Unit connec-tors.
Clip the bonnet opening cable.
Disconnect the screen washer tubes.
Refit:
- the Protection and Switching Unit cover,
- the Protection and Switching Unit cover mountingbolts,
- the oil filter (see 10A, Engine and peripherals, Oilfilter: Removal - Refitting ).
- the engine undertray.
Refit:
- the engine protectors,
- the front bumper (see MR365 Bodywork, 55A Ex-terior protection, Front bumper ).
Refill:
- the coolant circuit using the filling station (see62A, Air conditioning, Maintenance ),
- the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
10A-16
ENGINE AND LOWER ENGINE ASSEMBLYOil pressure 10A
I - ADAPTERS FOR USE WITH VARIOUS ENGINES
II - PRECAUTIONS TO TAKE DURING CHECKS
The oil pressure check must be carried out with the en-gine warm (≈ 80˚C ).
III - CHECKING PROCEDURE
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the oil pressure sensor (see 10A, Engine andperipherals, Oil pressure sensor: Removal - Refit-ting ).
Position the (Mot. 836-05) with the appropriate adap-ters.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Start the vehicle.
Carry out the check.
Check the values.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the (Mot. 836-05) and the adapters.
Refit the oil pressure sensor (see 10A, Engine and pe-ripherals, Oil pressure sensor: Removal - Refitting).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Special tooling required
Mot. 836-05 Oil pressure gauge kit
Engine Adapters
K4J E + C + F
K4M E + C + F
F4R B + F
K9K E + C + F
F9Q B + F
M9R C + F
87363
EngineEnginesuffix
Minimum pressure (bar)
Idlespeed
3000 rpm
K4J 730 1 3
K4M760
1 3 782
F4R
770 1 3
771
776 1.2 3.5
K9K
722
1.2 3.5 728
732
F9Q804
1.2 3.5 812
M9R 700 0.9 4
10A-17
ENGINE AND LOWER ENGINE ASSEMBLYOil pressure sensor: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine protectors,
- the engine undertray,
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ).
Remove:
- the engine accessories unit cover mounting bolts(1) ,
- the engine accessories unit cover.
Disconnect the connectors (2) from the engine ac-cessories unit.
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Disconnect the screen washer tubes.
Unclip the air inlet scoop (6) .
Special tooling required
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Tightening torquesm
oil pressure sensor 44 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
112658
115585
114933
10A-18
ENGINE AND LOWER ENGINE ASSEMBLYOil pressure sensor: Removal - Refitting
M9R, and 700
10A
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the oil pressure sensor connector (8) .
Remove the oil pressure sensor using the (Mot.1495-01) (1) .
102365
114061
115022
115021
Note:
Be careful not to damage the air conditioningcompressor connector.
10A-19
ENGINE AND LOWER ENGINE ASSEMBLYOil pressure sensor: Removal - Refitting
M9R, and 700
10AREFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the oil pressure sensor.
Tighten to torque the oil pressure sensor ( 44 Nm )using the (Mot. 1495-01) .
Connect the oil pressure sensor connector.
II - FINAL OPERATION
Refit:
- the front end panel,
- the upper mounting bolts of the front end panel,
- the lower mounting bolts of the front end panel.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) .
Clip the air inlet scoop into place.
Connect the screen washer pipes.
Position the bonnet opening cable.
Connect the engine accessories unit connectors.
Refit:
- the clips,
- the engine accessories unit cover,
- the engine accessories unit cover mounting bolts,
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ),
- the engine undertray,
- the engine protectors.
10A-20
ENGINE AND LOWER ENGINE ASSEMBLYOil level sensor: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A Lif-ting equipment, Underbody lift ).
Remove the front right-hand wheel.
Move the heat insulating material away from the oillevel sensor.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the oil level sensor (1) .
Remove the oil level sensor.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the oil level sensor.
Tighten to torque the oil level sensor ( 25 Nm ) .
Connect the oil level sensor.
II - FINAL OPERATION
Refit the heat insulating material around the oil levelsensor.
Refit the front right-hand wheel.
Tighten to torque the front right-hand wheel ( 110Nm ) .
Tightening torquesm
oil level sensor 25 Nm
front right-hand wheel 110 Nm
114932
10A-21
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
REMOVAL
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine undertray.
Drain the engine oil (see 05A, Draining - Filling,Engine ).
Remove:
- the engine covers,
- the dipstick,
- the front wheels,
- the wheel arch liners,
Remove the half sub-frame side reinforcements (1) .
Attach the cooling assembly to the upper crossmember using a safety belt .
Equipment required
safety belt
Tightening torquesm
sump mounting bolts 14 Nm
sump mounting boltsare tightened to torque
14 Nm
gearbox - sump moun-ting bolts
44 Nm
sump mounting bolts 14 Nm
sump mounting boltsare tightened to torque
14 Nm
gearbox - sump moun-ting bolts
44 Nm
bolt mounting the sumpon the multifunctionsupport
21 Nm
half sub-frame moun-ting bolts
105 Nm
half sub-frame moun-ting nuts
21 Nm
wheel bolts 110 Nm
battery cover bolts 4 Nm
101212
Note:
When positioning the safety belt , be careful not to:
- pinch the cooling hoses,
- strap the half sub-frame.
1
10A-22
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
Remove:
- the mounting nuts from the half sub-frame,
- the mounting bolts from the half sub-frame,
- the half sub-frame (2) .
Remove:
- the mounting bolts of the right-hand driveshaftbracket on the relay bearing,
- the bolts mounting the relay bearing on the sump.
Remove the mounting bolt of the sump on the multi-function support.
Remove:
- the sump mounting bolt,
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.
102008
CA or CAREG
2
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould cause damage to certain components(engine, radiator, etc.).
10A-23
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVESEALANT which are 5 mm in diameter .
- two points of SILICONE ADHESIVE SEALANT at(5) which are 7 mm in diameter , at the jointbetween the crankshaft closure panel and the cy-linder block.
I - FIRST FITTING
Refit the oil splash plate onto the cylinder block.
20167
20166
3
4
5
5
20170
Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positio-ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheelend are aligned to prevent deformation of theclutch housing.
77777
66666
10A-24
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
Refit the oil sump with a new seal.
Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tighte-ning.
Tighten to torque and in order the sump mountingbolts ( 14 Nm ) .
Check that all the sump mounting bolts are tighte-ned to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mountingbolts ( 44 Nm ) .
20171
14
3
13
2
121110
1 20
9
19
8
18
7
17
6
16
5
15
4
10A-25
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10AII - SECOND FITTING
Refit the oil sump with a new seal.
Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tighte-ning.
Tighten to torque and in order the sump mountingbolts ( 14 Nm ) .
Check that all the sump mounting bolts are tighte-ned to torque ( 14 Nm ) .
Tighten to torque the gearbox - sump mounting
bolts ( 44 Nm ) .
III - REFITTING (FOR FIRST AND SECOND FITTINGS)
Refit the bolt mounting the sump on the multifunctionsupport.
Tighten to torque the bolt mounting the sump onthe multifunction support ( 21 Nm ) .
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) ,
- the wheel bolts ( 110 Nm ) .
- the battery cover bolts ( 4 Nm ) .
Proceed in the reverse order to removal.
Top up the engine oil (see 05A, Draining - Filling,Engine ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
108881
20171
12345
6 7 8 9 10 11 12 13 14
15
16
17181920
CA or CAREG
10A-26
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F9Q, and 800 or 804 or 808
10A
REMOVALPlace the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine undertray.
Drain the engine oil (see 05A, Draining - Filling,Engine ).
Remove:
- the engine covers,
- the dipstick,
- the front wheels,
- the wheel arch liners,
Remove the half sub-frame side reinforcements (1) .
Attach the cooling assembly to the upper crossmember using a safety belt .
Equipment required
safety belt
Tightening torquesm
half sub-frame moun-ting bolts
105 Nm
half sub-frame moun-ting nuts
21 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
101212
Note:
When positioning the safety belt , be careful not to:
- pinch the cooling hoses,
- strap the half sub-frame.
1
10A-27
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F9Q, and 800 or 804 or 808
10A
Remove:
- the mounting nuts from the half sub-frame,
- the mounting bolts from the half sub-frame,
- the half sub-frame (2) .
Remove:
- the engine tie-bar,
- the sump mountings,
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.
102008
2
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould cause damage to certain components(engine, radiator, etc.).
Note:
There are two fitting procedures for preparing the cylinder block gasket face when refitting:
- the first fitting procedure is used if SILICONEADHESIVE SEALANT has been used to sealthe crankshaft closure panel,
- the second fitting is used if a seal is used for thecrankshaft closure panel sealing.
10A-28
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F9Q, and 800 or 804 or 808
10AI - FIRST FITTING
Apply a bead of SILICONE ADHESIVE SEALANT :
- at (A) , both sides of bearing No.1,
- at (B) , the joint between the cylinder block and thecrankshaft closure panel.
Refit the sump fitted with a new seal.
II - SECOND FITTING
Apply a bead of SILICONE ADHESIVE SEALANTat (A) , on the joint between the crankshaft closurepanel and the cylinder block.
Refit the sump fitted with a new seal.
15159
B
AA
B
15159
Note
Do not cut the two crankshaft closure panel sealtabs which sit higher than the cylinder block gas-ket face (B) .
A
B
10A-29
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F9Q, and 800 or 804 or 808
10AIII - REFITTING (FOR THE FIRST AND SECOND FITTINGS)
Stage 1:
• Tighten to torque and in order, bolts (8) , (15) , (4), (19) , (11) , (12) to ( 18 Nm ).
- Stage 2:
• Tighten to torque and in order, bolts (10) , (13) ,(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (13), (18) , (3) , (20) , (2) , (21) , (1) and (22) to ( 15Nm ).
Refit the lower engine tie-bar (see 19D, Enginemounting, Suspended engine mounting ).
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) ,
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) ,
Proceed in the reverse order to removal.
Top up the engine oil (see 05A, Draining - Filling,Engine ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
15195
2 8
19 18
13
1
7
12
6
11
17
10
5
21
16
22
4
15
3 9
1420
10A-30
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10AREMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine covers,
- the dipstick,
- the engine undertray.
Remove:
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ),
- the front wheels,
- the wheel arch liners.
Drain the engine oil (see 05A, Draining - Filling,Engine ).
Equipment required
safety belt
Tightening torquesm
sump mounting bolts 14 NM
sump mounting boltsare tightened to torque
14 NM
sump mounting bolts 44 NM
sump mounting bolts 14 NM
sump mounting boltsare tightened to torque
14 NM
sump mounting bolts 44 NM
bolt mounting the sumpon the multifunctionsupport
21 Nm
catalytic converter ups-tream stay mountingbolts
21 Nm
half sub-frame moun-ting bolts
105 Nm
half sub-frame moun-ting nuts
21 Nm
half sub-frame sidereinforcement mountingbolts
21 Nm
wheel bolts 110 Nm
10A-31
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10A
Remove the half sub-frame side reinforcements (1) .
Attach the cooling assembly to the upper crossmember using a safety belt .
Move the diesel drain pipe away from the injectionrail protector.
Remove:
- the mounting nuts from the half sub-frame,
- the mounting bolts from the half sub-frame,
- the half sub-frame (2) .
Remove:
- the lower engine tie-bar mounting bolts,
- the lower engine tie-bar,
- the lower engine tie-bar support lower mountingbolts.
Loosen the lower engine tie-bar upper bolt.
Remove:
- the bolts mounting the right-hand driveshaft brac-ket on the relay bearing,
- the bolts mounting the relay bearing on the sump,
- the relay bearing,
- the catalytic converter upstream stay mountingbolts,
- the catalytic converter upstream stay.
Disconnect the oil level sensor.
101212
Note:
When positioning the safety belt , be careful not to:
- pinch the cooling hoses,
- strap the half sub-frame.
K9K, and 732
1
102008
K9K, and 732
2
10A-32
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10A
Remove the mounting bolt from the sump on themultifunction support.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the sump mounting bolt,
- the sump.
REFITTING
I - REFITTING PREPARATION OPERATION
Clean the strainer with a soft, lint-free cloth.
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.
Apply:
- four beads at (3) and (4) of SILICONE ADHESIVESEALANT which are 5 mm in diameter .
- two points of SILICONE ADHESIVE at (5) whichare, 7 mm in diameter , at the joint between thecrankshaft closure panel and the cylinder block.
CA or CAREG
K9K, and 732
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould cause damage to certain components(engine, radiator, etc.).
20167
20166
33
5
4
5
4
10A-33
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10AII - REFITTING OPERATION FOR PART CONCERNED
1 - FIRST FITTING
Refit the oil splash plate onto the cylinder block.
Refit the oil sump with a new seal.
Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tighte-ning.
Tighten to torque and in order the sump mountingbolts ( 14 NM ) .
Check that all the sump mounting bolts are tighte-ned to torque ( 14 NM ) .
Tighten to torque and in order the sump mountingbolts ( 44 NM ) .
20170
Note:
When refitting the sump, check that:
- the tabs (6) on the oil splash plate are positio-ned correctly in the notches (7) ,
- the cylinder block and the sump at the flywheelend are aligned to prevent deformation of theclutch housing.
7
66666
7777
20171
7
18
14
172
6 13
5
12
16
11
4
10
15
9
20
8
1913
10A-34
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10A2 - SECOND FITTING
Refit the oil sump with a new seal.
Fit:
- the sump mounting bolts without tightening,
- the gearbox - sump mounting bolts without tighte-ning.
Tighten to torque and in order the sump mountingbolts ( 14 NM ) .
Check that all the sump mounting bolts are tighte-ned to torque ( 14 NM ) .
Tighten to torque and in order the sump mounting
bolts ( 44 NM ) .
III - FINAL OPERATION
Connect the oil level sensor.
Refit the bolt mounting the sump on the multifunctionsupport.
Tighten to torque the bolt mounting the sump onthe multifunction support ( 21 Nm ) .
Refit the catalytic converter upstream stay.
Tighten the mounting bolts of the catalytic converterupstream stay until contact is made.
Tighten to torque the catalytic converter upstreamstay mounting bolts ( 21 Nm ) .
Refit:
- the relay bearing,
- the bolts mounting the relay bearing on the sump,
- the bolts mounting the right-hand driveshaft brac-ket on the relay bearing.
Refit the lower engine tie-bar support lower moun-ting bolts (see 19A, Engine mounting, Suspendedengine mounting ).
Tighten the lower engine tie-bar support lowermounting bolts (see 19A, Engine mounting, Sus-pended engine mounting ).
Refit the lower engine tie-bar (see 19A, Enginemounting, Suspended engine mounting ).
108881
20171
CA or CAREG
K9K, and 732
Note:
Apply a drop of LOCTITE FRENBLOC to the halfsub-frame mounting bolts.
10A-35
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
10ARefit:
- the half sub-frame mounting bolts,
- the half sub-frame mounting nuts,
- the half sub-frame.
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) .
Fit the diesel drain pipe to the injection rail protector .
Remove the safety belt .
Refit:
- the half sub-frame side reinforcements,
- the half sub-frame side reinforcement mountingbolts.
Tighten to torque the half sub-frame side reinfor-cement mounting bolts ( 21 Nm ) .
Refit:
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ),
- the engine undertray,
- the wheel arch liners,
- the front wheels.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Top up the engine oil (see 05A, Draining - Filling,Engine ).
Refit:
- the dipstick,
- the engine protectors.
K9K, and 732
10A-36
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F4R, and 770 or 771 or 776
10A
REMOVALPlace the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine undertray.
Drain the engine oil (see 05A, Draining - Filling,Engine ).
Remove:
- the engine covers,
- the dipstick,
- the front wheels,
- the wheel arch liners.
Remove:
- the half sub-frame side reinforcement mountingbolts,
- the side reinforcements (1) .
Attach the cooling assembly to the upper crossmember using the safety belt .
Equipment required
safety belt
Tightening torquesm
half sub-frame moun-ting bolts
105 Nm
half sub-frame moun-ting nuts
21 Nm
wheel bolts (F4R 776) 130 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
101212
Note:
When positioning the safety belt , be careful not to:
- pinch the cooling hoses,
- strap the half sub-frame.
1
10A-37
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Remove:
- the mounting nuts from the half sub-frame,
- the mounting bolts from the half sub-frame,
- the half sub-frame (2) .
Remove:
- the engine tie-bar,
- the sump mountings,
- the sump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned: waitapproximately ten minutes, then remove the residueusing a wooden spatula.
Apply a bead of SILICONE ADHESIVE SEALANTat (A) , at the joint between the crankshaft closurepanel and the cylinder block.
Refit the sump with a new gasket.
102008
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould cause damage to certain components(engine, radiator, etc.).
2
15159
Note:
Do not cut the two tabs on the crankshaft closurepanel seal, which sit higher than the joint face ofthe cylinder block (B) .
BB
AA
10A-38
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Stage 1:
• Tighten to torque and in order, bolts (8) , (15) , (4), (19) , (11) , (12) ( 18 Nm ).
- Stage 2:
• Tighten to torque and in order, bolts (10) , (13) ,(9) , (14) , (8) , (15) , (7) , (16) , (6) , (17) , (5) , (18), (3) , (20) , (2) , (21) , (1) and (22) ( 15 Nm ).
Refit the lower engine tie-bar (see 19D, Enginemounting, Suspended engine mounting ).
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) ,
- the wheel bolts (F4R 776) ( 130 Nm ) ,
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Proceed in the reverse order to removal.
Top up the engine oil (see 05A, Draining - Filling,Engine ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
15195
12
20 1517
21
2
1
65 94
1419 18
22
10
3 7
11
13
16
8
10A-39
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a lift (see 02A, Lifting equi-pment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery :Removal - Refitting ).
Remove:
- the engine protectors.
- the dipstick,
- the front wheels,
- the front wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ).
Remove:
- the lower mounting bolts (1) from the side reinfor-cements,
- the half sub-frame (2) .
Drain the engine oil (see 10A, Engine and periphe-rals, Engine oil: Draining-refilling ).
Special tooling required
Mot. 1716 Removes housing withsilicone seals.
Tightening torquesm
sump mounting bolts 16 Nm
half sub-frame moun-ting bolts
105 Nm
half sub-frame moun-ting nuts
21 Nm
the side reinforcementlower mounting bolts
21 Nm
102008
10A-40
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
M9R, and 700
10AII - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the sump mounting bolts.
Remove the sump using the (Mot. 1716) .
Remove the lower cover.
REFITTING
I - REFITTING PREPARATION OPERATION
Check that the sump is not:
- scratched,
- deformed.
If this is the case, replace the sump.
Check that the base plate is not scratched.
II - REFITTING OPERATION FOR PART CONCERNED
Apply a bead of SILICONE ADHESIVE SEALANT(77 11 227 484) with a diameter of 5 mm ± 2 to thesump to make a seal.
Fit the sump.
Tighten the sump mounting bolts until contact is ma-de.
Tighten to torque and in order the sump mountingbolts ( 16 Nm ) .
114997
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Wear gloves during the operation.
WARNING
Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could cause damage tocer tain components (engine, radiator, etc.).
WARNING
The sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).
114410
10A-41
ENGINE AND LOWER ENGINE ASSEMBLYSump: Removal - Refitting
M9R, and 700
10AIII - FINAL OPERATION
Refit:
- the half sub-frame,
- the half sub-frame mounting bolts,
- the half sub-frame mounting nuts.
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) .
Refit the side reinforcement lower mounting bolts.
Tighten to torque the side reinforcement lowermounting bolts ( 21 Nm ) .
Refit:
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ),
- the engine undertray,
- the front wheel arch liners,
- the front wheels.
Connect the battery (see 80A, Battery, B attery :Removal - Refitting ).
Fill up the engine oil (see 10A, Engine and periphe-rals, Engine oil: Draining-refilling ).
Refit:
- the dipstick,
- the engine protectors.
10A-42
ENGINE AND LOWER ENGINE ASSEMBLYOil pump: Removal - Refitting 10A
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the under-engine protectors
Drain the engine oil.
Remove the sump (see 10A, Engine and periphe-rals, Sump ).
Example for F9Q engine
Remove:
- the bolt (1) and the oil splash plate,
- the oil pump bolts (2) ,
- the oil pump.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the oil pump mounting bolts ( 25Nm ) .
Refit the sump (see 10A, Engine and peripherals,Sump ).
Top up the engine oil.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover bolts ( 4 Nm ) .
Tightening torquesm
oil pump mounting bolts 25 Nm
battery cover bolts 4 Nm
23224
1
2
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
10A-43
ENGINE AND LOWER ENGINE ASSEMBLYOil pump: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the sump (see 10A, Engine and periphe-rals, Sump: Removal - Refitting ).
Remove:
- the strainer mounting bolts ,
- the strainer.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the oil pump mounting bolts on the anti-splash pla-te,
- the oil pump mounting bolts on the cylinder block,
- the oil pump.
REFITTING
I - REMOVAL PREPARATION OPERATION
If necessary, use a locally-produced hook to fit theoil pump chain to the oil pump sprocket.
II - REFITTING OPERATION FOR PART CONCERNED
Finger tighten:
- the oil pump mounting bolts on the anti-splash pla-te,
- the oil pump mounting bolts on the cylinder block.
Tighten to torque the oil pump mounting bolts onthe cylinder block (5 Nm) .
Tighten to torque:
- the oil pump mounting bolts on the cylinderblock ( 25 Nm ) ,
- the oil pump mounting bolts on the anti-splashplate ( 10 Nm ) ,
Tightening torquesm
oil pump mounting boltson the cylinder block
25 Nm
oil pump mounting boltson the anti-splash plate
10 Nm
strainer mounting bolts 10 Nm
113156
113157
10A-44
ENGINE AND LOWER ENGINE ASSEMBLYOil pump: Removal - Refitting
M9R, and 700
10AIII - FINAL OPERATION
Replace the oil strainer O-ring.
Fit the strainer to the oil pump and finger tighten thetwo mounting bolts in the following tightening order -.
Tighten the strainer mounting bolts ( 10 Nm ) inthe following tightening order -.
Remove:
- the sump (see 10A, Engine and peripherals,Sump: Removal - Refitting .
- the engine undertray.
Fill up the engine oil (see 10A, Engine and periphe-rals, Engine oil: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Start the engine and wait until the engine oil warninglight goes out.
Check the engine oil level.
Refit the engine undertray.
113156
10A-45
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
REMOVALPlace the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Remove the engine protectors.
Disconnect the battery (see 80A, Battery, Battery :Removal - Refitting ).
Remove:
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ),
- the alternator (see 16A, Starting-Charging, Alter-nator: Removal - Refitting ).
Remove:
- the multifunction support mounting bolts (1) ,
- the bolt (2) mounting the multifunction support onthe sump,
- the multifunction support.
Tightening torquesm
multifunction supportmounting bolts
44 Nm
multifunction supportmounting bolt on thesump
21 Nm
CA or CAREG
102265
10A-46
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
Remove:
- the multifunction support mounting bolts (3) ,
- the multifunction support.
REFITTING
Refit:
- the multifunction support,
- the multifunction support mounting bolts.
Tighten to torque and in order:
- the multifunction support mounting bolts ( 44Nm ) ,
- the multifunction support mounting bolt on thesump ( 21 Nm ) .
CHAUFO
111057
CA or CAREG
102265
10A-47
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
10A
Refit:
- the multifunction support,
- the multifunction support mounting bolts.
Tighten to torque and in order the multifunctionsupport mounting bolts (44 Nm) .
Refit:
- the alternator (see 16A, Starting-Charging, Alter-nator: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ),
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ),
- the engine undertray,
- the right and left-hand wheel arch liners,
- the front wheels.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Refit the engine protectors.
CHAUFO
111057
10A-48
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove:
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the alternator (see 16A, Starting-Charging, Alter-nator: Removal - Refitting ).
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the multifunction support mounting bolts (1) ,
- the bolt (2) mounting the multifunction support onthe sump,
- the multifunction support.
Tightening torquesm
multifunction supportmounting bolt on thesump
21 Nm
multifunction supportmounting bolts
44 Nm
CA or CAREG
102265
10A-49
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
10A
Remove:
- the multifunction support mounting bolts (3) ,
- the multifunction support.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the multifunction support,
- the multifunction support mounting bolts.
Tighten to torque and in order:
- the multifunction support mounting bolt on thesump ( 21 Nm ) .
- the multifunction support mounting bolts ( 44Nm ) ,
CHAUFO
111057
CA or CAREG
102265
10A-50
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
10A
Refit:
- the multifunction support,
- the multifunction support mounting bolts.
Tighten to torque and in order the multifunctionsupport mounting bolts (44 Nm) .
II - FINAL OPERATION
Refit:
- the alternator (see 16A, Starting-Charging, Alter-nator: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
- the engine undertray,
- the right and left-hand wheel arch liners,
- the front wheels.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Refit the engine covers.
CHAUFO
111057
10A-51
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
10A
REMOVALPlace the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Drain the coolant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the alternator (see 16A, Starting - Char-ging, Alternator ).
Disconnect:
- the air conditioning compressor connector,
- the pressure switch connector (1) .
Remove:
- the air conditioning compressor pipe (2) ,
- the air conditioning pipe between the compressorand the dehydration canister (3) .
Remove:
- the air conditioning compressor mounting bolts,
- the air conditioning compressor.
Equipment required
filling station
Tightening torquesm
multifunction supportmounting bolts
44 Nm
air conditioning com-pressor mounting bolts
25 Nm
air conditioning com-pressor strut mountingbolts
44 Nm
battery cover bolts 4 Nm
109537
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
1
2
3
10A-52
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
10A
Remove:
- the multifunction support mounting bolts (4) ,
- the multifunction support.
REFITTING
Refit the multifunction support.
Tighten to torque:
- the multifunction support mounting bolts ( 44Nm ) ,
- the air conditioning compressor mountingbolts ( 25 Nm ) .
- the air conditioning compressor strut mountingbolts ( 44 Nm )
Refit the alternator (see 16A, Starting - Charging,Alternator ).
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
Fill the coolant circuit using the filling station (62A,Air conditioning, Maintenance).
104337
44444
10A-53
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the alternator (see 16A, Starting-Char-ging, Alternator: Removal - Refitting ).
Disconnect the connector (1) from the air conditio-ning compressor.
Remove the air conditioning compressor mountingbolts (2) .
Move the air conditioning compressor to one side.
Attach the air conditioning compressor to the halfsub-frame.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the multifunction support mounting bolts (3) ,
- the multifunction support.
Tightening torquesm
multifunction supportmounting bolts
44 Nm
air conditioning com-pressor mounting bolts
25 Nm
114861
114862
10A-54
ENGINE AND LOWER ENGINE ASSEMBLYMultifunction support: Removal - Refitting
M9R, and 700
10AREFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Position the multifunction support.
Finger tighten (until contact is made) the threemounting bolts in the following order ( (4) - (1) - (2) ).
Finger tighten the two remaining mounting bolts ( (3)(5) ) until contact is made.
Tighten to torque the multifunction support moun-ting bolts ( 44 Nm ) in the following tightening order( (4) - (1) - (2) - (3) - (5) ).
II - FINAL OPERATION
Fit the air conditioning compressor.
Tighten to torque the air conditioning compressormounting bolts ( 25 Nm )
Refit the alternator (see 16A, Starting-Charging,Alternator: Removal - Refitting ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
114862
10A-55
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10AREMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ),
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
safety belt
filling station
hydraulic crane
load positioner
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
21 Nm
wheel bolt 110 Nm
battery cover bolts 4 Nm
IMPORTANT
During this operation, secure the vehicle to thelift with a safety belt , to avoid any imbalance.
CA or CAREG
101212
1
10A-56
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10A- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the two connectors (2) .
Unclip the front bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Disconnect:
- the petrol inlet pipe from the injector rail (7) ,
- the radiator top hose, using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors,
Unclip the wiring harness from the fan unit.
Disconnect the hoses from the expansion bottle onthe cooling radiator side (8) .
102504
102365
54
3
22
666
101795
109537
7
988
11
1010
10A-57
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10A
Disconnect the pressostat connector on the lower airconditioning pipe on the condenser (9) .
Remove:
- the air conditioning pipes from the condenser (10) .
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (11),
Remove the cooling assembly.
Remove the air filter outlet duct (12) .
Disconnect the computer connectors (13) .
Remove the battery tray mounting bolts (14) .
Remove:
- the battery tray,
- the computer mounting.
Remove the air filter unit (15) .
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
101807
12
101822
104553
141414
131313
15
10A-58
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10A
Disconnect the wiring harness connectors from therelay board.
Disconnect the earth strap on the body.
Remove the brake servo pipe (17) .
Disconnect:
- the hoses (18) and (19) using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,
- the downstream oxygen sensor connector.
101978
111051
16
101812
104240
17
1918
10A-59
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10A
Unclip the lever cables on the gearbox:
- grip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
Remove the gearbox controls (20) .
Remove:
- the multifunction switch cable ball joint (21) ,
- the multifunction switch cable (22) by unlocking thesleeve stop.
K4M, and 760
101743
101699
C
B
A
A
20
K4M, and 761
103409
22
21
10A-60
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10A
Pull out clip (23) .
Disconnect the hydraulic clutch supply pipes.
Remove:
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the half sub-frame (24) .
Position the hydraulic crane fitted with a load posi-tioner or a chain.
K4M, and 760
101740
Note:
Plug the pipes to prevent fluid from escaping.
23
102008
24
10A-61
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10A
Mark the suspended engine mounting in relation tothe body.
Remove the suspended engine mounting.
Remove the suspended gearbox mounting.
Remove the suspended gearbox mounting.
Rotate the « engine and gearbox » assembly in or-der to remove it.
REFITTING
To carry out a normal engine replacement operation(see Technical Note 3784A, Petrol engine - 4 cy-linders - K4, 10A, Engine and peripherals, Nor-mal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ),
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ).
Proceed in the reverse order to removal.
101866
K4M, and 760
102112
K4M, and 761
103273
10A-62
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4M, and 760 or 761
10ATighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 21 Nm ) ,
- the wheel bolt ( 110 Nm ) .
Add brake fluid to the brake fluid reservoir.
Bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ).
Perform the following operations:
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
- fill up the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment) .
K4M, and 760
CA or CAREG
IMPORTANTCorrectly attach the brake hose and the sensorwiring for the ABS system.
Do not twist the brake hose.
Note:
If the vehicle is fitted with xenon lamps, it isessential to initialise the system (see 80C,Xenon bulbs, Xenon headlights: Adjustment).
10A-63
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
safety belt
filling station
hydraulic crane
load positioner
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
wheel mounting bolt 110 Nm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
321 Nm
battery cover bolts 4 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler:
- detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,
- refit the clip in the same recess in the event thatthe hoses are not replaced,
- it is essential to replace the hoses and/or the inter-cooler if they are damaged.
If this procedure is not followed the hoses may leakor come undone.
IMPORTANT
During this operation, secure the vehicle to thelift with a safety belt , to avoid any imbalance.
CA or CAREG
10A-64
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the connectors (2) .
Unclip the bonnet release cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .
Disconnect the electrical connector (9) .
Fit plugs into the openings.
101212
102504
1
54
3
2
102365
104338
WARNING
Follow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines).
Be aware of the residual pressure and the quan-tity of diesel fuel in the pipes.
66
8
79
10A-65
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
Disconnect:
- the intercooler hose (10) ,
- the cooling radiator top hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors.
Unclip the wiring harness from the fan unit.
Disconnect the hoses from the expansion bottle onthe cooling radiator side (11) .
Disconnect the pressostat connector on the lower airconditioning pipe from the condenser (12) .
Remove:
- the air conditioning pipes from the condenser (13) .
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (14).
Disconnect the air duct from the intercooler (15) .
Remove the cooling assembly.
106275
109537
10
11 12
13
14
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
102473
15
10A-66
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
Remove the air filter outlet duct (16) .
Disconnect the computer connectors (17) .
Remove:
- the battery tray mounting bolts (18) ,
- the battery tray,
- the computer mounting.
Remove:
- the Protection and Switching Unit mounting bolt,
- the fuse box (19) ,
- the relay box (20) .
Disconnect the connectors from the Protection andSwitching Unit.
Remove:
- the earth strap (21) ,
- the pre-postheating unit (22) .
102500
101822
16
1717171818
104245
104340
19
20
21
22
10A-67
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
Remove the brake servo pipe (23) from the vacuumpump.
Disconnect the heater radiator top hose (24) on thescuttle panel side using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .
Remove the gearbox controls (25) .
Unclip the lever cables on the gearbox:
- clip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
104322
101699
23
24
25
101743
C
B
A
A
10A-68
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
Press the clip (26) .
Disconnect the supply pipes.
Remove the clutch hydraulic control at the bulkhead.
Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (27) .
Position the hydraulic crane fitted with a load posi-tioner or a chain.
102513
Note:
Plug the pipes to prevent fluid from escaping.
26
102008
27
10A-69
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A
Mark the suspended engine mounting in relation tothe body.
Remove:
- the lower engine tie-bar,
- the upper engine tie-bar.
- the suspended engine mounting,
- the gearbox suspended mounting,
Rotate the « engine and gearbox » assembly in or-der to remove it.
REFITTING
To replace the engine (see Technical Note 3652A,High pressure diesel engine - Common Rail 4 cy-linder cast iron, 10A, Engine and peripherals,Normal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ) in accordancewith the marks,
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting )
- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ).
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the wheel mounting bolt ( 110 Nm ) ,
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 321 Nm) .
Add the brake fluid to the brake fluid reservoir.
Perform the following operations:
- bleed the clutch (see 37A, Mechanical compo-nent controls): bleed the clutch circuit
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
102742
102419IMPORTANT
Correctly attach the brake hose and the sensorwiring for the ABS system.
Do not twist the brake hose.
10A-70
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 800 or 808
10A- fill up the coolant (see 19A, Cooling, Cooling sys-tem: Draining-refilling ).
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the engine cooling circuit (see 19A, Cooling,Cooling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment ).
CA or CAREG
Note:
Always initialise the xenon bulb system (if fittedto the vehicle; see 80C, Xenon bulbs, Xenonheadlight: Adjustment ).
10A-71
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
safety belt
filling station
hydraulic crane
load positioner
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
wheel mounting bolts 110 Nm
half sub-frame frontmounting bolt
165 Nm
half sub-frame rearmounting bolt
21 Nm
battery cover bolts 4 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler:
- detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,
- refit the clip in the same recess in the event thatthe hoses are not replaced,
- it is essential to replace the hoses and/or the inter-cooler if they are damaged.
If this procedure is not followed the hoses may leakor come undone.
IMPORTANT
During this operation, secure the vehicle to thelift with a safety belt , to avoid any imbalance.
CA or CAREG
10A-72
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the side reinforcements (1) from the half sub-framecross member,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
101212
102504
1
54
3
22
102365
66
10A-73
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
Remove:
- the fuel supply pipe (7)
- the fuel return pipe (8) .
Fit plugs into the openings.
Disconnect:
- the radiator top hose, using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors.
Unclip the wiring harness from the fan unit.
Remove the intercooler air ducts (9) and (10) .
102514
WARNING
Follow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines).
Be aware of the residual pressure and the quan-tity of diesel fuel in the pipes.
7
8
106275
102473
9
10
10A-74
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
Disconnect the hoses from the expansion bottle onthe cooling radiator side (11) .
Disconnect the pressostat connector on the lower airconditioning pipe on the condenser (12) .
Remove:
- the air conditioning pipes on the condenser (13) ,
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (14),
Remove the cooling radiator assemblies.
Disconnect the computer connectors (15) .
Remove the battery tray mounting bolts (16) .
Remove:
- the battery tray,
- the computer mounting.
Move the turbocharger pressure regulation solenoidvalve to one side.
Disconnect:
- the air filter outlet duct,
- the flow meter connector (if fitted to the vehicle).
109537
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
11
14
13
1211
13
101822
K9K, and 728
151515
161616
10A-75
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
Remove the air filter unit (17)
Disconnect the wiring harness connectors from therelay board.
Disconnect:
- the pre-postheating unit (18) ,
- the earth strap on the body (19) .
Remove the brake servo pipe (20) .
Disconnect the heater radiator hoses from the scutt-le panel (21) using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .
104553
101978
17
104340
102263
18
19
2121
20
10A-76
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
Disconnect the heater radiator hoses from the scutt-le panel (22) using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .
Remove the gearbox controls (23) .
Unclip the lever cables on the gearbox:
- grip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
Remove the clutch hydraulic control (24) .
102264
101699
22
2323
101743
101701
A
C
B
A
24
10A-77
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10A
Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the half sub-frame (25) .
Position the hydraulic crane fitted with a load posi-tioner or a chain.
Mark the suspended engine mounting in relation tothe body.
Remove:
- the lower engine tie-bar,
- the suspended engine mounting,
- the gearbox suspended mounting,
Rotate the « engine and gearbox » assembly in or-der to remove it.
102008
25
101866
102112
10A-78
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 722 or 728
10AREFITTING
To replace the engine (see Technical Note 6006A,High pressure diesel engine « Common Rail » - 4cylinder cast iron, 10A, Engine and peripherals,Normal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ),
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the wheel mounting bolts ( 110 Nm ) ,
- the half sub-frame front mounting bolt ( 165 Nm) ,
- the half sub-frame rear mounting bolt ( 21 Nm ) .
Add the brake fluid to the brake fluid reservoir.
Perform the following operations:
- bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ),
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
- fill up the cooling system (see 19A, Cooling, Coo-ling system: Draining-Refilling .
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
IMPORTANT
Correctly attach the brake hose and the sensorwiring for the ABS system.
Do not twist the brake hose.
CA or CAREG
Note:
Always initialise the xenon bulb system (if fittedto the vehicle; see 80C, Xenon bulbs, Xenonheadlight: Adjustment ).
10A-79
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine undertrays,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the front wheels,
- the right-hand and left-hand wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ),
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the refrigerant circuit using the filling station (see62A, Air conditioning, Maintenance ).
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1390 Support for removingand refitt ing theengine and gearboxassembly
Equipment required
filling station
Tightening torquesm
rounded bracket boltswith their spring
21 Nm
half sub-frame rearmounting nuts
21 Nm
half sub-frame frontmounting bolts
105 Nm
intercooler upstreamhose
5.5 Nm
intercooler downs-tream pipe
5.5 Nm
intercooler downs-tream pipe on the airinlet valve
8 Nm
air conditioning pipeson the condenser
8 Nm
air conditioning pipebetween the air condi-tioning compressor andthe dehydration canister
8 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
battery tray bolts 21 Nm
wiring harness moun-ting nuts
8 Nm
Tightening torquesm
10A-80
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A
Remove:
- the Protection and Switching Unit cover mountingbolts (1) ,
- the Protection and Switching Unit cover.
Disconnect the connectors (2) from the Protectionand Switching Unit.
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- upper mounting bolts from the front end panel (5) ,
- the fuse box,
- the relay box.
Disconnect the computer connectors (6) .
Remove:
- the battery tray mounting bolts (7) ,
- the mounting nut (8) from the wiring harness.
Move the wiring harness to one side.
Remove the battery tray.
Unclip the air inlet scoop (9) .
112658
102504
112659
114933
10A-81
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A
Remove:
- the mounting bolts from the lower front end panel(10) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Remove the air resonator (11) .
Remove the air inlet duct (12) .
Remove the air filter unit.
102365
114659
115019
115020
10A-82
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A
Loosen the intercooler upstream hose clip (13) .
Disconnect the intercooler upstream hose.
Disconnect:
- the fan unit resistor connector (14) ,
- the fan unit connector.
Unclip the wiring harness from the fan unit.
102473
112661
10A-83
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A
Remove the bolt (1 5) mounting the intercoolerdownstream pipe on the cooling radiator.
Loosen:
- the clip (16) securing the intercooler downstreampipe on the intercooler,
- the clip securing the intercooler downstream pipeon the air inlet valve.
Move aside the intercooler downstream pipe on theintercooler.
Disconnect:
- the cooling radiator top and bottom hoses using the(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
- the hoses from the expansion bottle on the coolingradiator side (17) ,
- the pressostat connector on the condenser lowerair conditioning pipe (18) .
Release the wiring harness from the pressostat con-nector on the fan unit.
Remove:
- the air conditioning pipes from the condenser (19) .
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (20).
Remove the cooling assembly.
Disconnect:
- the fuel supply pipe,
- the fuel return pipe from the diesel filter,
- the fuel return pipe.
Insert plugs into the openings.
Disconnect:
- the pre-postheating unit connector (21) ,
- the earth strap on the body (22) .
115023
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
WARNINGFollow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines:Precautions dur ing repair ).
Watch out for diesel fuel splashing when discon-necting the supply union.
104340
10A-84
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A
Remove the clutch hydraulic control pipe at the bulk-head (23) .
Remove the brake assistance pipe from the vacuumpump.
Disconnect:
- the heater radiator hose from the scuttle panel out-let,
- the heater radiator hose from the scuttle panel out-let using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) .
Remove the gearbox controls (24) .
Unclip the lever cables on the gearbox:
- grip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
Remove:
- the side reinforcement mounting bolts (25) ,
- the side reinforcements,
- the half sub-frame mounting bolts (26) ,
- the half sub-frame mounting nuts (27) ,
115003
115001
101743
102008
10A-85
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10A- the half sub-frame.
Remove:
- the rear mounting (28) (see 19D, Engine moun-ting, Rear mounting: Removal and Refitting )
Remove the rounded bracket bolts with their springs(29) .
Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
114650
114991
10A-86
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10AII - OPERATION FOR REMOVAL OF PART CONCERNED
Position the (Mot. 1390) .
Remove:
- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ).
- the mounting nut on the left-hand suspendedmounting (see 19D, Engine mounting, Left-handsuspended mounting: Removal - Refitting ).
Rotate the « engine and gearbox » assembly in or-der to remove it.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Position:
- the right-hand suspended mounting in its housing,
- the « Engine and gearbox » assembly in the vehi-cle.
Refit:
- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ).
- the mounting nut on the left-hand suspendedmounting (see 19D, Engine mounting, Left-handsuspended mounting: Removal - Refitting ).
114989
10A-87
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10AII - FINAL OPERATION
Refit:
- the rear mounting (see 19D, Engine mounting,Rear mounting: Removal - Refitting ).
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Driveshaft,Front left-hand driveshaft ),
- the rounded bracket bolts with their spring.
Tighten to torque the rounded bracket bolts withtheir spring ( 21 Nm ) .
Refit:
- the half sub-frame,
- the half sub-frame mounting bolts,
- the half sub-frame mounting nuts.
Tighten to torque:
- the half sub-frame rear mounting nuts ( 21 Nm ),
- the half sub-frame front mounting bolts ( 105Nm ) .
Refit:
- the gearbox controls,
- the fuse box,
- the relay box,
- the earth strap on the body,
Connect:
- the pre-postheating unit connector,
- the brake servo pipe from the vacuum pump,
- the clutch hydraulic control pipe at the bulkhead,
- the heater radiator hose from the scuttle panel out-let,
- the heater radiator hose from the scuttle panel out-let using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) ,
- the fuel supply pipe,
- the fuel return pipe on the diesel filter,
- the fuel return pipe.
Refit the cooling assembly.
Connect:
- the cooling radiator top and bottom hoses using the(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the mounting bolt to the intercooler downstream pi-
pe,
- the intercooler upstream hose,
- the intercooler downstream pipe.
Tighten to torque:
- the intercooler upstream hose ( 5.5 Nm ) ,
- the intercooler downstream pipe ( 5.5 Nm ) ,
- the intercooler downstream pipe on the air inletvalve ( 8 Nm ) .
Refit:
- the air conditioning pipes to the condenser.
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister.
Tighten to torque:
- the air conditioning pipes on the condenser ( 8Nm ) ,
- the air conditioning pipe between the air condi-tioning compressor and the dehydration canis-ter ( 8 Nm ) .
Secure the wiring harness to the pressostat connec-tor on the fan unit.
Connect
- the hoses from the expansion bottle on the coolingradiator side,
- the pressostat connector on the condenser lowerair conditioning pipe.
- the fan unit resistor connector,
- the fan unit connector.
Clip the fan unit wiring harness into place.
Refit:
- the Protection and Switching Unit mounting bolt,
- the air inlet duct,
- the air resonator,
- the front end panel,
- the front end panel lower mounting bolts,
- the front end panel upper mounting bolts,
- the clips.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) .
Clip on the air inlet scoop.
10A-88
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
M9R, and 700
10ARefit:
- the battery tray, the injection computer and itsmounting,
- the battery tray mounting bolts,
- the wiring harness,
- the wiring harness mounting nut.
Tighten to torque:
- the battery tray bolts ( 21 Nm ) ,
- the wiring harness mounting nuts ( 8 Nm ) .
Connect
- the computer connectors,
- the Protection and Switching Unit connectors.
Clip the bonnet opening cable.
Refit:
- the rounded bracket mounting bolts with theirspring (see 19A, Exhaust ),
- the rear mounting (see 19D, Engine mounting,Rear mounting: Removal - Refitting ).
Perform the following operations:
- bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ),
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil if necessary,
- fill up the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ),
- fill and bleed the cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).
Refit:
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ),
- the engine undertray,
- the side reinforcements,
- the side reinforcement mounting bolts,
- the front wheels,
- the right-hand and left-hand wheel arch liners,
- the battery (see 80A, Battery, Battery: Removaland Refitting )
- the engine protector.
10A-89
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
safety belt
filling station
hydraulic crane
load positioner
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
wheel bolts 110 Nm
wheel bolt (F4R 776) 130 Nm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
21 Nm
battery cover mountingbolts
4 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler (F4R 776):
- detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,
- refit the clip in the same recess if the hoses arenot replaced,
- it is essential to replace the hoses and/or the inter-cooler if they are damaged.
If this procedure is not followed the hoses may leakor come undone.
Note:
During this operation, strap the vehicle to the liftusing a safety belt , to avoid any imbalance.
CA or CAREG
10A-90
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Disconnect the fuel supply pipe (7) from the injectorrail.
101212
102504
1
54
3
22
102365
F4R, and 770 or 771
101795
666
7
10A-91
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Disconnect:
- the injector rail (8) from the fuel supply pipe
- the cooling radiator top hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the fan unit connectors.
Unclip the wiring harness from the fan unit.
Disconnect the intercooler hose (9) .
Disconnect:
- the turbocharging pressure sensor connector (10) ,
- the air temperature sensor connector (11) ,
- the fan unit resistor connector (12) ,
Move the air duct (13) to one side.
Remove the air filter outlet duct (14) .
F4R, and 776
106271
F4R, and 776
106275
8
9
109536
F4R, and 770 or 771
101807
1312
11
10
14
10A-92
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Disconnect the hoses from the cooling radiator ex-pansion bottle (15) .
Disconnect the pressostat connector on the lower airconditioning pipe from the condenser (16) .
Remove:
- the air conditioning pipes from the condenser (17) .
- the air conditioning pipe between the compressorand the dehydration canister (18) .
Remove the cooling assembly.
Disconnect the computer connectors (19) .
Remove the battery tray mounting bolts (20) .
Remove the battery tray.
109537
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
18
17
1615
101822
20191919 2020
10A-93
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Move the fuel vapour recirculation solenoid valve toone side (21) .
Undo the bolt (22) .
Pull the mounting bracket away from the electriccoolant pump.
Move the electric water pump (23) to one side.
Remove the electric pump mounting (24) .
Remove the computer and its mounting (25) .
Remove the air filter unit.
F4R, and 776
106278
106632
21
22
24
23
106280
104553
25
10A-94
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Disconnect the wiring harness connectors from therelay board.
Disconnect the earth strap (26) .
Remove the brake servo pipe (27) .
Disconnect the downstream oxygen sensor connec-tor.
Remove the brake servo pipe (28) .
101978
111051
26
F4R, and 770 or 771
101812
F4R, and 776
106787
27
28
10A-95
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Disconnect hoses (29) and (30) using the (Mot.1202-01) or (Mot. 1202-02) or (Mot. 1448) .
Remove the control cables from the gearbox (31) .
Unclip the two gear lever cables on the gearbox:
- grip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
Remove:
- the multifunction switch cable ball joint (32) ,
104240
F4R, and 770 or 776
101699
2930
3131
101743
F4R, and 771
103409
B
C
A
A
33
32
10A-96
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A- the multifunction switch cable (33) by loosening thesleeve stop.
Place a cloth under the master cylinder.
Remove the clip (33) from the union on the mastercylinder return.
Disconnect the pipes from the slave cylinder.
Fit plugs into the openings.
Withdraw the slave cylinder feed pipes.
Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (34) .
Position the hydraulic crane fitted with a load posi-tioner or a chain.
F4R, and 770 or 776
101740
33
102008
34
10A-97
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A
Mark the suspended engine mounting in relation tothe body.
Remove the suspended engine mounting.
Remove the suspended gearbox mounting.
Remove the suspended gearbox mounting.
Rotate the « engine and gearbox » assembly in or-der to remove it.
REFITTING
To carry out a normal engine replacement operation(see Technical Note 6027A, Petrol engine - 4 cy-linders - F4, 10A, Engine and peripherals, Nor-mal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ) in accordancewith the marks,
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
102742
F4R, and 770 or 776
102112
F4R, and 771
103273
10A-98
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F4R, and 770 or 771 or 776
10A- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the wheel bolts ( 110 Nm ) ,
- the wheel bolt (F4R 776) ( 130 Nm ) ,
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 21 Nm ) .
Add the brake fluid to the brake fluid reservoir.
Bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ).
Perform the following operations:
- fill up the gearbox oil (see 05A, Draining-refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-refilling,Engine ),
- fill up the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment ).
IMPORTANT
Correctly attach the flexible brake pipe and ABSsensor wiring.
Do not twist the brake hoses.
F4R, and 770 or 776
CA or CAREG
Note:
Be sure to initialise the xenon bulb system (if fit-ted to the vehicle) see 80C, Xenon bulbs,Xenon headlights: Adjustment ).
10A-99
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right-hand and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
safety belt
filling station
hydraulic crane
load positioner
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
210 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler:
- detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,
- refit the clip in the same recess if the hoses arenot replaced,
- it is essential to replace the hoses and/or the inter-cooler if they are damaged.
If this procedure is not followed the hoses may leakor come undone.
IMPORTANT
During this operation, secure the vehicle to thelift with a safety belt , to avoid any imbalance.
CA or CAREG
10A-100
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- front end panel mounting bolts (6) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
101212
102504
1
54
3
22
102365
666
10A-101
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .
Fit plugs into the openings.
Disconnect:
- the radiator top hose, using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors.
Unclip the wiring harness from the fan unit.
Disconnect the intercooler hoses (9) and (10) .
102514
WARNING
Follow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines).
Be aware of the residual pressure and the quan-tity of diesel fuel in the pipes.
78
106275
102473
9
10
10A-102
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
Disconnect the hoses from the cooling radiator ex-pansion bottle (11) .
Disconnect the pressostat connector on the lower airconditioning pipe from the condenser (12) .
Remove:
- the air conditioning hoses from the condenser (13),
- the air conditioning hose between the air conditio-ning compressor and the dehydration canister (14).
Remove the cooling radiator assemblies.
Remove the air filter outlet duct (15) .
Disconnect the computer connectors (16) .
Remove the battery tray mounting bolts (17) .
Move the turbocharger pressure solenoid valve toone side.
Remove:
- the battery tray,
- the computer and its support.
Disconnect the flowmeter connector (if fitted to thevehicle).
109537
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
1112
14
1313
101807
101822
15
161616171717
10A-103
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
Disconnect:
- the relay plate harness connectors,
- the relay,
- the fuse box,
- the earth strap from the body,
Remove the brake servo pipe from the vacuumpump (18) .
Disconnect the heater radiator hose from the scuttlepanel (19) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
Remove the air filter unit.
Remove:
- the multifunction switch cable ball joint (20) ,
- the multifunction switch cable (21) by unlocking thesleeve stop.
Disconnect:
- the engine speed sensor,
- the connector by releasing the slide from the con-nector.
104245
102263
18
19
104553
103409
2120
10A-104
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
Disconnect:
- the pre-postheating unit (22) ,
- the automatic transmission computer connector(23) .
Open the gearbox computer wiring harness moun-ting bracket (24) .
Remove:
- the exhaust mounting nuts (25) ,
- the lower engine tie-bar (26) .
110681
103413
23
22
24
103749
262626
2525
10A-105
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10A
Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
- the half sub-frame (27) .
Position the hydraulic crane fitted with a load posi-tioner .
Mark the suspended engine mounting in relation tothe body.
Remove:
- the lower engine tie-bar,
- the suspended engine mounting,
- the suspended gearbox mounting,
Rotate the « engine and gearbox » assembly in or-der to remove it.
102008
27
102114
103273
10A-106
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 729, and DP0
10AREFITTING
To replace the engine (see Technical Note 6006A,High pressure diesel engine « Common Rail » - 4cylinder cast iron, 10A, Engine and peripherals,Normal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ) in accordancewith the marks,
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ).
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 210 Nm) .
- the wheel bolts ( 110 Nm ) ,
Add the brake fluid to the brake fluid reservoir.
Perform the following operations:
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
- fill up the coolant circuit (see 19A, Cooling, Blee-ding the cooling circuit ),
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Bleed the engine cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment ).
IMPORTANTCorrectly attach the flexible brake pipe and ABSsensor wiring.
Do not twist the brake hoses.
CA or CAREG
Note:
Always initialise the xenon bulb system (if fittedto the vehicle; see 80C, Xenon bulbs, Xenonheadlights: Adjustment ).
10A-107
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10AREMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right-hand and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
safety belt
filling station
hydraulic crane
load positioner
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
21 Nm
wheel bolt 110 Nm
battery cover bolts 4 Nm
IMPORTANT
During this operation, secure the vehicle to thelift with a safety belt , to avoid any imbalance.
CA or CAREG
101212
1
10A-108
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10A- the half sub-frame side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- front end panel mounting bolts (6) ,
- the front end panel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Disconnect the fuel supply union (7) .
Disconnect:
- the cooling radiator top hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors,
Unclip the wiring harness from the fan unit.
Disconnect the hoses from the cooling radiator ex-pansion bottle (8) .
102504
102365
54
3
22
666
101802
109537
7
8 9
10
11
10A-109
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10A
Disconnect the pressostat connector on the lower airconditioning pipe from the condenser (9) .
Remove:
- the air conditioning pipes from the condenser (10) .
- the air conditioning pipe between the compressorand the dehydration canister (11) .
Remove the cooling assembly.
Remove:
- the air resonator mounting bolt (12) ,
- the air resonator.
Disconnect the computer connectors (13) .
Remove the battery tray mounting bolts (14) .
Remove:
- the battery tray,
- the computer mounting.
Disconnect the wiring harness connectors from therelay board.
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
101103
12
101822
101978
131313141414
10A-110
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10A
Disconnect the earth strap from the body.
Remove the brake servo pipe (16) .
Disconnect:
- the hoses (17) and (18) using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,
- the downstream oxygen sensor connector.
Unclip the lever cables on the gearbox:
- grip the gearbox control at (A) ,
- pull the pin at (B) ,
- raise the gearbox control at (C) .
111051
101812
15
16
104240
101743
1817
C
B
A
A
10A-111
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10A
Remove the gearbox controls (19) .
Pull out clip (20) .
Disconnect the hydraulic clutch supply pipes.
Remove:
- the front left-hand driveshaft (see 29A, Driveshaft,Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the half sub-frame (21) .
Position the hydraulic crane fitted with a load posi-tioner or a chain.
101699
101740
Note:
Plug the pipes to prevent fluid from escaping.
1919
20
102008
21
10A-112
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10A
Mark the suspended engine mounting in relation tothe body.
Remove:
- the suspended engine mounting,
- the suspended gearbox mounting,
Rotate the « engine and gearbox » assembly in or-der to remove it.
Remove the « engine and gearbox assembly » .
REFITTING
To carry out a normal engine replacement operation(see Technical Note 3784A, Petrol engine - 4 cy-linders - K4, 10A, Engine and peripherals, Nor-mal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ),
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the front left-hand driveshaft (see 29A, Driveshaft,Front left-hand driveshaft ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 21 Nm ) ,
- the wheel bolt ( 110 Nm ) .
Add the brake fluid to the brake fluid reservoir.
Perform the following operations:
- bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ),
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
- fill up the coolant circuit (see 19A, Cooling, Blee-ding the cooling circuit ).
101866
102112
IMPORTANTCorrectly attach the brake hose and the sensorwiring for the ABS system.
Do not twist the brake hose.
10A-113
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K4J, and 730 or 732
10AConnect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Blee-ding the cooling circuit: ).
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment) .
CA or CAREG
Note:
If the vehicle is fitted with xenon bulbs, it isessential to initialise the xenon bulb system (see80C, Xenon bulbs, Xenon headlights: ).Adjustment ).
10A-114
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right-hand and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox (see 05A, Draining-Refilling, Gear-box ),
- the engine (see 05A, Draining-Refilling, Engine ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the refrigerant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1390 Support for removingand refitt ing theengine and gearboxassembly
Equipment required
safety belt
filling station
Tightening torquesm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
21 Nm
wheel bolt 130 Nm
battery cover mountingbolts
4 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler:
- detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,
- refit the clip in the same recess if the hoses arenot replaced,
- it is essential to replace the hoses and/or the inter-cooler if they are damaged.
If this procedure is not followed the hoses may leakor come undone.
IMPORTANT
During this operation, strap the vehicle to the liftusing a safety belt , to avoid any imbalance.
CA or CAREG
10A-115
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10ARemove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the scuttle panel grille (see MR 371 Bodywork,55A, Exterior protection, Scuttle panel grille ).
Disconnect the connectors (1) .
Unclip the bonnet opening cable (2) .
Remove:
- the clip (3) ,
- the fastening (4) .
Remove:
- the half sub-frame side reinforcements (5) ,
- the front bumper (see MR 371, Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the pressostat connector from the lowerair conditioning pipe on the condenser.
Remove:
- the two air conditioning pipes from the condenser,
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister.
Disconnect the screen washer tubes.
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel.
102504
101212
2
11
43
5
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
102365
666
10A-116
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10A
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .
Disconnect the electrical connector (9) .
Insert plugs into the openings.
Disconnect.
Disconnect:
- the intercooler hose (10)
- the cooling radiator top hose using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) .
- the fan unit connectors,
- the hoses from the expansion bottle on the coolingradiator side.
Unclip the wiring harness from the fan unit.
Disconnect the duct (11) .
104338
WARNING
Follow the cleanliness guidelines closely (see13B, Diesel injection, Cleanliness guidelines).
Watch out for diesel fuel splashing when discon-necting the supply union.
9
8
7
106275
102473
10
11
10A-117
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10A
Disconnect the connector (12) .
Remove the air filter outlet duct (13) .
Disconnect the computer connectors (14) .
Remove:
- the battery tray mounting bolts (15) ,
- the battery tray,
- the computer mounting.
Remove:
- the Protection and Switching Unit mounting bolt,
- the fuse box (16) ,
- the relay box (17) .
Disconnect the connectors from the Protection andSwitching Unit.
Remove:
- the earth strap (18) ,
- the pre-postheating unit (19) .
102500
101822
13
12
151515
141414
104245
104340
17
16
19
18
10A-118
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10A
Remove the brake servo pipe (20) from the vacuumpump.
Disconnect the heater radiator hoses (21) from thescuttle panel side using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) .
Remove the gearbox controls (2 2) , using ascrewdriver.
Pull the clip (23) from the clutch pipes.
Disconnect the hydraulic clutch supply pipes.
Remove:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ),
104322
104085
21212121
20
22
101740
Note:
Plug the pipes to prevent fluid from escaping.
102008
23
24
10A-119
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10A- the exhaust downpipe mountings,
- the lower engine tie-bar,
- the upper engine tie-bar.
- the half sub-frame (24) .
Position the (Mot. 1390) .
Mark the suspended engine mounting in relation tothe body.
Remove:
- the suspended engine mounting,
- the suspended gearbox mounting,
Rotate the « engine and gearbox » assembly in or-der to remove it.
Remove the « engine and gearbox assembly » .
111879
111880
102742
102419
10A-120
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
F9Q, and 804
10AREFITTING
To replace the engine (see Technical Note 3652A,High pressure diesel engine - Common Rail 4 cy-linder cast iron, 10A, Engine and peripherals,Normal replacement ).
Position the « engine and gearbox assembly » in thevehicle.
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ) in accordancewith the marks,
- the suspended gearbox mounting (see 19D, Engi-ne mounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).
Proceed in the reverse order to removal.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) ,
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 21 Nm ) ,
- the wheel bolt ( 130 Nm ) .
Add the brake fluid to the brake fluid reservoir.
Perform the following operations:
- bleed the clutch system (see 37A, Mechanicalcomponent controls, Bleeding the clutch sys-tem: ),
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
- fill up the coolant circuit (see 19A, Cooling, Blee-ding the cooling circuit ).
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the engine cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment ).
IMPORTANT
Correctly attach the flexible brake pipe and ABSsensor wiring.
Do not twist the brake hoses.
CA or CAREG
Note:
If the vehicle is fitted with xenon bulbs, it isessential to initialise the system (see 80C,Xenon bulbs, Xenon headlights: ). Adjust-ment ).
10A-121
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray.
Drain:
- the gearbox, if necessary,
- the engine, if necessary.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the coolant circuit using the filling station .
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1390 Support for removingand refitt ing theengine and gearboxassembly
Equipment required
filling station
Tightening torquesm
half sub-frame frontmounting bolt
105 Nm
half sub-frame rearmounting bolt
21 Nm
front end panel uppermounting bolt
21 Nm
front end panel lowermounting bolt
44 Nm
wheel bolts 110 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler (there is a danger of leakage and dislo-cation if this procedure is not complied with):
- detach the hose using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the bearing face on the intercooler and onthe hose with a dry, lint-free cloth,
- always replace the clip with a new one,
- replace the new clip in the same position if thehose is not replaced,
- it is essential to replace the hose and/or the inter-cooler if they are damaged,
IMPORTANT
During this operation, secure the vehicle to thelift with a strap, to avoid any imbalance.
CA or CAREG
10A-122
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Remove:
- the battery,
- the side reinforcements (1) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Remove:
- the relay plate cover mounting bolts.
- the relay plate cover.
Disconnect the connectors (2) from the relay board.
Unclip the bonnet opening cable (3) ,
Remove:
- the clip (4) ,
- the fastening (5) .
Disconnect the screen washer tubes.
Remove:
- front end panel mounting bolts (6) ,
- the front end panel.
Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).
101212
102504
102365
10A-123
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Remove:
- the fuel supply pipe (7) ,
- the fuel return pipe (8) .
Place plugs in the holes (see 13B, Diesel injection,Cleanliness guidelines ).
Disconnect:
- the hoses from the intercooler (9) ,
- the radiator top hose, using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) .
- the fan unit resistor connector (10) ,
- the fan unit connector.
Unclip the wiring harness from the fan unit.
112656
WARNING
- Follow the cleanliness guidelines closely.
- Beware of diesel fuel splashing when discon-necting the supply unions.
106275
112661
10A-124
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Disconnect the hoses from the cooling radiator ex-pansion bottle (11) .
Disconnect the pressostat connector from the lowerair conditioning pipe on the condenser. (12)
Remove:
- the air conditioning pipes from the condenser (13) .
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister (14).
Remove the cooling radiator assemblies.
Disconnect the computer connectors (15) .
Unclip:
- the wiring harness from the battery negative termi-nal,
- the wiring harness.
Remove:
- the battery tray mounting bolts (16) ,
- the battery tray with the computer and its support.
Move the turbocharger pressure solenoid valve toone side.
Disconnect:
- the connector from the flowmeter,
- the air duct between the air filter unit and the turbo-charger.
109537
CA or CAREG
Note:
Plugs must be fitted to the hoses and the expan-sion valve to prevent moisture from entering thesystem.
101822
10A-125
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Loosen the air filter unit upstream air duct retainingtabs slightly (17) .
Remove:
- the air filter unit upstream air duct,
- the air filter unit (18) .
Disconnect the wiring harness connectors from therelay board.
Disconnect:
- the pre-postheating unit connector (19) ,
- the earth strap from the body (20) .
112657
104553
101978
104340
10A-126
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Remove the brake servo pipe (21) from the vacuumpump.
Disconnect:
- the heating radiator hose from the scuttle panel(22) using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) ,
- the heating radiator hose (23) using the (Mot.1202-01) or (Mot. 1202-02) or (Mot. 1448) .
Remove the gearbox controls.
Pull clip (24) .
Disconnect the clutch hydraulic control.
Remove:
- the lower engine tie-bar,
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
112946 101743
WARNING
Do not touch the gearbox control slides.
101740
10A-127
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A- the front left-hand driveshaft (see 29A, Driveshaft,Front left-hand driveshaft ),
- the exhaust downpipe mountings,
- the half sub-frame.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Position the (Mot. 1390) .
112814
112813
10A-128
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Mark the suspended engine mounting in relation tothe body.
Remove:
- the rear suspended mounting (see 19D, Enginesuspension, Rear suspended mounting: Remo-val - Refitting ),
- the left-hand suspended mounting (see 19D, Engi-ne mounting, Left-hand suspended mounting:Removal - Refitting ),
- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ),
Rotate the engine and gearbox assembly in order toremove it.
Remove the engine and gearbox assembly.
REFITTING
I - REFITTING PREPARATION OPERATION
To replace the engine (see Technical Note 6006A,High pressure diesel engine « Common Rail » - 4cylinder cast iron, 10A, Engine and peripherals,Normal replacement ).
II - REFITTING OPERATION FOR PART CONCERNED
Position the engine and gearbox assembly in the ve-hicle.
Refit:
- the right-hand suspended mounting (see 19D, En-gine mounting, Right-hand suspended moun-ting: Removal - Refitting ),
- the left-hand suspended mounting (see 19D, Engi-ne mounting, Left-hand suspended mounting:Removal - Refitting ),
- the rear suspended mounting (see 19D, Enginesuspension, Rear suspended mounting: Remo-val / Refitting ).
Remove the (Mot. 1390) .
III - FINAL OPERATION
Refit:
- the half sub-frame,
- the half sub-frame mounting bolts.
Tighten to torque:
- the half sub-frame front mounting bolt ( 105 Nm) ,
- the half sub-frame rear mounting bolt ( 21 Nm ) .
Refit:
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ),
- the front left-hand driveshaft (see 29A, Drives-hafts, Front left-hand driveshaft ).
113927
112655
IMPORTANT
Correctly attach the flexible brake pipe and ABSsensor wiring.
10A-129
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10AConnect:
- the clutch hydraulic control.
- the heater radiator hose using the (Mot. 1202-01)or (Mot. 1202-02) or (Mot. 1448) .
- the heater radiator hose from the scuttle panelusing the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) .
Refit the gearbox controls.
Connect:
- the pre-postheating unit connector,
- the earth strap on the body,
- the relay plate harness connectors.
Refit:
- the air filter unit,
- the air duct upstream of the air filter.
Connect:
- the air duct between the air filter unit and the turbo-charger.
- the connector from the flowmeter.
Reposition the turbocharging pressure regulatingsolenoid valve.
Refit:
- the battery tray,
- the battery tray bolts,
Connect the computer connectors.
Refit:
- the negative terminal wiring harness,
- the wiring harness.
Connect:
- the fuel supply pipe,
- the fuel return pipe.
Prime the diesel circuit using the priming pump.
Refit the cooling assembly.
Connect:
- the cooling radiator hoses,
- the intercooler hoses,
- the fan unit connectors.
Connect:
- the air conditioning pipes to the condenser.
- the air conditioning pipe between the air conditio-ning compressor and the dehydration canister.
- the pressostat connector on the condenser lowerair conditioning pipe
Refit the fan unit wiring harness.
Refit:
- the front end panel,
- the front end panel mounting bolts,
- the two cooling assembly guide clips.
- the mounting bolts,
- the front bonnet opening cable clip.
Tighten to torque:
- the front end panel upper mounting bolt ( 21 Nm) ,
- the front end panel lower mounting bolt ( 44 Nm) .
Connect:
- the connectors to the relay board,
- the screen washer tubes.
Refit:
- the front bumper (see Workshop Repair Manual365 Bodywork, 55A, Exterior protection, Frontbumper ),
- the side reinforcements,
- the right-hand and left-hand wheel arch liners,
- the front wheels,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the air inlet duct,
- the relay plate cover,
- the relay plate cover mounting bolts.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect the battery ( 80A, Battery, Battery: Remo-val - refitting) .
CA or CAREG
10A-130
ENGINE AND LOWER ENGINE ASSEMBLYEngine/gearbox assembly: Removal - Refitting
K9K, and 732
10A
Fill the refrigerant circuit using the filling station(see 62A Air conditioning, Maintenance ).
Perform the following operations:
- bleed the clutch system (see 37A, Mechanicalcomponent controls, Clutch system: Bleeding),
- fill up the gearbox oil (see 05A, Draining-Refilling,Gearbox ),
- fill up the engine oil (see 05A, Draining-Refilling,Engine ),
- fill up the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Draining-refilling ).
Adjust the headlights (see, depending on equip-ment, 80B, Headlights, Halogen headlights: Ad-justment or 80C, Xenon bulbs, Xenon headlights:Adjustment ).
Refit the engine covers.
CA or CAREG
You must initialise the xenon bulb system (if fittedto the vehicle).
10A-131
ENGINE AND LOWER ENGINE ASSEMBLYEngine speed and position sensor: Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the engine undertray.
Move the heat insulating material to one side.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the engine speed and position sensor.
Remove:
- the engine speed and position sensor mountingbolt (1) ,
- the engine speed and position sensor (2) .
III - REFITTING OPERATION FOR PART CONCERNED
Refit the engine speed and position sensor.
Tighten the engine speed and position sensormounting bolt until contact is made.
Tighten to torque the engine speed and positionsensor mounting bolt ( 10 Nm ) .
IV - FINAL OPERATION
Refit:
- the heat insulating material around the enginespeed and position sensor,
- the engine undertray.
Tightening torquesm
engine speed and posi-tion sensor mountingbolt
10 Nm
114979
10A-132
ENGINE AND LOWER ENGINE ASSEMBLYCrankshaft seal at timing end Removal - Refitting
M9R, and 700
10A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the front right-hand wheel,
- the front right-hand wheel arch liner.
Remove:
- the right-hand side reinforcement mounting boltson the half sub-frame cross member,
- the right-hand side reinforcement from the half sub-frame cross member (1) ,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the crankshaft sealing ring using the (2)supplied in the spare parts kit for the new gasket.
Tightening torquesm
the crankshaft timingend sealing ring
47 Nm
101212
114853
10A-133
ENGINE AND LOWER ENGINE ASSEMBLYCrankshaft seal at timing end Removal - Refitting
M9R, and 700
10AREFITTING
I - REMOVAL PREPARATION OPERATION
II - REFITTING OPERATION FOR PART CONCERNED
Position the sealing ring notches opposite the not-ches in the timing cover.
Engage the sealing ring notches in the timing covernotches.
Tighten the sealing ring by hand using the tool sup-plied in the new gasket spare parts kit.
113656
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
114850
114851
10A-134
ENGINE AND LOWER ENGINE ASSEMBLYCrankshaft seal at timing end Removal - Refitting
M9R, and 700
10A
Using tool supplied in the new gasket spare parts kittighten to torque the crankshaft timing end sea-ling ring ( 47 Nm ) .
III - FINAL OPERATION
Refit:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the right-hand side reinforcements on the half sub-frame,
- the front right-hand wheel arch liner,
- the front right-hand wheel.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
114852
11A-1
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
K4J, and 730 or 732, and CA or CAREG – K4M, and 760 or 761, and CA or CAREG – C84 or G84 or S84, andK9K, and 722 or 728 or 729 or 732, and CA or CAREG
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner.
Remove the right-hand side reinforcement (1) .
Turn the accessories belt auto tensioner clockwiseusing a 16 mm spanner.
Remove:
- the accessories belt,
- the tensioning roller.
Tightening torquesm
tensioning roller moun-ting bolt
40 Nm
wheel bolts 110 Nm
battery cover bolts 4 Nm
IMPORTANT
Wear protective gloves during every operation.
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
WARNING
It is imperative to replace the accessories belt andthe tensioning rollers.
WARNING
Do not run the engine without the accessories beltto avoid damaging the crankshaft and the accesso-ries pulley.
101212
101878
1
11A-2
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
K4J, and 730 or 732, and CA or CAREG – K4M, and 760 or 761, and CA or CAREG – C84 or G84 or S84, andK9K, and 722 or 728 or 729 or 732, and CA or CAREG
11A
REFITTING
Use a brush to remove any deposits from thecrankshaft pulley V-grooves.
Refit the tensioning roller.
Tighten to torque the tensioning roller mountingbolt ( 40 Nm ) .
Refit the accessories belt.
Rotate the crankshaft twice to position the accesso-ries belt correctly.
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) .
- the battery cover bolts ( 4 Nm ) .
106000
WARNING
The accessories belt has five teeth, but the airconditioning compressor pulley has six grooves.When fitting the accessories belt, it is essential tocheck that the groove (2) remains free.
22
11A-3
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
K9K, and 722 or 728 or 729, and CHAUFO – K4J, and 730 or 732, and CHAUFO – K4M, and 760 or 761, andCHAUFO
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner.
Remove the side reinforcement (1) .
Loosen the tensioning roller bracket mounting bolts.
Remove:
- the accessories belt,
- the tensioning roller.
REFITTING
Use a brush to remove any deposits from thecrankshaft pulley V-grooves.
Refit the accessories belt.
Refit the tensioning roller fitted with new bolts.
Special tooling required
Mot. 1638 Accessories belt ten-sioning tool
Mot. 1505 Belt tension settingtool (frequency meter)
Mot. 1715 Belt tension settingtool (frequency meter)
Tightening torquesm
tensioning roller moun-ting bolt
35 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Wear protective gloves during the operation.
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
WARNING
It is imperative to replace the accessories belt andthe tensioning rollers.
WARNING
Do not run the engine without the accessories beltto avoid damaging the crankshaft and the accesso-ries pulley.
101212
WARNING
- The two Torx mounting bolts of the tensioningroller must be replaced by M8 x 20 bolts (partnumber 77 03 002 059 ).
11A-4
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
K9K, and 722 or 728 or 729, and CHAUFO – K4J, and 730 or 732, and CHAUFO – K4M, and 760 or 761, andCHAUFO
11A
Tension the accessories belt using the (Mot. 1638)by tightening nut (3) (with the two tensioning rollermounting bolts loosened).
Check (4) and using the (Mot. 1505) or the (Mot.1715) , that the accessories belt tension is between223 and 245 Hz .
It is essential to turn the engine through two revolu-tions to position the accessories belt correctly.
Check that the accessories belt tension is between223 and 245 Hz at the measuring point (4) . If not,readjust the tension.
Tighten to torque the tensioning roller mountingbolt ( 35 Nm ) .
Proceed in the reverse order to removal
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
20845
WARNING
The accessories belt has five teeth, but the pul-leys have six grooves. It is essential to check thatgroove (2) remains free when the belt is fitted. 21861
11A-5
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner.
Remove the right-hand side reinforcement (1) .
Turn the accessories belt auto tensioning roller anti-clockwise using a 16 mm spanner.
Remove:
- the accessories belt,
- the tensioning roller.
REFITTING
Use a brush to remove any deposits from thecrankshaft pulley V-grooves.
Tightening torquesm
tensioning roller moun-ting bolt
50 Nm
wheel bolts 110 Nm
battery cover bolts 4 Nm
IMPORTANT
Wear gloves throughout the operation.
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
WARNING
It is imperative to replace the accessories belt andthe tensioning rollers.
WARNING
Do not run the engine without the accessories beltto avoid damaging the crankshaft and the accesso-ries pulley.
101212
104339
1
11A-6
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
F4R, and 770 or 771 or 776, and CA or CAREG – F9Q, and 800 or 804 or 808, and CA or CAREG
11ATighten to torque the tensioning roller mountingbolt ( 50 Nm ) .
Rotate the crankshaft twice to position the accesso-ries belt correctly.
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover bolts ( 4 Nm ) .
11A-7
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
M9R, and 700
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine undertray.
Remove:
- the front right-hand wheel,
- the front right-hand wheel arch liner;
- the right-hand side reinforcement mounting boltson the half sub-frame cross member,
- the right-hand side reinforcement from the half sub-frame cross member (1) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
Place a 3 mm Allen key in the tensioning roller hole(2) .
Move accessories belt tensioning pulley clockwiseuntil the Allen key is fully inserted.
Remove the accessories belt.
Special tooling required
Mot. 1770 Crankshaft pulley loc-king tool
Tightening torquesm
tensioning roller moun-ting bolt
44 Nm
tensioning roller moun-ting bolt
25 Nm
crankshaft accessoriespulley mounting bolt
50 Nm + 85˚ ±±±±6˚
101212
114854
11A-8
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
M9R, and 700
11A
Remove:
- the tensioning roller mounting bolts (3) ,
- the tensioning roller.
Remove:
- the fixed roller mounting bolt plastic cover (4) ,
- the fixed roller mounting bolts (5) ,
- the fixed roller (6) .
Remove:
- the crankshaft accessories pulley mounting boltusing the (Mot. 1770) (1) ,
- the washer,
- the crankshaft accessories pulley.
114856
114857
114849
11A-9
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
M9R, and 700
11AREFITTING
I - REMOVAL PREPARATION OPERATION
Use a brush to remove any deposits from thecrankshaft pulley V-grooves.
II - REFITTING OPERATION FOR PART CONCERNED
Refit the fixed roller.
Tighten to torque the tensioning roller mountingbolt ( 44 Nm )
Refit the plastic cover on to the fixed roller mountingbolt.
Refit the tensioning roller.
.
Tighten to torque the tensioning roller mountingbolt ( 25 Nm ) .
Refit the crankshaft accessories pulley by inserting itonto the two crankshaft flat surfaces.
Refit the washer inside the crankshaft accessoriespulley by inserting it onto the two crankshaft flat sur-faces.
Finger tighten the crankshaft accessories pulleymounting bolt.
Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 50 Nm + 85˚ ±±±± 6˚ )using the (Mot. 1770) .
Refit the accessories belt.
Remove the tensioning roller pin.
Turn the crankshaft twice.
Check that the accessories belt V-blocks are wellpositioned in the V-grooves of all the pulleys.
WARNING
Only use brushes with plastic or non-corrosivemetal (brass) bristles.
WARNING
Do not run the engine without the accessoriesbelt so as not to damage the crankshaft accesso-ries pulley.
WARNING
When replacing the accessories belt recommen-ded by the manufacturer, always replace:
- the accessories belt,
- the tensioning roller and fixed roller,
- the crankshaft accessories pulley bolt,
- the crankshaft accessories pulley.
Note:
The Parts Department supplies the tensioningroller pin.
WARNING
Check that the washer fits properly on thecrankshaft flat surfaces.
11A-10
TOP AND FRONT OF ENGINEAccessories belt: Removal - Refitting
M9R, and 700
11AIII - FINAL OPERATION
Refit:
- the right-hand side reinforcement from the half sub-frame cross member.
- the right-hand side reinforcement mounting boltson the half sub-frame cross member,
- the front right-hand wheel arch liner;
- the front right-hand wheel.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
11A-11
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1489 TDC locating pin
Mot. 1368 Tool for tightening ten-sioner bolt. 8 mm Torxwrench 12.7 mmsquare
Mot. 799-01 Timing gear wheelimmobiliser
Mot. 1496 Camshaft setting tool
Mot. 1750 Adapter for camshaftsetting tool Mot. 1496
Mot. 1490-01 Locking and adjustingcamshaft pulleys
Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)
Mot. 1488 Tool for refitting cams-haft covers (43 mmdiameter)
Tightening torquesm
fixed roller mountingbolt
45 Nm
tensioning roller moun-ting nut
27 Nm
crankshaft accessoriespulley mounting bolt
40 Nm + 145˚±±±± 15˚
tensioning roller moun-ting nut
27 Nm
tensioning roller moun-ting nut
27 Nm
fixed roller mountingbolt
45 Nm
tensioning roller moun-ting nut
27 Nm
crankshaft accessoriespulley mounting bolt
40 Nm + 145˚±±±± 15˚
tensioning roller moun-ting nut
27 Nm
tensioning roller moun-ting nut
27 Nm
fixed roller mountingbolt
45 Nm
tensioning roller moun-ting nut
27 Nm
tensioning roller moun-ting nut
27 Nm
accessories pulleymounting bolt
40 Nm + 115˚±±±± 15˚
new camshaft pulleynuts
30 Nm + 84˚ ±±±±4˚
tensioning roller moun-ting nut
27 Nm
TDC setting pin plug 20 Nm
upper timing cover boltsand nuts
41 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Wear protective gloves during every operation.
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
WARNING
The belt must be replaced with a new one if it hasbeen removed.
Tightening torquesm
11A-12
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine undertray,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Position the (Mot. 1453) and the (Mot. 1453-01) withretaining straps.
WARNING
When replacing the belt, be sure to replace the ten-sioning rollers and fixed rollers.
Note:
The timing belt procedure is the same for engineswith or without camshaft dephasers
102450
102451
11A-13
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Mark the suspended engine mounting in relation tothe body.
Remove:
- the « engine and suspended engine mounting »assembly,
- the lower engine tie-bar.
Remove:
- the air resonator mounting,
- the air resonator,
Pierce the middle of the plugs on the end of thecamshaft using a screwdriver.
Remove:
- the sealing plugs at the camshaft end with ascrewdriver,
- the TDC pin plug (1) ,
- the engine lifting eye (flywheel end),
101866
WARNING
Do not damage the air conditioning pipe.
101103
14491
1
11A-14
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11AADJUSTING THE TIMING
Position the camshaft grooves (2) almost horizontal-ly and offset downwards, turning the crankshaft in itsnormal operating direction (timing end clockwise).
Screw in the TDC setting pin (3) (Mot. 1489) .
Turn the crankshaft in its operating direction (timingend clockwise), until the crankshaft comes into con-tact with TDC setting pin.
Check that the camshaft grooves are horizontal andoffset downwards.
Remove:
- the crankshaft accessories pulley (4) , locking theflywheel with a screwdriver,
- the upper timing cover (5) ,
- the lower timing cover (6) .
14491-1
14489
3
2
14490
14487
5
4
6
11A-15
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Undo the nut (7) on the tensioning roller to slackenthe timing belt.
Remove:
- the fixed roller (8) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the cranks-haft sprocket,
- the timing sprocket,
- the tensioning roller.
REFITTING - PROCEDURE 1
I - PROCEDURE FOR ENGINES FITTED WITH A TIMING COVER WITHOUT FLAP
1 - ADJUSTING THE TIMING
The first procedure is used when replacing any timi-ng component that does not require one or morecamshaft pulleys to be loosened.
Set the camshaft grooves horizontally and below thecentre line by turning the camshafts with the (Mot.799-01) if necessary.
101872
8
7 WARNING
Replace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the fixedroller.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the contact surfaces of the crankshaft andaccessories pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
14490
11A-16
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Fit the (Mot. 1496) with the (Mot. 1750) (9) .
Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts.
Position the TDC setting pin (Mot. 1489) (10) .
Check that the crankshaft is in contact with the TDCsetting pin (Mot. 1489) (10) (crankshaft groove (11)should be at the top).
111337
111336
14489
108875
11A-17
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A2 - REFITTING
Refit the tensioning roller by positioning the tensio-ning roller lug in rib (12) .
Refit:
- the crankshaft timing sprocket (13) ,
- the timing belt,
- the fixed roller (14) .
Tighten to torque the fixed roller mounting bolt (45 Nm ) using the (Mot. 1368) .
3 - BELT TENSION
Using a 6 mm Allen key, bring the adjustable index(15) opposite the notch (16) , by turning the eccen-tric (17) clockwise.
108879
14487-3
14487-2
103263
11A-18
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11ATighten to torque the tensioning roller mountingnut ( 27 Nm ) .
Refit the crankshaft accessories pulley.
Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 40 Nm + 145˚ ±±±± 15˚ )(crankshaft in contact with TDC setting pin)
Remove:
- the camshaft setting tool (Mot. 1496) ,
- the TDC setting pin (Mot. 1489) .
Rotate the crankshaft clockwise (timing end) throu-gh two revolutions and before completing the se-cond revolution.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.
Remove the TDC setting pin (Mot. 1489) .
Check that adjustable index (18) is opposite thenotch (19) .
Loosen the tensioning roller nut by up to one turn,holding the adjustable index with a 6 mm Allen key.
Gradually move the adjustable index (18) facing thenotch (19) turning the eccentric (20) in a clockwisedirection.
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
4 - CHECKING THE TIMING AND TENSION
a - Checking the tension
Rotate the crankshaft clockwise through two revolu-tions (timing end).
Screw in the TDC setting pin (Mot. 1489) .
Move the crankshaft slowly and smoothly to rest onthe TDC setting pin (Mot. 1489) .
Remove the TDC setting pin.
Check the tensioning roller indexes are aligned; ifnot readjust the tension by loosening the tensioningroller eccentric by a single turn.
Correctly align the adjustable index with the fixed in-dex or the notch (depending on the type of tensio-ning roller).
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
b - Checking the timing
Check that the tensioning roller indexes are correctlypositioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly until it isresting against the pin.
103263
11A-19
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Fit the camshaft adjusting tool (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland below the centre line).
Remove the TDC setting pin.
II - PROCEDURE FOR ENGINES FITTED WITH TIMING COVER WITH FLAP
1 - ADJUSTING THE TIMING
The first procedure is used when replacing any timi-ng component that does not require one or morecamshaft pulleys to be loosened.
Set the camshaft grooves horizontally and below thecentre line by turning the camshafts with the (Mot.799-01) , if necessary.
14490
WARNING
The timing adjustment and tensioning operationmust be repeated if the camshaft setting tooldoes not engage.
WARNINGReplace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the fixedroller.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the contact surfaces of the crankshaft andaccessories pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
14490
11A-20
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Fit the (Mot. 1496) with the (Mot. 1750) (21) .
Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts
Position the TDC setting pin (Mot. 1489) (22) .
Check that the crankshaft is in contact with the TDCsetting pin (Mot. 1489) (22) (crankshaft groove (23)should be at the top).
111337
111336
14489
108875
11A-21
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A2 - REFITTING
Refit the tensioning roller by positioning the tensio-ning roller lug in rib (24) .
Refit the crankshaft timing sprocket.
Refit:
- the timing belt,
- the timing fixed roller (25)
Tighten to torque the fixed roller mounting bolt (45 Nm ) using the (Mot. 1368) .
3 - TIMING BELT TENSION
Bring the adjustable index (26) opposite the notch(27) , by turning the eccentric (28) clockwise using a6 mm Allen key.
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
Refit the lower timing cover.
108879
14487-3
103263
109054
11A-22
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Refit the crankshaft accessories pulley.
Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 40 Nm + 145˚ ±±±± 15˚ )(crankshaft in contact with TDC setting pin).
Remove the cover plate from the lower timing cover.
Remove:
- the camshaft setting tool (Mot. 1496) ,
- the TDC setting pin (Mot. 1489) .
Rotate the crankshaft twice in a clockwise direction,on the timing end, before aligning the markings (onthe camshaft dephaser) already made by the opera-tor.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to rest onthe TDC setting pin.
Remove the TDC setting pin (Mot. 1489) .
109055
109052
11A-23
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Check through the lower timing cover window thatthe adjustable index (30) is opposite the notch (29) ,if not, loosen the timing tensioning roller screw by asingle turn while holding the eccentric using a 6 mmAllen key.
Gradually move the adjustable index (30) facing thenotch (29) turning the eccentric (31) in a clockwisedirection.
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
Check that dephaser marking is in alignment withmarking already made by the operator.
4 - CHECKING THE TIMING AND TENSION
a - Checking the tension
Rotate the crankshaft twice in a clockwise direction,on the timing end, before aligning the markings (onthe camshaft dephaser) already made by the opera-tor.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.
Remove the TDC setting pin.
Check through the lower timing cover window thatthe index and the notch of the timing tensioning rol-ler are aligned; if not, readjust the tension by loose-ning the tensioning roller nut on the eccentric by asingle turn.
Align the adjustable index with the notch.
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
b - Checking the timing
Ensure that the index and the notch on the timingtensioning roller are in the correct position beforechecking the timing.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to rest onthe TDC setting pin.
109051
103263
11A-24
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Fit (without forcing) the camshaft setting tool (Mot.1496) (the camshaft grooves must be horizontal andoffset towards the bottom).
Refit the lower timing cover plate, checking that thelocating pin (32) fits properly in the notch (33) .
REFITTING -PROCEDURE 2
I - ADJUSTING THE TIMING
The second procedure is used for the replacementof all components requiring the slackening of one ormore of the camshaft pulleys.
Refit the camshaft pulleys and the old nuts, tighte-ning to a torque of 15 Nm .
14490
Note:
The timing adjustment and tensioning operationmust be repeated if the camshaft setting tooldoes not engage.
109052
WARNINGIf the stud is loosened with the nut (see NT3887A, Replacing camshaft pulley studs K9 -K4, 11A, Top and front of engine, Camshaft ).
WARNINGReplace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the fixedroller.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the crankshaft accessories pulley bearingfaces,
- the camshaft ends (timing end),
- the camshaft sprocket bores and contact surfa-ces.
This is to avoid timing slippage.
This slippage causes engine damage.
11A-25
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Position the camshaft grooves horizontally and off-set downwards, by turning the camshafts with the(Mot. 1496) if necessary.
Fit the (Mot. 1496) with the (Mot. 1750) (34) .
Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts
Remove the old camshaft pulley nuts and replacethem with new ones (without tightening the nuts: 0.5to 1 mm play between nuts and pulleys).
14490
103261
111337
111336
11A-26
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Check that the crankshaft is in contact with the TDCsetting pin (Mot. 1489) (35) (crankshaft groove (36)should be at the top).
Position the RENAULT badge (37) etched on thecamshaft pulley spokes vertically at the top.
II - REFITTING
Refit the tensioning roller by positioning the tensio-ning roller lug in groove (38) .
Refit:
- the timing sprocket (39) ,
- the timing belt on the camshaft pulleys (without mo-ving the camshaft pulleys).
14489
14487-1
108879
14487-3
11A-27
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Fit the camshaft pulley locking tool (Mot. 1490-01)(40) (use the timing cover mountings to mount thetool).
Refit the fixed roller (41) .
Tighten to torque the fixed roller mounting bolt (45 Nm ) using the (Mot. 1368) .
Refit the crankshaft accessories pulley (without tigh-tening the bolt, 2 to 3 mm play between bolt and pul-ley).
III - BELT TENSION
Using a 6 mm Allen key, bring the adjustable index(42) in line with the notch (43) , by turning the eccen-tric (44) clockwise.
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
Remove camshaft pulley locking tool (Mot. 1490-01).
Rotate the timing system through six revolutionswith the exhaust camshaft sprocket, using the (Mot.799-01) .
101876
14487-3
103263
Note:
Check that the camshaft pulley nuts and bolt donot come into contact with their respective pul-leys. In addition, from time to time, press thecamshaft pulleys against the camshafts.
11A-28
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11A
Check that adjustable index (45) is opposite thenotch (46) .
Loosen the tensioning roller nut by up to one turn,holding the adjustable index with a 6 mm Allen key.
Gradually move the adjustable index (45) facing thenotch (46) turning the eccentric (47) in a clockwisedirection.
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
Position the camshaft pulley locking tool (Mot. 1490-01) .
Tighten to torque and angle:
- the accessories pulley mounting bolt ( 40 Nm +115˚ ±±±± 15˚ ) (crankshaft in contact with TDC settingpin)
- the new camshaft pulley nuts ( 30 Nm + 84˚ ±±±± 4˚) starting with the exhaust pulley
Remove:
- the camshaft setting tool (Mot. 1496) ,
- the camshaft pulley locking tool (Mot. 1490-01) ,
- the TDC setting pin (Mot. 1489) .
IV - CHECKING THE TIMING AND TENSION
1 - Checking the tension
Rotate the crankshaft clockwise through two revolu-tions (timing end).
screw the TDC setting pin (Mot. 1489) into the cylin-der block.
slowly and smoothly position the crankshaft in con-tact with the TDC setting pin (Mot. 1489) .
Remove the TDC setting pin (Mot. 1489) .
103263
14839
14489
WARNING
Check that the crankshaft is in contact with theTDC setting pin (Mot. 1489) .
11A-29
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4J, and 730 or 732
11ACheck the tensioning roller indexes are aligned; ifnot readjust the tension by loosening the tensioningroller eccentric by a single turn.
Correctly align the adjustable index with the fixed in-dex or the notch (depending on the type of tensio-ning roller).
Tighten to torque the tensioning roller mountingnut ( 27 Nm ) .
2 - Checking the timing
Check that the timing pulley indexes are correctlypositioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly and rest iton the TDC setting pin (Mot. 1489) .
Fit the camshaft adjusting tool (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland offset downwards).
Remove the TDC setting pin.
REFITTING
Refit the TDC setting pin plug, applying a drop ofJOINT SILICONE ADHERENT onto the thread hole.
Tighten to torque the TDC setting pin plug ( 20 Nm) .
Refit the lower timing cover.
Refit the upper timing cover.
Tighten to torque the upper timing cover bolts andnuts ( 41 Nm ) .
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- new inlet camshaft sealing plugs (Mot. 1487) ,
- new exhaust camshaft sealing plugs (Mot. 1488) .
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm )
- the battery cover mounting bolts ( 4 Nm ) .
14490
Note:
The timing adjustment and tensioning operationmust be repeated if the camshaft setting tooldoes not engage.
15103-1
11A-30
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11AREMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the accessories belt (see 11A, Top andfront of engine, Accessories belt: Removal - Re-fitting ).
Position the (Mot. 1453) and (Mot. 1453-01) with re-taining straps.
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1489 TDC locating pin
Mot. 1430 Set of 5 crankshaftand camshaft pulleytiming pins
Tightening torquesm
tensioning roller bolt 25 Nm
crankshaft accessoriespulley M12 mountingbolt
60 Nm + 100˚±±±± 10˚
crankshaft accessoriespulley M14 mountingbolt
120 Nm + 95˚±±±± 15˚
tensioning roller moun-ting bolt
25 Nm
TDC setting pin plug 20 Nm
cylinder head suspen-ded mounting bolts
21 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
102450
102451
11A-31
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Remove the lower tie-bar bolts (1) .
Remove the lower engine tie-bar.
Mark the position of the suspended engine moun-ting.
Slacken the bolt (2)
Remove the suspended engine mounting.
102115
102114
WARNING
Do not damage the air conditioning pipe.
1
2
11A-32
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Remove the upper timing cover by unclipping thetabs (3) .
19654
3
11A-33
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Remove:
- the cylinder marking sensor on the high pressurepump (4) ,
- the plastic bolt (6) .
Unclip the tabs (5) .
Remove the lower timing cover.
19654-1
11A-34
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Remove the cylinder head suspended mounting.
Remove the TDC setting pin plug.
Positioning the timing at the adjustment point
Rotate the crankshaft clockwise (timing end) to posi-tion the hole (8) in the camshaft pulley partially inline with the hole (9) in the cylinder head.
19654-2
19650
7
19702
9
8
11A-35
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Screw in the TDC setting pin (1) (Mot. 1489) .
Turn the crankshaft clockwise (timing end) smoothlyuntil the crankshaft comes in contact with the TDCsetting pin (Mot. 1489) .
Insert the pin (2) (Mot. 1430) in the camshaft pulleyand cylinder head holes.
Remove:
- the pin (Mot. 1430) ,
- the TDC setting pin (Mot. 1489) .
19650-1
14489-1
1
19655
2
11A-36
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Remove the crankshaft accessories pulley, lockingthe flywheel with a screwdriver.
19656
11A-37
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Undo the tensioning roller bolt (10) to slacken the ti-ming belt.
Remove:
- the timing belt (take care not to drop the crankshaftsprocket),
- the timing sprocket,
- the tensioning roller.
REFITTING19656-1
10
WARNING
It is imperative to replace the timing belt, the ten-sioning roller and the accessories pulley bolt.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the contact surfaces of the crankshaft accesso-ries pulley.
This is to avoid timing slippage.
This slippage causes engine damage.
11A-38
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Refit the crankshaft timing sprocket.
19710
11A-39
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11AI - ADJUSTING THE TIMING
Refit the tensioning roller.
Insert the pin (2) (Mot. 1430) in the camshaft pulleyand cylinder head holes.
Screw the TDC setting pin into the cylinder block.
Check that the mark (13) on the high pressure pumppulley is in line with the bolt head (14) .
Check that the crankshaft is hard against the TDCsetting pin (Mot. 1489) (crankshaft groove (15) fa-cing upwards).
19656-2
15
1413
12
11
2
Note:
Check that the tensioning roller lug (11) is cor-rectly positioned in the groove (12) .
14489
11A-40
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Fit the new timing belt, aligning the marks on the beltwith those on the camshaft sprockets and the highpressure pump.
Position the tensioning roller adjustable index (16)opposite the lug using a 6 mm Allen key, turning itanticlockwise.
Tighten to torque the tensioning roller bolt ( 25 Nm) .
Refit the crankshaft accessories pulley.
Tighten to torque and angle (crankshaft in contact with the TDC setting pin):
- crankshaft accessories pulley M12 mountingbolt ( 60 Nm + 100˚ ±±±± 10˚ ) ,
- crankshaft accessories pulley M14 mountingbolt ( 120 Nm + 95˚ ±±±± 15˚ ) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
19657
Note:
19 belt tooth spaces between the camshaftsprocket and pump marks.
19658
16
11A-41
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Rotate the crankshaft clockwise through two revolu-tions (timing end).
Before the camshaft pulley hole (17) comes in linewith the cylinder head hole (18) , screw the TDC set-ting pin (Mot. 1489) into the cylinder block.
Bring the crankshaft slowly and smoothly into con-tact with the pin.
Check:
- that the timing pin (Mot. 1430) engages properly inthe camshaft and cylinder head holes,
- that there are 19 belt tooth spaces between thecamshaft sprocket mark (19) and the high pressurepump sprocket mark (20) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
19702
18
17
19655
After two turns, the tensioning roller indexes maybe in two different positions.
The rotation of the tensioning roller eccentricdepends on the position.
2019
11A-42
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11AFirst position
Loosen the tensioning roller bolt by no more thanone turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index (21) , turningthe Allen key anticlockwise, to the middle of the timi-ng window (22) .
Second position
Loosen the tensioning roller bolt by no more thanone turn, holding it with a 6 mm Allen key.
Gradually align the adjustable index (23) , turningthe key clockwise, to the middle of the timing window(24) .
111083
111081
21
111082
111081
23
23
24
11A-43
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11AII - REFITTING
Tighten to torque the tensioning roller mountingbolt ( 25 Nm ) .
Refit the TDC setting pin plug, applying JOINT SILI-CONE ADHERENT to the thread hole.
Tighten to torque the TDC setting pin plug ( 20 Nm) .
Refit the cylinder head suspended mounting.
Tighten to torque the cylinder head suspendedmounting bolts ( 21 Nm ) .
19654-2
11A-44
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Refit the lower timing cover, positioning the tab (25)in the lower timing cover aperture (26) .
19654-1
19659
26
25
11A-45
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 722 or 728 or 729
11A
Refit:
- the upper timing cover,
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ) in accordancewith the marks,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
.
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
19654
11A-46
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F9Q, and 800 or 804 or 808
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine undertray,
- the accessories belt (see 11A, Cylinder head, Ac-cessories belt: Removal - Refitting ).
Position the (Mot. 1453) and (Mot. 1453-01) with re-taining straps.
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1054 TDC setting pin
Mot. 1543 Tool for pretensioningtiming belt
Mot. 1705 Adapter for timing beltpretensioning tool
Mot. 1505 Belt tension settingtool (frequency meter)
Mot. 1715 Belt tension settingtool (frequency meter)
Tightening torquesm
TDC setting pin plug 20 Nm
tensioning roller moun-ting nut
45 Nm
crankshaft accessoriespulley mounting bolt
40 Nm + 110˚±±±± 10˚
wheel bolts 110 Nm
battery cover bolts 4 Nm
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
102450
102451
11A-47
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F9Q, and 800 or 804 or 808
11A
Remove:
- the upper engine tie-bar.
- the lower engine tie-bar.
Mark the position of the suspended engine mountingin relation to the body.
Slacken the bolt (1)
Remove the suspended engine mounting.
Remove:
- the TDC setting pin plug.
- the flywheel guard cover plate.
Remove:
- the crankshaft accessories pulley, locking theflywheel with a screwdriver,
- the timing cover mounting bolts (2) ,
- the timing cover.
102420
WARNING
Do not damage the air conditioning pipes (if fittedto the vehicle).
1
15102
104739
22
11A-48
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F9Q, and 800 or 804 or 808
11AADJUSTING THE TIMING
Rotate the crankshaft clockwise (timing end); bringthe camshaft pulley mark to half a tooth before themark on the guard.
When the mark on the camshaft pulley is half a toothbefore the mark on the guard, press in the TDC set-ting pin (Mot. 1054) until the crankshaft is timed.
Undo the tensioning roller mounting nut (3) to slac-ken the tensioning roller.
Remove the timing belt.
REFITTING
104329
104330
104326
WARNING
Replace the timing belt, the tensioning roller, thecrankshaft accessories pulley and bolt.
3
11A-49
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F9Q, and 800 or 804 or 808
11A
Refit the tensioning roller, taking care to position itcorrectly on the locating pin (4) .
Check that the TDC setting pin (Mot. 1054) is in pla-ce.
Fit the new timing belt, aligning the marks on the beltwith those on the crankshaft, camshaft and highpressure pump sprockets (count 28 belt tooth spa-ces between the mark on the camshaft sprocket andthe mark on the high pressure pump sprocket).
Press the tensioning roller against the belt by tighte-ning the bolt (8) on the tensioning roller mounting.
Remove the TDC setting pin (Mot. 1054) .
Position the crankshaft accessories pulley bolt.
104336
16187
Note:
The crankshaft groove (5) must be in the middleof the two ribs (6) on the crankshaft guard plate.The crankshaft timing sprocket mark (7) shouldbe offset one tooth to the left of the vertical axisof the engine.
4
66
7
5
104327
Note:
The bolt (8) is manufactured locally.
8
11A-50
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F9Q, and 800 or 804 or 808
11A
Mount the timing belt pretensioning tool (Mot. 1543)fitted with the cover (Mot. 1705) (9) on the cranks-haft accessories pulley bolt.
Pretension the timing belt between the crankshaft ti-ming sprocket and the tensioning roller using the(Mot. 1543) and a torque wrench set to a torque of(11 Nm) .
16563
104331
9
104332
11A-51
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F9Q, and 800 or 804 or 808
11A
Position the sensor of the (Mot. 1505) or (Mot.1715) between the crankshaft sprocket and the ten-sioning roller.
Tension the belt to obtain the recommended value90 ±±±± 3 Hz by turning the bolt (10) .
Tighten to torque the tensioning roller mountingnut (10 Nm) .
Turn the crankshaft through two revolutions.
Reposition the TDC setting pin (Mot. 1054) .
Position the timing at its setting point (start pressingon the pin half a tooth before alignment of the cams-haft pulley mark and the cover plate mark, to avoidgoing into a camshaft balancing hole).
Remove the TDC setting pin (Mot. 1054) .
Refit the TDC setting pin plug, applying a drop ofRHODORSEAL 5661 onto the thread.
Tighten to torque the TDC setting pin plug ( 20 Nm) .
Apply a pretensioning force between the crankshafttiming sprocket and the tensioning roller using the(Mot. 1543) and a torque wrench set to a torque of11 Nm .
Place the sensor of the (Mot. 1505) between thecrankshaft sprocket and the tensioning roller.
Check that the tension value is 80 ±±±± 5 Hz ; if not, rea-djust.
Tighten to torque the tensioning roller mountingnut ( 45 Nm ) .
Remove the (Mot. 1543) .
Remove the crankshaft accessories pulley bolt.
Refit the crankshaft accessories pulley, without se-parating its two component parts.
Tighten to torque and angle the crankshaft acces-sories pulley mounting bolt ( 40 Nm + 110˚ ±±±± 10˚ ).
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended mounting ),
- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended mounting ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
To refit, proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover bolts ( 4 Nm ) .
104333
10
105435
11A-52
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1672 Lower engine support
Mot. 1054 TDC setting pin
Mot. 1509 Camshaft sprocketlocking tool
Mot. 1509-01 Conversion kit for Mot.1509
Mot. 799-01 Timing gear wheelimmobiliser
Mot. 1496 Camshaft setting tool
Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Tightening torquesm
toothed sprocket nuts 80 Nm
toothed sprocket nuts 80 Nm
fixed roller mountingbolt
50 Nm
tensioning roller nut 7 Nm
toothed sprocket nuts (80 Nm)
old inlet camshaftdephaser mounting bolt
(30 Nm)
old exhaust camshaftpulley nut
30 Nm
toothed sprocket nuts (80 Nm)
old inlet and exhaustcamshaft pulley nuts
(30 Nm)
toothed sprocket nuts 80 Nm
toothed sprocket nuts 80 Nm
tensioning roller nut 28 Nm
toothed sprocket nuts 80 Nm
inlet camshaft depha-ser mounting bolt
(30 Nm)
exhaust camshaft pul-ley nut
(30 Nm)
inlet camshaft depha-ser mounting bolt
100 Nm
camshaft pulley depha-ser blanking cover
25 Nm
exhaust camshaft pul-ley nut
86˚ ±±±± 6˚
toothed sprocket nuts 80 Nm
inlet and exhaust cams-haft pulley nuts
86˚ ±±±± 6˚
nuts 80 Nm
inlet and exhaust cams-haft pulley nuts
30 Nm + 86˚ ±±±±6˚
crankshaft accessoriespulley bolt
40 Nm + 110˚±±±± 10˚
M6 lower timing coverbolts
80 Nm
M8 lower timing coverbolts
20 Nm
M8 upper timing coverbolts
18 Nm
M10 upper timing coverbolts
38 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
Note
The timing belt procedure is the same for engineswith or without camshaft dephasers.
Tightening torquesm
11A-53
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- the engine covers.
Position the (Mot. 1453) and (Mot. 1453-01) with re-taining straps.
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
WARNING
Do not run the engine without the accessories beltto avoid damaging the crankshaft accessories pul-ley.
WARNINGOn the F4R engine, it is essential to fit the cranks-haft sprocket with the integral key.
WARNING
Replace the following parts when they are removed:
- the camshaft pulley nuts,
- the crankshaft accessories pulley,
- the crankshaft accessories pulley bolt.
WARNING
When replacing the belt, it is imperative to replacethe tensioning roller and the fixed roller.
102450
102451
11A-54
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Remove:
- the radiator cross member right-hand side reinfor-cement (1) ,
- the lower engine tie-bar.
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the fastening (5) ,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the screen washer tubes.
Remove:
- the front end panel mounting bolts (6) ,
- the front end panel,
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft ).
Position the (Mot. 1672) with retaining straps.
106077
F4R, and 776
102504
1
54
3
22
102365
105432
666
11A-55
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Mark the suspended engine mounting in relation tothe body.
Remove the suspended mounting assembly.
Remove the accessories belt (see 11A, Top andfront of engine, Accessories belt: Removal - Re-fitting ).
Remove:
- the air filter outlet duct (7) ,
- the throttle valve (8) ,
- the connector on the lifting bracket.
Remove the fuel vapour recirculation solenoid valve(9) .
102742
Note:
Be careful not to bend the air conditioning pipe.
F4R, and 770 or 771
101807
7
8
F4R, and 776
106278
9
11A-56
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Loosen the nut (10) .
Pull the mounting bracket away from the electriccoolant pump.
Move the electric coolant pump (11) to one side.
Remove the wiring harness mounting bracket.
Remove the TDC setting pin plug (12) .
Remove the camshaft sealing plugs.
I - ADJUSTING THE TIMING
Rotate the engine clockwise (timing end) so that thecamshaft grooves are offset below the centre lineand almost horizontal, as shown in the drawing.
Insert the TDC setting pin (Mot. 1054) so that it isbetween the balancing hole and the crankshaft set-ting groove.
106632
15102
1011
12
15105
15106
11A-57
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Turn the engine slightly in the same direction,pushing in the TDC setting pin (Mot. 1054) until thesetting point is reached.
At the setting point, the camshaft grooves must behorizontal and offset below the centre line, as shownin the drawing.
Correct position
Incorrect position
Remove the TDC setting pin (Mot. 1054) .
15163-2
15106-1
15163-1
15163
11A-58
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Remove:
- the flywheel guard,
- the crankshaft pulley, locking the flywheel with ascrewdriver.
Refit the TDC setting pin (Mot. 1054) .
106519
15303
11A-59
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Remove:
- the upper timing cover (13) ,
- the lower timing cover (14) .
F4R, and 770 or 771
18433
14
13
11A-60
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Remove:
- the heat shield (15) ,
- the upper timing cover (16) ,
F4R, and 776
106338
15
104719
16
17
11A-61
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A- the lower timing cover (17) .
Slacken the timing belt by loosening the tensioningroller nut (18) .
Remove:
- the fixed roller (19) ,
- the timing belt,
- the crankshaft timing sprocket.
18433-2
18
19
WARNING
When replacing the timing belt, it is imperative toreplace the tensioning roller and the fixed roller.
WARNING
A belt which has been removed MUST be repla-ced.
WARNING
Never turn the engine in the opposite direction toits normal operation.
11A-62
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11AII - ADJUSTING THE TIMING
104703
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces(20) ,
- the contact surfaces of the crankshaft accesso-ries pulley,
This is to prevent slippage between the timinggear and the crankshaft.
This slippage causes engine damage.
WARNING
Never turn the engine in the opposite direction toits normal operation.
WARNING
In this case, the old camshaft pulley nuts must beremoved in order to correctly set the belt tension.
2020
11A-63
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Check that the camshaft dephaser wheel is correctlylocked (no rotation of the wheel to the left or to theright).
F4R, and 770 or 771
15815-3
11A-64
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Position the (Mot. 1509) with sprocket (Mot. 1509-01) .
Position the spacer (21) of the (Mot. 1509-01) on thestud (22) .
Fit the upper bolt (23) , positioning the spacer (24)(Mot. 1509-01) between the tool and the rocker co-ver (do not tighten the bolt).
Tighten the bolt and the shouldered nut (25) .
Bring the toothed sprockets of the (Mot. 1509) intocontact with the camshaft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (26) .
Remove:
- the inlet camshaft dephaser blanking cover (27) ,
- the inlet camshaft dephaser mounting bolt,
- the exhaust camshaft pulley nut,
- the (Mot. 1509) ,
- the camshaft pulleys.
Loosen the stud with the nut (see NT 3884A, Repla-cing F4 camshaft pulley studs, Top and front ofengine, Camshaft ).
16019
16019-1
22
21
23
24
16019-3
26 252526
27
11A-65
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Install the (Mot. 1509) with its toothed sprocket(Mot. 1509-01) .
Tighten the bolt and the shouldered nut (28) .
Bring the toothed sprockets into contact with thecamshaft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (29) .
Remove:
- the camshaft pulley nuts,
- the (Mot. 1509) ,
- the camshaft pulleys.
Loosen the stud with the nut (see NT 3884A, Repla-cing F4 camshaft pulley studs, Top and front ofengine, Camshaft ).
Refit the degreased camshaft pulleys with the oldmountings.
Tighten to torque the old mountings (15 Nm max.)using the (Mot. 799-01) .
Position the grooves offset horizontally below thecentre-line as shown above by turning the cams-hafts using the (Mot. 799-01) .
F4R, and 776
104711
28
29
28
29
WARNING
When removing the timing belt, it is essential to replace:
- the crankshaft accessories pulley,
- the tensioning roller and fixed roller,
- the accessories and timing belts.
15106-1
11A-66
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Position the (Mot. 1496) , attaching it to the end ofthe camshafts.
Loosen:
- the exhaust camshaft pulley nut,
- the inlet camshaft dephaser pulley bolt,
Loosen the camshaft pulley nuts.
Correct position
15104
F4R, and 770 or 771
F4R, and 776
15114
15163-1
WARNING
Check that the crankshaft is correctly centered.
The crankshaft groove (30) must be between thetwo ribs (31) .
31
30
11A-67
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Refit the tensioning roller, correctly positioning the(32) of the tensioning roller in the groove (33) .
Refit:
- the timing sprocket,
- the timing belt,
- the fixed roller (34) .
Tighten to torque the fixed roller mounting bolt (50 Nm ) .
15201
33
32
15815-1
34
11A-68
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11AIII - ADJUSTING THE TENSION
Align the marks (35) and (36) on the tensioning rollerusing an Allen key (6 mm) in (37) .
Tighten to torque the tensioning roller nut ( 7 Nm ).
Position the (Mot. 1509) with the toothed sprocket(Mot. 1509-01) for locking the camshaft pulleys.
Tighten the bolt and the shouldered nut (38) .
Bring the toothed sprocket nuts into contact with thecamshaft pulleys.
Tighten to torque:
- the toothed sprocket nuts ( (80 Nm) ) (39) ,
- the old inlet camshaft dephaser mounting bolt ((30 Nm) ) ,
- the old exhaust camshaft pulley nut ( 30 Nm ) .
Remove the (Mot. 1509) fitted with the (Mot. 1509-01) .
15256
Note:
Do not rotate the tensioning roller anticlockwise.
37
36
35
F4R, and 770 or 771
104728
38
39
38
39
11A-69
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Position the (Mot. 1509) for locking the camshaftpulley.
Tighten the bolt and the shouldered nut (40) .
Bring the toothed sprocket nuts into contact with thecamshaft pulleys.
Tighten to torque:
- the toothed sprocket nuts ( (80 Nm) ) (40) ,
- the old inlet and exhaust camshaft pulley nuts ((30 Nm) ) (41) ,
Remove the (Mot. 1509) fitted with the (Mot. 1509-01) .
Make a pencil mark (42) between the camshaft pul-leys and the camshaft bearing cap.
Remove the following tools:
- TDC setting pin (Mot. 1054) ,
- camshaft setting tool (Mot. 1496) .
Rotate the crankshaft clockwise through two revolu-tions (timing end).
F4R, and 776
104711
41
4040
41
21877
42424242
11A-70
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11AIV - CHECKING THE TIMING AND THE TENSION
1 - Checking the tension
Before the end of the second revolution (i.e. half atooth before alignment of the marks made previouslyby the operator), insert the crankshaft TDC settingpin (Mot. 1054) (so that it is between the balancinghole and the timing hole).
Bring the timing to its adjustment point.
Position the camshaft adjustment tool (Mot. 1496) .
15163-2
15163-1
15104
11A-71
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Position the (Mot. 1509) with the toothed sprockets(Mot. 1509-01) for locking the camshaft pulleys.
Tighten the bolt and the shouldered nut (43) .
Offer up the toothed sprocket nuts against the cams-haft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (44) .
Loosen:
- the old inlet camshaft dephaser pulley mountingbolt,
- the old exhaust camshaft pulley nut.
Remove the (Mot. 1509) with the sprocket (Mot.1509-01) for locking the camshaft pulleys.
Position the (Mot. 1509) for locking the camshaftpulley.
Tighten the bolt and the shouldered nut (45) .
Offer up the toothed sprocket nuts against the cams-haft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (46) .
Loosen:
- the old inlet camshaft pulley nut,
- the old exhaust camshaft pulley nut.
Remove the (Mot. 1509) for locking the camshaftpulley.
F4R, and 770 or 771
104728
444343
44
F4R, and 776
104711
46
4545
46
11A-72
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Align mark (47) with mark (48) by loosening the ten-sioning roller nut by up to one turn, while holding it inposition with a 6 mm (49) Allen key.
Final tighten the tensioning roller nut ( 28 Nm ) .
15256
49
48
47
11A-73
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Position the (Mot. 1509) with toothed sprockets tolock the camshaft pulleys.
Tighten the bolt and the shouldered nut (50) .
Bring the toothed sprockets into contact with thecamshaft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (51) .
Remove:
- the old inlet camshaft pulley dephaser bolt,
- a new nut on the exhaust camshaft pulley.
Refit:
- a new bolt on the inlet camshaft pulley,
- a new nut on the exhaust camshaft pulley.
Tighten to torque:
- the inlet camshaft dephaser mounting bolt ( (30Nm) ) ,
- the exhaust camshaft pulley nut ( (30 Nm) ) .
Remove the camshaft adjustment tool (Mot. 1496) .
Tighten to torque:
- the inlet camshaft dephaser mounting bolt ( 100Nm ) ,
- the camshaft pulley dephaser blanking cover (25 Nm )
Tighten to angle the exhaust camshaft pulley nut (86˚ ±±±± 6˚ ) .
Remove the following tools:
- TDC setting pin (Mot. 1054) ,
- camshaft pulley locking tool (Mot. 1509) with too-thed sprockets (Mot. 1509-01) .
Rotate the crankshaft clockwise through two revolu-tions (timing end).
F4R, and 770 or 771
104728
50
51
11A-74
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Position the (Mot. 1509) for locking the camshaftpulley.
Tighten the bolt and the shouldered nut (52) .
Bring the toothed sprocket nuts into contact with thecamshaft pulleys.
Tighten the toothed sprocket nuts ( 80 Nm ) (53) .
Remove:
- the old inlet camshaft pulley nut,
- the old exhaust camshaft pulley nut.
Refit a new nut onto the inlet and exhaust camshaftpulley.
Tighten to torque the inlet and exhaust camshaftpulley nuts 30 Nm .
Remove the camshaft adjustment tool (Mot. 1496) .
Tighten to angle the inlet and exhaust camshaftpulley nuts ( 86˚ ±±±± 6˚ ) .
Remove the following tools:
- TDC setting pin (Mot. 1054) ,
- camshaft pulley locking tool (Mot. 1509) .
Rotate the crankshaft clockwise through two revolu-tions (timing end).
Position the camshaft locking tool (Mot. 1509) , tor-que tightening the nuts ( 80 Nm ) (54) .
Tighten the bolt and the shouldered nut (55) .
Remove the old camshaft pulley nuts and replacethem with new ones.
Tighten to torque and angle the inlet and exhaustcamshaft pulley nuts ( 30 Nm + 86˚ ±±±± 6˚ ) .
Remove the following tools:
- (Mot. 1496) ,
- camshaft pulley locking tool (Mot. 1509) .
- the TDC setting pin (Mot. 1054) .
Rotate the crankshaft clockwise through two revolu-tions.
F4R, and 776
104711
52
53
104711
5454
55
11A-75
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A2 - Checking the timing
Before the end of the second revolution (i.e. half atooth before alignment of the marks made previouslyby the operator), insert the crankshaft TDC settingpin ( (Mot. 1054) so that it is between the balancinghole and the timing hole).
Check that mark (56) is aligned with mark (57) onthe tensioning roller before checking the timing ad-justment.
The offset grooves (58) should be horizontal and be-low the centre line.
Position the camshaft setting tool (Mot. 1496) wi-thout forcing it. If the tool does not engage, repeatthe timing and tensioning procedure.
REFITTING
Refit:
- the lower timing cover,
- the upper timing cover.
15649
15106-1
56
57
58
15104
WARNING
It is imperative to replace the crankshaft acces-sories pulley and bolt.
11A-76
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
F4R, and 770 or 771 or 776
11A
Lock the flywheel using a large screwdriver.
Tighten to torque and angle the crankshaft acces-sories pulley bolt ( 40 Nm + 110˚ ±±±± 10˚ ) .
Refit:
- the crankshaft accessories belt (see 11A, Top andfront of engine, Accessories belt ),
- the TDC setting pin plug, applying a drop of RHO-DORSEAL 5661 to the thread hole.
Refit:
- the new sealing plugs:
• on the inlet camshaft (Mot. 1487) ,
• on the exhaust camshaft (Mot. 1448) ,
- the right-hand suspended mounting (see 19D, En-gine mounting, Suspended mounting ) in accor-dance with the marks.
Proceed in the reverse order to removal.
Tighten to torque:
- the M6 lower timing cover bolts ( 80 Nm ) ,
- the M8 lower timing cover bolts ( 20 Nm ) ,
- the M8 upper timing cover bolts ( 18 Nm ) ,
- the M10 upper timing cover bolts ( 38 Nm ) ,
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
15303
WARNING
To avoid damaging the crankshaft accessoriespulley, do not start the engine without the acces-sories belt.
15103-1
11A-77
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine undertray,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1489 TDC locating pin
Mot. 1368 Tool for tightening ten-sioner bolt. 8 mm Torxwrench 12.7 mmsquare
Mot. 799-01 Timing gear wheelimmobiliser
Mot. 1496 Camshaft setting tool
Mot. 1750 Adapter for camshaftsetting tool Mot. 1496
Mot. 1490-01 Locking and adjustingcamshaft pulleys
Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)
Mot. 1488 Tool for refitting cams-haft covers (43 mmdiameter)
Tightening torquesm
crankshaft accessoriespulley bolt
40 Nm + 145˚±±±± 15˚
timing tensioning rollernut
27 Nm
pulley mounting bolt 45 Nm
exhaust camshaft pul-ley nut
30 Nm + 84˚ ±±±±4˚
inlet camshaft pulleydephaser bolt
75 Nm
TDC pin plug 20 Nm
upper timing cover nutsand bolts
41 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
WARNING
Never turn the engine in the opposite direction to itsnormal operation.
Tightening torquesm
11A-78
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Fit the (Mot. 1453) and the (Mot. 1453-01) and theretaining straps.
Mark the suspended engine mounting in relation tothe body.
Remove:
- the « engine/suspended engine mounting » as-sembly,
- the lower engine tie-bar.
Remove:
- the air filter outlet duct (1) ,
- the throttle valve (2) ,
- the connector from the lifting bracket,
- the lifting eye (flywheel end).
102450
102451
101866
WARNING
Do not damage the air conditioning pipe.
101807
1
2
11A-79
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Pierce the centre of the plugs on the end of thecamshaft using a screwdriver.
Remove:
- the sealing plugs at the camshaft end with ascrewdriver,
- the TDC setting pin plug (3) .
ADJUSTING THE TIMING
Position the camshaft grooves (5) almost horizontal-ly and offset towards the bottom while turning thecrankshaft in its operating direction (clockwise timi-ng end).
Screw in the TDC setting pin (4) (Mot. 1489) .
Turn the crankshaft in its operating direction (timingend clockwise), until the crankshaft comes into con-tact with TDC setting pin.
14491
3
14491-1
14489
5
4
5
11A-80
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Check that the camshaft grooves are horizontal andoffset downwards.
Remove:
- the crankshaft accessories pulley (6) , locking theflywheel with a screwdriver,
- the upper timing cover (7) ,
- the lower timing cover (8) .
Undo the tensioning roller bolt (9) to slacken the timi-ng belt.
Remove:
- the pulley (10) using the (Mot. 1368) ,
- the timing belt, taking care not to drop the cranks-haft sprocket,
- the timing sprocket,
- the tensioning roller.
14490
14487
6
8
7
101872
10
9
11A-81
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11AREFITTING - PROCEDURE 1
I - PROCEDURE FOR AN ENGINE FITTED WITH A TIMING COVER WITHOUT A FLAP
1 - ADJUSTING THE TIMING
The first procedure is used when replacing any timi-ng component that does not require one or morecamshaft pulleys to be loosened.
Position the camshaft grooves horizontally and be-low the centre line by turning the camshafts usingthe (Mot. 799-01) if necessary.
Fit the (Mot. 1496) with (Mot. 1750) (11) .
Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts
WARNING
Replace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the pul-ley.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the accessories pulley contact surfaces,
- the camshaft ends (timing end),
- the camshaft sprocket bores and contact surfa-ces.
This is to avoid slippage between:
- the timing,
- the crankshaft,
- the camshaft sprockets.
This slippage causes engine damage.
111337
111336
11A-82
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Check that the mark (12) on the dephaser is verticaland pointing upwards.
Make a mark (13) with a pencil between the depha-ser wheel and the rocker cover.
103269
11A-83
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Check:
- that the crankshaft is correctly in contact with theTDC setting pin (Mot. 1489) (15) with the cranks-haft groove (14) facing upwards,
- that the inlet camshaft dephaser wheel is correctlylocked (wheel does not rotate right or left).
.
2 - REFITTING
Refit the tensioning roller by positioning the tensio-ning roller lug in the groove (16) .
Refit:
- the timing sprocket (18) ,
- the timing belt,
- the pulley (17) .
Tighten to torque the pulley mounting bolt (45 Nm)using (Mot. 1368) .
3 - BELT TENSION
Using a 6 mm Allen key, bring the adjustable indexmarker (19) opposite the notch (20) , by turning theeccentric (21) clockwise.
14489
108879
14487-3
103263
11A-84
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11ATighten to torque the tensioning roller mountingnut (7 Nm)
Refit the crankshaft accessories pulley.
Tighten to torque and angle the crankshaft acces-sories pulley bolt ( 40 Nm + 145˚ ±±±± 15˚ ) (cranks-haft in contact with the TDC setting pin).
Remove:
- the camshaft setting tool (Mot. 1496) ,
- the TDC setting pin (Mot. 1489) .
Rotate the crankshaft through two clockwise revolu-tions (timing end) before aligning the marks (on thecamshaft dephaser).
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.
Remove the TDC setting pin (Mot. 1489) .
Check that the adjustable index marker (22) is oppo-site the notch (23) .
Loosen the tensioning roller nut by up to one turn,holding the adjustable index with a 6 mm Allen key.
Gradually move the adjustable indexing marker (22)opposite the notch (23) turning the eccentric (24) ina clockwise direction.
103263
11A-85
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Tighten to torque the timing tensioning roller nut(27 Nm) (25) .
Check that the dephaser mark (26) is aligned withthe mark (27) .
4 - CHECKING THE TIMING AND TENSION
a - Checking the tension
Rotate the crankshaft through two clockwise revolu-tions (timing end) before aligning the marks (on thecamshaft dephaser).
Screw in the TDC setting pin (Mot. 1489) .
Move the crankshaft slowly and smoothly to rest onthe TDC setting pin (Mot. 1489) .
Remove the TDC setting pin.
Check that the tensioning roller markers are aligned.If not, repeat the tensioning procedure.
b - Checking the timing
Check that the timing pulley index markers are cor-rectly positioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly until it isresting against the pin.
Fit the camshaft adjusting the (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland below the centre line).
103267
WARNING
If the tool cannot be engaged, readjust the timingand the tension.
11A-86
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11AII - PROCEDURE FOR AN ENGINE FITTED WITH A TIMING COVER WITH A FLAP
1 - ADJUSTING THE TIMING
The first procedure is used when replacing any timi-ng component that does not require one or morecamshaft pulleys to be loosened.
Set the camshaft grooves horizontally and below thecentre line by turning the camshafts using the (Mot.799-01) if necessary.
Fit the (Mot. 1496) with (Mot. 1750) (28) .
Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts
WARNINGReplace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the pul-ley.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the accessories pulley contact surfaces,
- the camshaft ends (timing end),
- the camshaft sprocket bores and contact surfa-ces.
This is to avoid slippage between:
- the timing,
- the crankshaft,
- the camshaft sprockets.
This slippage causes engine damage.
111337
111336
11A-87
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Check that the mark (29) on the dephaser is verticaland pointing upwards.
Make a mark (30) with a pencil between the depha-ser wheel and the rocker cover.
103269
11A-88
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Check:
- that the crankshaft is correctly in contact with theTDC setting pin (Mot. 1489) (32) with the cranks-haft groove (48) facing upwards,
- that the inlet camshaft dephaser wheel is correctlylocked (wheel does not rotate right or left).
.
2 - REFITTING
Refit the tensioning roller by positioning the tensio-ning roller lug in the groove (33) .
Refit:
- the timing sprocket (35) ,
- the timing belt,
- the pulley (34) .
Tighten to torque the pulley mounting bolt (45 Nm)using (Mot. 1368) .
14489
108879
14487-3
14487-2
11A-89
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A3 - BELT TENSION
Move the adjustable index marker (36) opposite thenotch (37) , by turning the eccentric (38) clockwiseusing a 6 mm Allen key.
Refit the lower timing cover.
Refit the crankshaft accessories pulley.
Tighten to torque and angle the crankshaft acces-sories pulley bolt (40 Nm + 145˚ ±±±± 15˚) .
103263
109054
109055
11A-90
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Remove the timing flap from the lower timing cover.
Remove:
- the camshaft setting tool (Mot. 1496) ,
- the TDC setting pin (Mot. 1489) .
Rotate the crankshaft twice in a clockwise direction,on the timing end, before aligning the markings (onthe camshaft dephaser) already made by the opera-tor.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.
Remove the TDC setting pin (Mot. 1489) .
Using the lower timing cover window, check that theadjustable index marker (40) is opposite the notch(39) .
Loosen the timing tensioning roller nut by up to oneturn while holding the eccentric with a 6 mm Allenkey.
Gradually move the adjustable indexing marker (40)opposite the notch (39) turning the eccentric (41) ina clockwise direction.
Tighten to torque the timing tensioning roller nut(27 Nm) .
109052 109051
103263
11A-91
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A4 - CHECKING THE TIMING AND TENSION
a - Checking the tension
Rotate the crankshaft twice in a clockwise direction,on the timing end, before aligning the markings (onthe camshaft dephaser) already made by the opera-tor.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.
Remove the TDC setting pin.
Using the lower timing cover window, check that theindex marker and the timing tensioning roller notchare aligned.
Reset the tension by loosening the tensioning rollereccentric nut by up to one turn.
Align the adjustable indexing marker with the notch.
Tighten to torque the timing tensioning roller nut (27 Nm ) .
b - Checking the timing
Check that the index marker and the timing tensio-ning roller notch are correctly positioned beforechecking the timing.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly to pressagainst the TDC setting pin.
Position (without forcing) the camshaft timing tool(Mot. 1496) (the camshaft end grooves must be ho-rizontal and offset towards the bottom).
Refit the lower timing cover flap, checking that thepin (42) fits into the notch properly (43) .
14490
WARNING
The timing adjustment and tensioning operationmust be repeated if the camshaft setting tooldoes not engage.
109052
11A-92
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11AREFITTING -PROCEDURE 2
I - ADJUSTING THE TIMING
The second procedure is used for the replacementof all components requiring the loosening of one ormore of the camshaft pulleys.
Refit the camshaft pulleys and the old nuts, tighte-ning them to a torque of 15 Nm .
Position the camshaft grooves horizontally and off-set downwards, by turning the camshafts using the(Mot. 1496) if necessary.
WARNINGIf the stud is loosened with the nut (see Techni-cal Note 3887A, Replacement of K9 -K4 cams-haft pulley studs, 11A, Top and front ofengine, Camshaft ).
WARNING
Replace the timing belt, the crankshaft accesso-ries pulley bolt, the tensioning roller and the pul-ley.
WARNING
Be sure to degrease:
- the end of the crankshaft (timing end),
- the timing sprocket bore and contact surfaces,
- the accessories pulley contact surfaces,
- the camshaft ends (timing end),
- the camshaft sprocket bores and contact surfa-ces.
This is to avoid timing slippage.
This slippage causes engine damage.
14490
103261
11A-93
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Fit the (Mot. 1496) with (Mot. 1750) (44) .
Fix the (Mot. 1496) fitted with the (Mot. 1750) on theend of the camshafts
111337
111336
11A-94
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Check that the crankshaft is in contact with the TDCsetting pin (Mot. 1489) (45) (crankshaft groove (46)should be at the top).
14489
103269
11A-95
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Fit the camshaft dephaser into a vice with jaws.
Fit a bolt in the dephaser hub.
Check that the dephaser hub is mechanically secu-red correctly using a tubular hexagon box spanner(the hub must not be able to rotate towards the left orright).
Refit:
- the exhaust camshaft pulley with a new nut,
- the inlet camshaft dephaser with a new bolt.
Position:
- the RENAULT logo (47) engraved on the camshaftpulley spokes vertically at the top,
- the dephaser marking (48) vertically and at the top.
Make a mark (49) with a pencil between the depha-ser wheel and the rocker cover.
111338
111339
111340
11A-96
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11AII - REFITTING
When refitting the tensioning roller, ensure that thetensioning roller lug fits correctly into the groove (50).
Refit:
- the timing sprocket (51) ,
- the timing belt on the camshaft pulleys (without mo-ving the camshaft pulleys).
Fit the camshaft pulley locking tool (Mot. 1490-01)(52) (use the timing cover mountings to fit the tool).
Refit the pulley (53) .
Tighten to torque the pulley mounting bolt ( 45 Nm) using the (Mot. 1368) .
Refit the crankshaft accessories pulley (without tigh-tening the bolt, leaving 2 to 3 mm play between boltand pulley).
108879
14487-3
103265
14487-3
11A-97
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11AIII - BELT TENSION
Using a 6 mm Allen key, bring the adjustable indexmarker (54) opposite the notch (55) , by turning theeccentric (56) clockwise.
Tighten to torque the tensioning roller mountingnut (7 Nm).
Remove the camshaft pulley immobilising tool (Mot.1490-01) .
Rotate the timing system through six revolutionswith the exhaust camshaft pulley, using the (Mot.799-01) .
Check that the adjustable index marker (57) is ali-gned with the fixed index marker (58) .
Loosen the tensioning roller nut by up to one turn,holding the adjustable index with a 6 mm Allen key.
Gradually move the adjustable index marker (57)opposite the notch (58) , turning the eccentric (59) ina clockwise direction.
103263
Note:
Check that the camshaft pulley nuts and bolt donot come into contact with their respective pul-leys. In addition, from time to time, press thecamshaft pulleys against the camshafts.
103263
11A-98
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Tighten to torque the tensioning roller mountingnut (27 Nm) .
Check that:
- the RENAULT logo (60) engraved on the camshaftpulley spokes is positioned vertically at the top,
- the dephaser mark (61) is aligned with the mark(62) already made by the operator.
Fit the camshaft pulley immobilising tool (Mot. 1490-01) .
103268
14839
11A-99
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A
Tighten to torque and angle the crankshaft acces-sories pulley bolt (40 Nm + 145˚ ±±±± 15˚) (crankshaftin contact with the TDC setting pin).
Tighten to torque and angle the exhaust camshaftpulley nut ( 30 Nm + 84˚ ±±±± 4˚ ) .
Tighten to torque the inlet camshaft pulley depha-ser bolt ( 75 Nm ) .
Refit the new inlet camshaft dephaser blanking co-ver (64) .
Remove:
- (Mot. 1496) ,
- the camshaft pulley immobilising tool (Mot. 1490-01) ,
- the TDC setting pin (Mot. 1489) .
IV - CHECKING THE TIMING AND TENSION
1 - Checking the tension
Rotate the crankshaft clockwise through two revolu-tions (timing end).
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Slowly and smoothly position the crankshaft so thatis in contact with TDC setting pin (Mot. 1489) .
Remove the TDC setting pin (Mot. 1489) .
Check that the pulley indexes are aligned, otherwisecontinue with the tensioning process.
14489
WARNING
Check that the crankshaft is pressing against theTDC setting pin (Mot. 1489) (63) .
103265
11A-100
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K4M, and 730 or 732
11A2 - Checking the timing
Check that the tensioning roller indexes are correctlypositioned before checking the timing setting.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Move the crankshaft slowly and smoothly into posi-tion against the pin.
Fit the camshaft adjusting tool (Mot. 1496) withoutforcing (the camshaft grooves must be horizontaland offset downwards).
REFITTING
Refit the TDC pin plug, applying a drop of SILICONEADHESIVE SEAL onto the threading.
Tighten to torque the TDC pin plug ( 20 Nm ) .
Refit the lower timing cover.
Refit the upper timing cover.
Tighten to torque the upper timing cover nuts andbolts ( 41 Nm ) .
Refit:
- the suspended engine mounting (see 19D, Enginemounting, Suspended engine mounting ),
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- the new inlet camshaft sealing plugs (Mot. 1487) ,
- the new exhaust camshaft sealing plugs (Mot.1488) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the wheel bolts ( 110 Nm )
- the battery cover mounting bolts ( 4 Nm ) .
14490
WARNING
If the tool cannot be engaged, readjust the timingand the tension.
15103-1
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
11A-101
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11AI - PRECAUTIONS FOR REPAIR
II - PARTS AND CONSUMABLES FOR THE REPAIR
Parts always to be replaced:
- timing belt,
- timing belt tensioning roller,
- crankshaft accessories pulley bolts.
Consumables:
- Silicone adhesive seal part no. 77 11 227 484 .
III - ESSENTIAL EQUIPMENT
Equipment:
- Protective gloves,
- Large screwdriver,
- female torx socket ( 14 ),
- Allen key ( 6 mm ),
- Offset spanner ( 18 mm ),
- bolt tightening gauge,
- Torque wrench.
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1489 TDC locating pin
Mot. 1430 Set of 5 crankshaftand camshaft pulleytiming pins
Tightening torquesm
camshaft pulley wheelbolts
14 Nm
tensioning roller bolt 27 Nm
camshaft pulley wheelbolts
14 Nm
crankshaft pulley M14bolt
120 Nm + 95˚±±±± 15˚
TDC pin plug cap 20 Nm
cylinder head suspen-ded mounting bolts
21 Nm
ball joint bracket moun-ting bolts with theirsprings
21 Nm
wheel bolts 110 Nm
IMPORTANTWear protective gloves during all operations.
WARNING
The belt must be replaced with a new one if ithas been removed.
Never turn the engine in the opposite direction toits normal operation.
Do not run the engine without the accessoriesbelt so as not to break the crankshaft accesso-ries pulley.
When replacing the belt, be sure to replace thetensioning rollers and pulleys.
11A-102
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11AIV - REMOVAL
1 - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove:
- the engine covers,
- the scuttle panel grille (see MR 365 Bodywork,55A, Exterior protection, Scuttle panel grille ),
- the front right-hand wheel,
- the right-hand wheel arch liners,
- the engine undertray,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ).
Fit the (Mot. 1453) and the (Mot. 1453-01) with theretaining straps.
Remove:
- the exhaust ball joint bracket mounting bolts,
- the lower engine tie-bar mounting bolts.
Detach the manual priming pump.
102450
102451
WARNING
Be careful not to damage the air conditioningpipes.
11A-103
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Remove the right-hand suspended mounting (1) and(2) (see 19D, Engine mounting, Right-hand sus-pended mounting: Removal - Refitting ).
Unclip the tabs (3) .
Remove:
- the upper timing cover,
- the plastic bolt (4) .
Unclip the tabs (5) .
Remove the lower timing cover.
Undo the cylinder head suspended mounting bolts.
Twist the timing belt slightly (to remove the cylinderhead suspended mounting).
Remove the cylinder head suspended mounting (6) .
113927
112990
112998
112989
11A-104
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Remove the TDC pin plug (7) using a torx socket(14).
2 - OPERATION FOR REMOVAL OF PART CONCERNED
Turn the crankshaft to position the hole (8) of thecamshaft pulley almost opposite the hole (9) in thecylinder head.
Screw in the TDC setting pin (10) (Mot. 1489) .
Turn the crankshaft clockwise (timing end) smoothlyuntil the crankshaft is pressed against the TDC set-ting pin.
19650
107270
19650-1
14489
11A-105
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Engage the pin (11) (Mot. 1430) in the camshaftpulley and cylinder head holes.
Remove:
- the timing pin from the camshaft pulley (Mot. 1430),
- the TDC setting pin (Mot. 1489) .
Remove the crankshaft accessories pulley, lockingthe engine flywheel using a screwdriver passing itthrough orifice under the starter motor.
Undo the tensioning roller bolt (12) to slacken the ti-ming belt.
Remove:
- the timing belt,
- the timing tensioning roller.
109049
107260
109046
11A-106
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11AV - REFITTING
1 - REFITTING PART CONCERNED
Refit the timing tensioning roller.
Place the tensioning roller lug (13) in the cylinderhead groove (14) .
Engage the pin (15) (Mot. 1430) in the holes of thecamshaft pulley and cylinder head, turning thecamshaft using an 18 mm offset spanner if necessa-ry.
Check that:
- the mark on the high-pressure pump (16) is offsetby one tooth to the right of the vertical axis (17) ,
- the crankshaft is in contact with the TDC setting pin(Mot. 1489) (crankshaft timing sprocket collet (18)at the top).
Remove one bolt from the camshaft pulley wheel.
Loosen the two other camshaft pulley wheel bolts(19) by one turn.
109042
109043
14489
109042
11A-107
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Fit the timing belt, starting with the crankshaft sproc-ket, aligning the marks on the belt with those on thecrankshaft sprockets, the camshaft and the high-pressure pump. There should be 19 tooth spacesbetween the sprocket marks and 51 tooth spacesbetween the crankshaft sprockets and the high pres-sure pump.
109044
11A-108
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Position the tensioning roller adjustable index mar-ker (20) opposite the lug (21) using a 6 mm Allenkey, turning it anti-clockwise.
Tighten to torque the tensioning roller bolt (27Nm) .
Check that the camshaft pulley hub bolts are not ful-ly up against the camshaft pulley wheel.
19658
109047
11A-109
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Refit camshaft pulley wheel bolt (22) .
Tighten to torque the camshaft pulley wheel bolts( 14 Nm ) .
Remove:
- the TDC setting pin (Mot. 1489) ,
- the timing pin from the camshaft pulley (Mot. 1430),
Tighten the old crankshaft accessories pulley bolt fit-ted with a spacer (23) (which does not cover the timi-ng sprocket mark) onto the crankshaft.
109045
107272
11A-110
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Rotate the crankshaft twice in a clockwise direction(timing end) before the camshaft pulley hole (24) isopposite the cylinder head hole (25) .
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Bring the crankshaft slowly and smoothly against theTDC setting pin.
Set the camshaft pulley using the (Mot. 1430) .
If the (Mot. 1430) does not engage:
loosen the camshaft pulley wheel bolts by one turn,
Turn the camshaft pulley hub using an offset span-ner to facilitate setting of the camshaft pulley hub.
Do not retighten the camshaft pulley wheel bolts.
107270
109049
109048
11A-111
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Check that the crankshaft timing sprocket collet (26)is positioned vertically facing upwards.
109045
Note:
After two turns, the tensioning roller markers maybe in two different positions.
The rotation of the tensioning roller eccentricdepends on the position.
11A-112
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11Aa - First position
Loosen the tensioning roller bolt by a maximum ofone turn, holding the tensioning roller using a 6 MMAllen key.
Gradually align the adjustable index marker (27) tothe middle of the timing window (28) , turning the keyanti-clockwise.
b - Second position
Loosen the tensioning roller bolt by a maximum ofone turn, holding the tensioning roller using a 6 MMAllen key.
Gradually align the adjustable index marker (29) tothe middle of the timing window (30) , turning the keyclockwise.
Tighten to torque:
- the tensioning roller bolt ( 27 Nm ) ,
- the camshaft pulley wheel bolts ( 14 Nm ) .
111083
111081
111082
111081
11A-113
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11ARemove:
- the TDC setting pin (Mot. 1489) ,
- the camshaft pulley timing pin (Mot. 1430) .
Rotate the crankshaft twice in a clockwise direction(timing end) before the camshaft pulley hole is oppo-site the cylinder head hole.
Screw the TDC setting pin (Mot. 1489) into the cylin-der block.
Bring the crankshaft slowly and smoothly against theTDC setting pin.
Set the camshaft pulley using the (Mot. 1430) .
If this is not possible, repeat the operation for refit-ting the timing belt.
Refit the accessories crankshaft pulley with a newbolt.
Tighten to torque and angle (crankshaft in contactwith the TDC setting pin) the crankshaft pulley M14bolt ( 120 Nm + 95˚ ±±±± 15˚ )
Remove the following tools:
- TDC setting pin (Mot. 1489) ,
- timing pin from camshaft pulley (Mot. 1430) .
2 - FINAL OPERATION
Refit the TDC pin plug, coating the thread with SILI-CONE ADHESIVE SEAL .
Tighten to torque the TDC pin plug cap ( 20 Nm ) .
109049
107260
11A-114
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Refit the cylinder head suspended mounting (31) .
Tighten to torque the cylinder head suspendedmounting bolts ( 21 Nm )
Refit:
- the lower timing cover (32) , positioning the tab (33)in the hole (34) in the inner timing cover,
- the timing cover plastic bolt (35) .
112989 112990
19659
11A-115
TOP AND FRONT OF ENGINETiming belt: Removal - Refitting
K9K, and 732
11A
Refit the upper timing cover (36) Refit the right-hand suspended mounting support(see 19D, Engine mounting, Right-hand suspen-ded engine mounting: Removal - Refitting ).
Remove the (Mot. 1453) and the (Mot. 1453-01) .
Refit the manual priming pump
Refit:
- the rear suspended engine mounting (see 19D,Engine mounting, Right-hand suspended engi-ne mounting: Removal - Refitting ).
- the exhaust ball joint bracket mounting bolts
Tighten to torque the ball joint bracket mountingbolts with their springs ( 21 Nm )
Refit:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- the right-hand wheel arch liner,
- the front right-hand wheel,
- the engine undertray,
- the scuttle panel grille (see MR 365 Bodywork,55A, Exterior protection, Scuttle panel grille ),
- the engine covers.
Tighten to torque the wheel bolts ( 110 Nm )
Connect the battery (see 80A, Battery: Removal -Refitting ).
112990 113927
11A-116
TOP AND FRONT OF ENGINETiming chain: Removal - Refitting
M9R, and 700
11AREMOVAL
Removing the timing chain requires the engine andgearbox assembly to be removed (see 10A, Engineand peripherals, Engine and gearbox assembly:Removal - Refitting ).
To remove the timing chain (see Technical Note6017A, M9R diesel engine ).
REFITTINGTo refit the timing chain (see Technical Note6017A, M9R diesel engine ).
Refit the engine and gearbox assembly (see 10A,Engine and peripherals, Engine and gearbox as-sembly: Removal - Refitting ).
11A-117
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
REMOVALPosition the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine covers,
- the engine undertray,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).
Special tooling required
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1490-01 Locking and adjustingcamshaft pulleys
Mot. 1573 Cylinder head support
Mot. 104 Cylinder head ali-gning tool
Ele. 1382 Spark plug spannertoolkit 16 & 21 mm tor-que 1.75 & 28 Nm +square adapter 9-9.52for spanner Ele. 1086
Mot. 1491 Camshaft oil seal fit-ting tool
Mot. 1632 Tool for fitting thecamshaft seal
Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)
Mot. 1488 Tool for refitting cams-haft covers (43 mmdiameter)
Equipment required
cylinder head testing tool
Tightening torquesm
rocker cover mountingbolts 22, 23, 20, 13
12 Nm
oil separator mountingbolts (new) in the non-threaded housings
15 Nm
(new or original) oilseparator mount ingbolts in the pre-threadedhousings
10 Nm
plugs 25 to 30 Nm
coil mounting bolts (ifthe holes are alreadythreaded)
12 Nm
coil mounting bolts (ifthe holes are not threa-ded)
15 Nm
inlet manifold mountingbolts
9 Nm
battery cover bolts 4 Nm
Tightening torquesm
11A-118
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Set up the engine stand (1) (Mot. 1672)
Remove the (Mot. 1453) and (Mot. 1453-01) .
Remove the camshaft pulleys using camshaft pulleylocking tool (2) (Mot. 1490-01) .
Loosen the stud with the nut if necessary (see Tech-nical Note 3887A, Replacement of K9 - K4 cams-haft pulley studs, 11A, Top and front of engine,Camshaft ).
Remove:
- the injection rail protector,
- the fuel supply pipe from the injection rail.
Move the fuel supply pipe aside.
Remove bracket mounting bolt (1) .
Move the bracket to one side.
Remove the wiring harness bracket mounting bolt(2) .
Disconnect:
- the brake servo vacuum pipe (3) from the inlet ma-nifold.
- the connector (4) from the coolant temperaturesensor,
- the water unit hoses,
105432
101876
IMPORTANT
Be careful of petrol splashing out when discon-necting the fuel supply union.
1
218699
14889
1
3
4
2
11A-119
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11AMove the bracket/wiring harness assembly aside.
Disconnect:
- the ignition coil connectors (5) ,
- the air temperature sensor connector (6) ,
- the inlet manifold pressure sensor connector (7) ,
- the fuel vapour recirculation solenoid valve pipe (8),
- the catalytic converter upstream oxygen sensorconnector.
Disconnect the connector (9) from the injectors
Unfasten the clip (10) .
Move the wiring harness to one side.
Remove:
- the ignition coils,
- the plugs,
- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting ).
- the throttle valve (see 12A, Fuel mixture, Throttlevalve: Removal - Refitting ).
18666
5
5
8 7
6
104240
10
9
11A-120
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Remove:
- the lifting bracket (11) ,
- the inlet manifold mounting bolts (12)
- the inlet manifold.
Remove:
- the catalytic converter/gearbox stay mounting bolts(13) ,
- the catalytic converter/gearbox stay
- the exhaust pipe mounting nuts (14) .
Detach the exhaust pipe.
Remove:
- the oil separator mounting bolts (15) ,
- the oil separator.
Remove:
- the rocker cover mounting bolts,
- detach the rocker cover vertically, tapping the lugs(16) with a copper hammer.
18706
101793
12121212
11
13
141414
18431
103256
WARNING
Do not damage the aluminium surfaces.
151515
16
16
11A-121
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Remove the inlet and exhaust camshafts.
14498
11A-122
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Remove:
- the valve rockers (17) ,
- the hydraulic tappets (18) .
Remove:
- the cylinder head mounting bolts,
- the cylinder head.
Mount the cylinder head on the cylinder head moun-ting (Mot. 1573) .
Remove the cylinder head gasket from the cylinderblock.
I - CLEANING THE CYLINDER HEAD
Clean the gasket faces with DÉCAPJOINT to dissol-ve any parts of the seal still attached to the lower co-ver and the cylinder block.
Apply the product to the section to be cleaned; Waitapproximately ten minutes, then remove the residueusing a wooden spatula.
II - CHECKING THE GASKET FACE
Use a ruler and feeler gauge to check that there isno gasket face bow.
Maximum bow: 0.05 mm
Test the cylinder head to detect any possible cracksusing the cylinder head testing tool .
For the cylinder head stripping procedure (seeTechnical Note 3784A, K4 4-cylinder petrol engi-ne, 10A, Engine and peripherals, Rebuilding thecylinder head) .
Position the pistons at mid-stroke to prevent anycontact with the valves when refitting the camshafts.
Be sure to degrease:
- the cylinder head combustion face,
- the cylinder block combustion face.
14499
Note:
To prevent any risk of unpriming the hydraulictappets make sure that they are vertical.
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
18
17
WARNING
Do not allow this product to drip onto the pain-twork.
Clean the cylinder head carefully to preventforeign bodies from entering the oil supply andreturn pipes.
Failure to follow this guideline could lead to bloc-kage of the oilways, resulting in rapid and seriousdamage to the engine.
WARNING
No regrinding of the cylinder head is permitted.
11A-123
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Check that the centring dowel is present (19) on thecylinder block.
Fit the (Mot. 104) (20) onto the cylinder block.
REFITTING
Fit the new cylinder head gasket.
Refit the cylinder head.
Check the cylinder head tightening bolts (see 11A,Top and front of engine, Cylinder head gasket:Removal - Refitting ).
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ).
Reprime the hydraulic tappets (hydraulic tappetsmay empty after a long down time).
To check if repriming is necessary, press the top ofthe tappet (21) with your thumb.
If the tappet piston depresses:
- immerse the tappets in a container full of dieselfuel,
- refit the hydraulic tappets.
Refit:
- the valve rockers,
- the camshafts, oiling the bearings.
14689
20 19
14499
21
11A-124
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11AI - CAMSHAFT MARKINGS
Inlet camshaft
Position the groove (22) on the end of the camshafthorizontally (groove below the centre line of thecamshaft).
The cams (23) for cylinder 1 must be located to theright of the vertical axis (24) , flywheel end view.
101880
11A-125
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11AExhaust camshaft
Position groove (25) horizontally on the end of thecamshaft (groove below the centre line of the cams-haft).
The cams (26) for cylinder 1 must be located to theleft of the vertical axis (27) , flywheel end view.
101881
11A-126
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Position the camshaft grooves horizontally and off-set downwards.
Using a stipple roller, apply LOCTITE 518 to thecamshaft rocker cover gasket face until it turns red-dish.
Using a cloth, remove the LOCTITE 518 from (28)the six camshaft rocker cover bearings.
Refit the rocker cover.
15106-1
WARNING
The sealing faces must be clean, dry and free ofgrease.
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould damage certain components (engine,radiator).
WARNING
Do not apply oil to the rocker cover gasket faces.
14517
28
11A-127
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11AII - TIGHTENING PROCEDURE
Tighten to torque and in order:
- rocker cover mounting bolts 22, 23, 20, 13 , 8Nm ,
- rocker cover mounting bolts 1 to 12, 14 to 19,21 to 24 (12 Nm) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order rocker cover moun-ting bolts 22, 23, 20, 13 ( 12 Nm ) .
14497
11A-128
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Using a stipple roller, apply LOCTITE 518 to thegasket face until it is reddish in colour.
Refit the oil separator.
Torque tighten in order
- the oil separator mounting bolts (new) in thenon-threaded housings ( 15 Nm )
- the (new or original) oil separator mountingbolts in the pre-threaded housings ( 10 Nm )
101869
WARNING
the gasket faces must be clean, dry and free ofgrease.
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould damage certain components (engine,radiator).
18431
8
7
6
54
3
2
1
11A-129
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
On the four ignition coils, apply a bead (2 9) ofFLUORINATED GREASE 82 00168 855 2 mm indiameter to the inner circumference of the high-ten-sion cap.
Refit the plugs.
Tighten to torque the plugs ( 25 to 30 Nm ) usingthe plug spanner set (Ele. 1382) .
Refit the coils.
Tighten to torque:
- the coil mounting bolts (if the holes are alreadythreaded) ( 12 Nm ) ,
- the coil mounting bolts (if the holes are notthreaded) ( 15 Nm ) ,
Always replace all the inlet manifold seals.
106443
29
11A-130
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Tighten to torque and in order the inlet manifoldmounting bolts ( 9 Nm ) .
Refit:
- the throttle valve (see 12A, Fuel mixture, Throttlevalve: Removal - Refitting ).
- the air filter unit (see 12A, Fuel mixture, Air filterunit: Removal - Refitting ).
III - REPLACING THE CAMSHAFT SEALS
There are two types of elastomer camshaft sealwhich are easy to identify.
The first type of elastomer seal is fitted with a spring(30) with a lip seal (31) in the shape of a « V »
14497-1
20256
31
30
11A-131
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
The second type of elastomer seal is fitted with a flatlip seal (32) and a protector (33) (which also assistsin fitting the seal to the engine).
1 - Fitting the first seal type to the inlet camshaft
Fit the seals using the (Mot. 1491) (34) and the oldnuts (35) .
20257
Note:
Both seal versions can be fitted on the sameengine. They are not interchangeable. It isessential to use the same version when replacingan old seal, except when one or more camshaftsare replaced.
3332
14892
35
34
11A-132
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A2 - Fitting the seal to the exhaust camshaft
Screw the stud of (38) the (Mot. 1632) onto thecamshaft.
18687
WARNING
It is very important to hold the protector (36)when handling the seal, as this type of seal isvery fragile. It is strictly forbidden to touch theelastomer seal (37) in order to prevent any oilleaks once the seal is fitted to the engine.
3736
105531
21687
38
38
11A-133
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Fit the protector, with a seal, to the camshaft.
Fit cover (39) and the collar nut (40) of the (Mot.1632) .
Screw in the collar nut until the cover comes intocontact with the cylinder head.
Remove the nut, cover, protector and threaded rod.
IV - REFITTING
Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal - Refitting ).
21687-1
21687-2
39
40
21687-3
WARNING
Follow the second procedure in the timing beltrefitting procedure.
11A-134
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4J, and 730 or 732
11A
Refit:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- new inlet camshaft sealing plugs using the (Mot.1487) ,
- new exhaust camshaft sealing plugs using the(Mot. 1488) ,
Proceed in the reverse order to removal.
Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 16A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
15103-1
11A-135
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11A
Special tooling required
Car. 1363 Trim removal lever
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
diagnostic tool
cylinder head testing tool
angular tightening wrench
Tightening torquesm
rocker cover mountingbolts
10 Nm
turbocharger oil returnpipe
9 Nm
intercooler hose clip 5.5 Nm
battery cover bolts 4 Nm
IMPORTANT
Before any operation:
- connect the diagnostic tool ,
- establish dialogue with the injection computer,
- check that the injection rail is depressurised,
- be aware of the fuel temperature,
- order the special high-pressure injection circuitplug kit.
WARNING
Procedure for removing the air inlet duct (K9K 728 and 729):
- make a mark on the inlet duct between the stain-less steel pipe and the hose,
- detach the hose, using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the stainless steel pipe and the hose with adry, lint-free cloth,
- refit the clip in the same recess in the event thatthe hoses are not replaced,
- rotate the clip around its axis to make torque tigh-tening easier,
- it is essential to replace the hose and/or the stain-less steel pipe in the event of damage.
There is a risk of leaks or dislodging if this proce-dure is not followed.
11A-136
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11AREMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the battery,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).
Fit the engine stand (Mot. 1672) .
Remove the (Mot. 1453) and (Mot. 1453-01) .
Disconnect:
- the air temperature and pressure sensor connector(1) ,
- the exhaust gas recirculation valve control connec-tor (2) ,
- the air hoses (3) ,
- the air hose (4) ,
- the turbocharging pressure regulation valve rubberpipe,
- the air sleeve from the air filter unit,
- the oil vapour rebreathing pipe from the rocker co-ver.
Remove the air resonator unit mounting stay (5) .
105432
K9K, and 722
102081
2
1
5
4 33
11A-137
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11A
Disconnect:
- the air temperature and pressure sensor connector(6) ,
- the exhaust gas regulation valve control connector(7) ,
- the engine speed and position sensor connector(8) ,
- the air hose (9) ,
- the rubber hose from the turbocharging pressurecontrol valve.
Pull out the clip.
Make a mark on the inlet duct between the stainlesssteel pipe and the hose (10) .
Undo the bolt (11) .
Remove the air duct (12) .
K9K, and 728 or 729
110326
9
87
6
110325
110322
11
10
12
11A-138
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11A
Disconnect:
- the injector connectors,
- the heater plug connectors,
- the rail pressure sensor connectors,
- the diesel fuel supply pipe from the pump,
- the diesel return pipe from the pump,
- the fuel temperature sensor (13) ,
- the fuel flow actuator connector (14) .
Remove the wiring and diesel return pipe support(15) .
Disconnect:
- the water unit hoses (16) using the (Mot. 1202-01)or (Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (17) on the vacuumpump side,
- the coolant temperature sensor connector on thewater unit.
- the radiator top hose from the cylinder head wateroutlet using the (Mot. 1202-01) or (Mot. 1202-02)or (Mot. 1448) .
Unclip the heater radiator hose (18) .
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).
102086
13
1515
14
102263
17
16
18
11A-139
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11A
Disconnect the turbocharger oil return pipe (19) .
Remove the inner timing cover (20) .
Remove:
- the rocker cover mounting bolts (21) ,
- the rocker cover.
Remove:
- the cylinder head mounting bolts (22) ,
- the cylinder head.
104175
19710
19
2020
19711
19712
21212121
222222
222222
11A-140
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11AI - CLEANING
Clean the cylinder head.
Clean the gasket faces with DÉCAPJOINT to dissol-ve the section of the gasket which is still attached.
Apply the product to the section to be cleaned; waitapproximately ten minutes, then remove the residueusing a wooden spatula.
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a feelergauge.
The maximum bow is 0.05 mm .
Test the cylinder head to detect any possible cracksusing the cylinder head testing tool .
For the cylinder head stripping procedure (seeTechnical Note 6006A, 4 cast iron cylinder HighPressure Common Rail Diesel Engine, 10A, En-gine and peripherals, Rebuilding the cylinderhead ).
REFITTINGProceed in the reverse order to removal.
Fit the new cylinder head gasket, centred by twodowels.
Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.
Refit the cylinder head.
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) usingthe angular tightening wrench .
Fit the new rocker cover gasket.
Apply beads (23) of SILICONE ADHESIVE SEAL 2mm in diameter.
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
WARNING
Please make sure, during this operation, that noforeign bodies enter the oilways (galleries in boththe cylinder block and the cylinder head).
WARNING
Protect the oilway to prevent any foreign bodiesfrom entering the cylinder head oil supply galle-ries.
Failure to follow this advice could lead to the pipeblocking, quickly damaging the camshaft.
WARNING
No regrinding of the cylinder head is permitted.
WARNING
The sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).
WARNINGThe sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Applying excess sealant could cause it to besqueezed out when parts are tightened. The pro-duct-fluid mix may damage some components(engine, radiator).
19712-1
23
23
2323
11A-141
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 722 or 728 or 729
11A
Refit the rocker cover.
Tighten to torque and in order the rocker covermounting bolts ( 10 Nm ) .
Reconnect the turbocharger oil return pipe, fittedwith new seals.
Tighten to torque the turbocharger oil return pipe( 9 Nm ) .
Reconnect:
- the oil vapour rebreather pipe,
- the new turbocharger air sleeves.
Reconnect the air duct by aligning the marks.
Tighten to torque the intercooler hose clip ( 5.5Nm ) .
Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Fill the cooling circuit (see 19D, Cooling, Coolingcircuit: Draining-refilling ).
Reprime the diesel circuit (see 13B, Fuel supply,Diesel fuel supply circuit ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .19711
19709
K9K, and 728 or 729
3
2
1
8
7
65
4
11A-142
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 800 or 808
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the battery tray,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).
Fit the engine stand (Mot. 1672) .
Remove the (Mot. 1453) and (Mot. 1453-01) .
Special tooling required
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
diagnostic tool
cylinder head testing tool
angular tightening wrench
Tightening torquesm
oil supply pipe bolt onthe turbocharger
22.5 Nm
oil supply pipe bolt onthe cylinder block
22.5 Nm
oil return pipe bolts 12 Nm
battery cover bolts 4 Nm
IMPORTANT
Before any operation:
- connect the diagnostic tool ,
- establish dialogue with the injection computer,
- check that the injection rail is depressurised,
- be aware of the fuel temperature,
- order the special high-pressure injection circuitplug kit.
WARNING
Fit plugs in the openings.
Be sure to follow the safety instructions.
Refer to (see 13B, Diesel injection, Cleanlinessguidelines ).
105432
11A-143
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 800 or 808
11A
Disconnect:
- the air filter outlet duct (1) ,
- the air duct (2) towards the turbocharger,
- the oil vapour rebreathing pipe (3) ,
- the engine damping device valve pipe (4) .
Remove:
- the air duct (5) from the inlet manifold,
- the oil vapour rebreathing canister (6) .
Remove the vacuum tank mounting bolts (7) .
Disconnect:
- the turbocharger pressure regulation solenoid val-ve pipes,
- the engine damping device solenoid valve connec-tor (8) ,
- the camshaft sensor connector (9) .
Remove the vacuum tank.
105511
1
2
3
4
5
6
18983
7
89
11A-144
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 800 or 808
11A
Disconnect:
- the exhaust gas recirculation solenoid valve con-nector (10) ,
- the injector connectors (11) ,
- the heater plug connectors (12) ,
- the rail pressure sensor connector (13) ,
- the high-pressure pump pressure regulator con-nector (14) ,
- the diesel return temperature sensor connector(15) ,
- the diesel filter connector,
- the diesel fuel supply pipe (16) ,
- the diesel return pipe (17) .
Insert the blanking plugs.
Move the wiring harnesses to one side.
Disconnect:
- the cylinder head outlet water unit hoses using the(Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the connector (18) from the coolant temperaturesensor.
Remove the three high-pressure pump supportmounting bolts (19) .
105512
10
11
1112
12
13
14
1516
17
104323
102348
18
19
11A-145
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 800 or 808
11A
Remove:
- the catalytic converter (20) (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).
- the oil supply pipe (21) ,
- the oil return pipe mountings (22) on the turbochar-ger.
Remove the cylinder head mounting bolts (23) .
Remove the cylinder head. This operation requirestwo people.
I - CLEANING
Clean the cylinder head.
Clean the gasket faces with DÉCAPJOINT to dissol-ve the section of the gasket which is still attached.
18997
20
21
22
16189
WARNING
When removing the cylinder head, take care notto cause any damage to its gasket face as it pas-ses the turbocharger above it.
IMPORTANTDo not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
2323232323
11A-146
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 800 or 808
11AApply the product to the section to be cleaned; waitapproximately ten minutes, then remove the residueusing a wooden spatula.
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a feelergauge.
The maximum bow is 0.05 mm .
Test the cylinder head to detect any possible cracksusing the cylinder head testing tool .
For the cylinder head stripping procedure (seeTechnical Note 3652A, 4-cylinder Cast Iron HighPressure Common Rail Diesel Engine, 10A, En-gine and peripherals, Rebuilding the cylinderhead ).
REFITTING
Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.
Fit the cylinder head gasket.
Refit the cylinder head.
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) using aangular tightening wrench .
Tighten to torque:
- the oil supply pipe bolt on the turbocharger (22.5 Nm ) ,
- the oil supply pipe bolt on the cylinder block (22.5 Nm ) ,
- the oil return pipe bolts ( 12 Nm ) .
Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining-refilling ).
Reprime the diesel circuit (see 13A, Fuel supply,Diesel fuel supply circuit ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
WARNING
To prevent any foreign bodies from entering theoil pipes (pipes in both the cylinder block andcylinder head).
WARNING
Protect the oilway to prevent any foreign bodiesfrom entering the cylinder head oil supply galle-ries.
Failure to follow this advice could block the oilsupply pipes, causing rapid camshaft damage.
WARNING
The cylinder head bolts must be replaced eachtime they are removed and must not be oiledbefore being fitted.
WARNING
No regrinding of the cylinder head is permitted.
11A-147
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).
Fit the engine stand (Mot. 1672) .
Special tooling required
Mot. 1672 Lower engine support
Mot. 1509 Camshaft sprocketlocking tool
Mot. 1509-01 Conversion kit for Mot.1509
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1573 Cylinder head support
Mot. 1517 Camshaft seal fittingtool
Mot. 1512 Camshaft oil seal fit-ting tool (28 x 47)
Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)
Mot. 1488 Tool for refitting cams-haft covers (43 mmdiameter)
Equipment required
cylinder head testing tool
angular tightening wrench
Tightening torquesm
rocker cover bolts 22,23, 20, 13
(8 Nm)
rocker cover bolts 1 to12, 14 to 19, 21 to 24
(12 Nm)
new or original oil sepa-rator mounting bolts (inthreaded holes)
10 Nm
new oil separatormounting bolts (in non-threaded holes)
15 Nm
plugs 25 to 30 Nm
coils (if holes alreadythreaded)
12 Nm
coils (if holes not threa-ded)
15 Nm
inlet manifold 9 Nm
battery cover mountingbolts
4 Nm
105432
Tightening torquesm
11A-148
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Fit the (Mot. 1509) with the gear (Mot. 1509-01) .
Tighten the collar nut (1) and the bolt (2) , then bringthe gears of (Mot. 1509) into contact with the cams-haft pulleys while torque tightening the nuts (80Nm) (3) .
Remove the inlet camshaft dephaser blanking coverusing a 14 mm Allen key.
Remove:
- the exhaust camshaft pulley nut,
- the inlet camshaft dephaser mounting bolt,
Loosen the nut stud if necessary (see TechnicalNote 3887A, Replacement of F4 camshaft pulleystuds, 11A, Top and front of engine, Camshaft ).
Remove the bracket mounting bolts (4) .
Move the bracket to one side.
16019-4
3
2
1
3
16019-4
18699
4
11A-149
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Remove the wiring harness bracket mounting bolts(5) .
Disconnect:
- the connector (6) from the coolant temperaturesensor,
- the water unit hoses using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (7) on the inlet mani-fold side.
Move the bracket/wiring harness assembly aside.
Disconnect:
- the ignition coil connectors (8) ,
- the air temperature sensor connector (9) ,
- the camshaft dephaser connector (10) ,
- the inlet manifold pressure sensor connector (11) ,
- the fuel vapour recirculation solenoid valve pipe(12) ,
- the injector connectors,
- the upstream oxygen sensor connector.
Unclip the wiring harness clip.
Move the wiring harness to one side.
Remove:
- the ignition coils,
- the plugs,
- the dephaser solenoid valve.
14889
102735
5
6
7
18666
8
8
9
101112
11A-150
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Remove:
- the lifting bracket (13) at the timing end,
- the inlet manifold mounting bolts (14) ,
- the inlet manifold.
Remove:
- the catalytic converter/gearbox stay mounting bolts(15) ,
- the catalytic converter/gearbox stay,
- the exhaust pipe mounting nuts (16) .
Remove:
- the oil separator mounting bolts.
- the oil separator (17) ,
- the lifting bracket at the flywheel end (18) .
102939
101793
13
14141414
1515
161616
102940
1817
11A-151
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Remove the rocker cover bolts.
Remove the rocker cover vertically, tapping the lugs(19) with a copper hammer.
Remove the camshaft seals.
102941
WARNING
Do not damage the aluminium surfaces.
19
19
11A-152
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Remove the inlet and exhaust camshafts (20)
15151
20
11A-153
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Remove:
- the valve rockers (21) ,
- the hydraulic tappets (22) .
14499
Note:
To prevent any risk of unpriming the hydraulictappets make sure that they are vertical.
21
22
11A-154
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Remove:
- the cylinder head bolts,
- the cylinder head.
Mount the cylinder head on the cylinder head moun-ting (Mot. 1573) .
Remove the cylinder head gasket from the cylinderblock
I - CLEANING
Clean the gasket faces with DÉCAPJOINT to dissol-ve any sections where the seal is still attached.
Apply the product to the section to be cleaned; Waitfor approximately ten minutes, then remove it usinga wooden spatula.
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a feelergauge.
Maximum bow: 0.05 mm
Test the cylinder head to detect any cracks using thecylinder head testing tool (see Technical Note3783A, F4 4-cylinder petrol engine, 10A, Engineand peripherals, Rebuilding the cylinder head)for the cylinder head stripping procedure.
Position the pistons at mid-stroke to prevent anycontact with the valves when the camshafts arebeing refitted.
15153
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
WARNING
To prevent any foreign bodies from entering theoil pipes (pipes in the cylinder block and cylinderhead).
WARNING
No regrinding of the cylinder head is permitted.
11A-155
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11ABe sure to degrease:
- The combustion face of the cylinder head,
- the combustion face of the cylinder block.
REFITTING
Fit the new cylinder head gasket.
Refit the cylinder head.
Check the bolts (see 11A, Top and front of engine,Tightening the cylinder head ).
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) using aangular tightening wrench .
Re-prime the hydraulic tappets (hydraulic tappetsmay empty if they have been removed for some ti-me).
To check or reprime them, press the top of the tap-pet at (23) with your thumb.
If the tappet piston depresses:
- immerse the tappets in a container full of dieselfuel,
- refit the hydraulic tappets.
Refit:
- the valve rockers,
- the camshafts, oiling the bearings.
The camshafts are identified by the pulley moun-tings.
Detailed view of the pulley mountings:
- (24) : exhaust camshaft,
- (25) : inlet camshaft.
14499
23 15152
2524
11A-156
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Position the camshaft grooves as shown in the dia-gram.
Using a stipple roller, apply LOCTITE 518 to thecamshaft rocker cover gasket face until it is reddishin colour.
Refit the rocker cover.
15106-1
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.).
WARNING
Do not apply oil to the sealing face of the cams-haft bearing cap cover.
14517
Note:
Using a cloth, remove the LOCTITE 518 from(26) the camshaft rocker cover bearings.
26
11A-157
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Tighten to torque and in order:
- rocker cover bolts 22, 23, 20, 13 ( (8 Nm) ) ,
- rocker cover bolts 1 to 12, 14 to 19, 21 to 24 ((12 Nm) ) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order mounting bolts 22,23, 20, 13 (12 Nm) .
14497
11A-158
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Using a stipple roller, apply LOCTITE 518 to the jointface of the oil separator until it is reddish in colour.
Refit the oil separator.
Tighten to torque and in order:
- the new or original oil separator mounting bolts(in threaded holes) ( 10 Nm ) ,
- the new oil separator mounting bolts (in non-threaded holes) ( 15 Nm ) .
102738
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.).
102729
11A-159
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
On the four ignition coils, apply a bead (2 7) ofFLUORINATED GREASE 82 00 169 855 2 mm indiameter to the lower circumference of the high-ten-sion cap.
106443
27
11A-160
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 770 or 771
11A
Refit the plugs.
Tighten to torque the plugs ( 25 to 30 Nm ) .
Refit the coils.
Tighten to torque:
- the coils (if holes already threaded) ( 12 Nm ) ,
- the coils (if holes not threaded) ( 15 Nm ) .
Refit the inlet manifold with its new gasket.
Tighten to torque and in order the inlet manifold ( 9Nm ) .
Refit the camshaft offset timer solenoid valve, with anew seal.
Replace the camshaft seals.
- use the (Mot. 1517) for the inlet camshaft seal.
- use the (Mot. 1512) for the exhaust camshaft seal.
Refit:
- the timing belt (it is essential to follow the procedu-re (see 11A, Top and front of engine, Timingbelt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Refit:
- the new sealing plugs:
• on the inlet camshaft (Mot. 1487) ,
• on the exhaust camshaft (Mot. 1488) ,
- the right-hand suspended engine mounting (see19D, Engine mounting, Suspended enginemounting ).
Proceed in the reverse order to removal.
Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining-refilling ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
102939 15103-1
11A-161
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
REMOVALPosition the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper ).
Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).
Special tooling required
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1669 Fitting cam followertappet
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1490-01 Locking and adjustingcamshaft pulleys
Mot. 1573 Cylinder head support
Mot. 104 Cylinder head ali-gning tool
Mot. 1513 Tool for refitting cams-haft dephaser solenoidvalve lip seal
Ele. 1382 Spark plug spannertoolkit 16 & 21 mm tor-que 1.75 & 28 Nm +square adapter 9-9.52for spanner Ele. 1086
Mot. 1632 Tool for fitting thecamshaft seal
Mot. 1487 Tool for refitting cams-haft covers (57 mmdiameter)
Mot. 1488 Tool for refitting cams-haft covers (43 mmdiameter)
Equipment required
cylinder head testing tool
Tightening torquesm
rocker cover mountingbolts 22, 23, 20, 13
12 Nm
oil separator mountingbolts
15 Nm
camshaft dephasersolenoid valve bolt
10 Nm
plugs 25 to 30 Nm
coil mounting bolts (ifholes already threaded)
12 Nm
coil mounting bolts (ifholes not threaded)
15 Nm
camshaft position sen-sor mounting bolt
10 Nm
inlet manifold mountingbolts
9 Nm
battery cover bolts 4 Nm
Tightening torquesm
11A-162
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Set up the engine stand (1) (Mot. 1672) .
Remove the (Mot. 1453) and (Mot. 1669) .
Remove the wiring harness support mounting bolt(1) .
Disconnect:
- the connector (2) from the coolant temperaturesensor,
- the water unit hoses using the (Mot. 1453) or (Mot.1453-01) or (Mot. 1490-01) ,
- the brake servo vacuum pipe (3) on the inlet mani-fold side.
Move the bracket/wiring harness assembly aside.
105432
1
14889
102735
2
1
3
11A-163
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Disconnect:
- the ignition coil connectors (4) ,
- the air temperature sensor connector (5) ,
- the camshaft dephaser solenoid valve connector(6) ,
- the inlet manifold pressure sensor connector (7) ,
- the fuel vapour recirculation solenoid valve pipe (8),
Disconnect:
- the camshaft position sensor connector (9) ,
- the catalytic converter upstream oxygen sensorconnector.
Disconnect the connector (10) from the injectors
Unfasten the clip (11) .
Move the wiring harness to one side.
Remove:
- the ignition coils,
- the plugs,
- the dephaser solenoid valve,
- the camshaft position sensor.
18666
101809
5
4
4
87 6
9
104240
11
10
11A-164
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Remove:
- the lifting bracket (12) ,
- the inlet manifold mounting bolts (13) ,
- the inlet manifold.
Remove:
- the catalytic converter-gearbox stay mounting bolts(14) ,
- the catalytic converter/gearbox strut,
- the exhaust pipe mounting nuts (15) .
Move the exhaust pipe aside.
Remove the camshaft pulleys using the (Mot. 1490-01) .
103272
131313
12
101793
151515
14
11A-165
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Remove:
- the oil separator mounting bolts (17) ,
- the oil separator.
Remove:
- the rocker cover mounting bolts,
- detach the rocker cover vertically, tapping the lugs(18) with a copper hammer.
Remove the inlet and exhaust camshafts.
103255
WARNING
Do not remove the bolt (16) as it acts as a stopfor the squared cam tappet.
1717171717
16
103256
WARNING
Do not damage the aluminium surfaces.
103258
18
18
11A-166
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Remove:
- the valve rockers (19) ,
- the hydraulic tappets (20) .
Remove:
- the cylinder head mounting bolts,
- the cylinder head.
Mount the cylinder head on the cylinder head moun-ting (Mot. 1573) .
Remove the cylinder head gasket from the cylinderblock.
I - CLEANING THE CYLINDER HEAD
Clean the gasket faces with DECAPJOINT to dissol-ve any parts of the seal still attached to the lower co-ver and the cylinder block.
Apply the product to the section to be cleaned; Waitapproximately ten minutes, then remove the residueusing a wooden spatula.
II - CHECKING THE GASKET FACE
Use a ruler and feeler gauge to check that there isno gasket face bow.
Maximum bow: 0.05 mm
Test the cylinder head to detect any possible cracksusing the cylinder head testing tool .
For the cylinder head stripping procedure (seeTechnical Note 3784A, K4 4-cylinder petrol engi-ne, 10A, Engine and peripherals, Rebuilding thecylinder head) .
Position the pistons at mid-stroke to prevent anycontact with the valves when refitting the camshafts.
Be sure to degrease:
- the cylinder head combustion face,
- the cylinder block combustion face.
14499
Note:
To prevent any risk of unpriming the hydraulictappets make sure that they are vertical.
IMPORTANT
Do not scratch the aluminium gasket faces.
During the operation, wear:
- goggles,
- gloves.
20
19
WARNING
Do not allow this product to drip onto the pain-twork.
Clean the cylinder head carefully to preventforeign bodies from entering the oil supply andreturn pipes.
Failure to follow this guideline could lead to bloc-kage of the oilways, resulting in rapid and seriousdamage to the engine.
WARNING
No regrinding of the cylinder head is permitted.
11A-167
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Check that the centring dowel is present (21) on thecylinder block.
Fit the (Mot. 104) (22) on the cylinder block.
REFITTING
Fit the new cylinder head gasket.
Refit the cylinder head.
Check the cylinder head tightening bolts (see 11A,Top and front of engine, Cylinder head gasket:Removal - Refitting ).
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ).
Reprime the hydraulic tappets (hydraulic tappetsmay empty after a long down time).
To check if repriming is necessary, press the top ofthe tappet (23) with your thumb.
If the tappet piston depresses:
- immerse the tappets in a container full of dieselfuel,
- refit the hydraulic tappets.
Refit:
- the valve rockers,
- the camshafts, oiling the bearings.
14689
22 21
14499
23
11A-168
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11AI - CAMSHAFT MARKINGS
Inlet camshaft
Exhaust camshaft
Position the pin (26) of the (Mot. 1669) against thebottom of the groove by loosening bolt (27) .
Mount the (Mot. 1669) on the rocker cover, correctlypositioning the pin (28) in the rocker cover hole (29) .
Fit the rocker cover tool (Mot. 1669) using the bolts(30) .
102507
(24) The inlet camshaft is fitted withthe camshaft sensor target.
102506
(25) The exhaust camshaft is fittedwith the square cam.
24
25
103685
103684
26
29
28
27
303030
11A-169
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Tighten the bolt (31) until the pin (32) is hard upagainst the bottom of the groove.
Position the bolt of the (Mot. 1669) in place of theoriginal bolt at (33) to hold the tappet in the com-pressed position.
Turn the bolt (34) until the pin (35) is hard up againstthe bottom of the groove.
Remove the (Mot. 1669) from the rocker cover.
103687
103688
32
31
33
103686
35
34
11A-170
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Position the camshaft grooves horizontally and off-set downwards.
Using a stipple roller, apply LOCTITE 518 to thecamshaft rocker cover gasket face until it turns red-dish.
Using a cloth, remove the LOCTITE 518 from (36)on the six camshaft rocker cover bearings.
Refit the camshaft rocker cover.
15106-1
WARNING
The sealing faces must be clean, dry and free ofgrease. (do not leave any finger marks).
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould damage certain components (engine,radiator).
14517
36
11A-171
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11AII - TIGHTENING PROCEDURE
Tighten to torque and in order:
- rocker cover mounting bolts 22, 23, 20, 13 (8Nm) ,
- rocker cover mounting bolts 1 to 12, 14 to 19,21 to 24 (12 Nm) .
Loosen bolts 22, 23, 20 and 13, in order.
Tighten to torque and in order rocker cover moun-ting bolts 22, 23, 20, 13 ( 12 Nm ) .
14497
11A-172
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Using a stipple roller, apply LOCTITE 518 to thegasket face until it is reddish in colour.
Refit the oil separator.
Tighten to torque and in order the oil separatormounting bolts ( 15 Nm ) .
Remove the bolt (10) of the (Mot. 1669) to releasethe tappet.
Refit the original bolt, applying a drop of LOCTITEFRENETANCH .
Refit:
- the camshaft dephaser solenoid valve seal usingthe (Mot. 1513) (37) ,
- the camshaft dephaser solenoid valve.
Tighten to torque the camshaft dephaser solenoidvalve bolt ( 10 Nm ) .
102073
WARNING
the sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Excess sealant could be squeezed out when theparts are tightened. A mixture of sealant and fluidcould damage certain components (engine,radiator).
101820
16016
54
32
110 9
8
7
6
37
11A-173
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
On the four ignition coils, apply a bead (3 8) ofFLUORINATED GREASE 82 00168 855 2 mm indiameter to the inner circumference of the high-ten-sion cap.
106443
38
11A-174
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Refit the plugs.
Tighten to torque the plugs ( 25 to 30 Nm ) usingthe plug spanner set (Ele. 1382) .
Refit the coils.
Tighten to torque
- the coil mounting bolts (if holes already threa-ded) ( 12 Nm ) ,
- the coil mounting bolts (if holes not threaded) (15 Nm )
.
Refit the cylinder reference sensor (39) with a newseal.
Tighten to torque the camshaft position sensormounting bolt ( 10 Nm ) .
Always replace all the inlet manifold seals.
Tighten to torque and in order the inlet manifoldmounting bolts ( 9 Nm ) .
III - REPLACING THE CAMSHAFT SEALS
The elastomer seal on these engines is fitted with aflat lip seal (40) and a protector (41) (also assists infitting the seal to the engine).
103257
39
103272
20257
2
1
8
7
6
5
4
3
4140
11A-175
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A1 - Fitting the seal to the exhaust camshaft
Screw the stud (44) of the (Mot. 1632) onto thecamshaft.
18687
WARNING
It is very important to hold the protector (42)when handling the seal, as this type of seal isvery fragile. It is strictly forbidden to touch theelastomer seal (43) in order to prevent any oilleaks once the seal is fitted to the engine.
4342
105531
21687
44
44
11A-176
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Fit the protector, with a seal, to the camshaft.
Fit the cover (45) and the collar nut (46) of the (Mot.1632) .
Screw in the collar nut until the cover comes intocontact with the cylinder head.
Remove the nut, cover, protector and threaded rod.
2 - Fitting the inlet camshaft seal
21687-1
21687-2
4645
21687-3
WARNING
It is very important to hold the protector whenhandling the seal, as this type of seal is very fra-gile. In order to prevent any oil leaks once theseal is fitted to the engine, it is strictly forbiddento touch the elastomer seal.
11A-177
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Fit the protector (47) , with a seal, to the camshaft.
Push the centre of the protector to force the seal intoits housing.
Remove the seal protector, taking care not to dropthe seal.
Screw the stud (48) of the (Mot. 1632) onto thecamshaft.
105532
105533
47
105531
105534
48
48
11A-178
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K4M, and 760 or 761
11A
Fit the cover (49) and the collar nut (50) of the (Mot.1632) .
Screw in the collar nut until the cover comes intocontact with the cylinder head.
Remove the nut, cover, protector and threaded rod.
IV - REFITTING
Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal and Refitting )
Refit:
- the accessories belt (see Top and front of engine,Accessories belt: Removal - Refitting ).
- new inlet camshaft sealing plugs using the (Mot.1487) ,
- new exhaust camshaft sealing plugs using the(Mot. 1488) ,
Proceed in the reverse order to removal.
Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining - refilling ).
Connect the battery (see 80A, Battery, Battery: Re-moval - refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover bolts ( 4 Nm ) .
105535
WARNING
Follow the second procedure in the timing beltrefitting procedure.
50
49
15103-1
11A-179
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F4R, and 776
11A
Removing the cylinder head gasket requires the en-gine and transmission assembly to be removed (see10A, Engine and peripherals, Engine and gear-box assembly: Removal - Refitting ).
To remove the cylinder head gasket (see TechnicalNote 3784A, F4 4-Cylinder Petrol Engine, 10A,Engine and peripherals, Cylinder head: Strip-ping - Refitting .
WARNING
Removing and refitting the turbocharger requirescareful application of the repair procedures toensure the system is properly sealed.
FAILURE TO COMPLY WITH THESE INSTRUC-TIONS MAY HAVE SERIOUS SAFETY-RELATEDCONSEQUENCES FOR THE DRIVER.
11A-180
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
REMOVING - REFITTING
Position the vehicle on a two-post lift.
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery, starting with the negativeterminal.
Drain the cooling circuit through the cooling radiatorusing (Mot. 1202-01) or (Mot. 1202-02) or (Mot.1448) .
Remove the scuttle panel grille (see MR 371 Bo-dywork, 55A, Exterior Protection, Scuttle PanelGrille ).
Remove:
- air filter access panel mounting bolts,
- the scuttle panel partition mounting bolt,
- the scuttle panel partition mounting bolts,
- the scuttle panel partition,
- the engine covers,
- the battery,
- the battery tray,
- the lower engine tie-bar.
Remove the catalytic pre-converter (see 19B, Ex-haust, Catalytic Pre-converter: Removal - Refit-ting ).
Remove:
- the timing belt (see 11A, Top and front of engine:Timing belt ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ) ,
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Equipment required
cylinder head testing equipment
angular tightening wrench
Tightening torquesm
battery cover mountingbolts.
4 Nm .
IMPORTANT
Before any operation:
- connect the diagnostic tool (After-Sales),
- establish dialogue with the injection computer,
- check that the injector rail is depressurised,
- watch out for the fuel temperature,
- order the special high-pressure injection circuitplug kit.
WARNING
Plug the orifices.
Make sure that you follow all the safety instruc-tions.
Refer to 13B, Diesel injection, Cleanliness ins-tructions).
11A-181
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
Fit the engine support with (Mot. 1672) .
Remove (Mot. 1453) and (Mot. 1453-01) .
Disconnect:
- the oil vapour rebreathing pipe (4)
- the air inlet duct (see 12A, Fuel mixture, Air inta-ke: Removal - Refitting ) (5) .
- the turbocharging pressure connector (7) ,
- the throttle valve connector (8) ,
- the turbocharging pressure solenoid valve connec-tor (9) ,
- the flowmeter connector (10)
- the rail pressure sensor connector (11) ,
- the diesel pressure regulator connector (12) .
Remove:
- the injector rail protector (13) (see 13B, Diesel in-jection, Injector rail protector ).
105432
111887
111888
11A-182
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
Disconnect:
- the vacuum pipe (14) from the vacuum pump,
- the air filter outlet duct (15) ,
- the exhaust gas recirculation connector (16) ,
- the coolant temperature sensor (17) ,
- the turbocharger vacuum pipes (18) .
Disconnect:
- the camshaft sensor connector (19) ,
- the injector connectors (20) ,
Insert the blanking plugs.
Move the wiring harness to one side.
Disconnect:
- the diesel return temperature sensor connector,
- the high-pressure pump pressure regulator con-nector,
- the heater plug connectors (21) ,
- the diesel return pipe (22) ,
- the diesel fuel supply pipe.
Remove the starter (see 16A, Starting-Charging,Starter: Removal - Refitting .
Remove:
- the turbocharger air duct,
- the turbocharger oil return pipe
- the coolant hoses.
- the turbocharger oil supply pipe.
Disconnect the scuttle panel hoses from the cylinderhead outlet.
111886
111965
111889
11A-183
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
Remove:
- the high-pressure pump rear mounting bolts (23) ,
- the windscreen wiper mounting,
- the bonnet,
- the cylinder head mounting bolts.
Remove the cylinder head.
Remove exhaust gas recirculation pipe mountingbolts (24) .
Remove the exhaust gas recirculation pipe moun-ting clip.
Remove the cylinder head mounting bolts.
Remove the cylinder head.
102348
WARNING
When removing the cylinder head, take care notto cause any damage to its gasket face as it pas-ses the turbocharger above it.
111861
111863
11A-184
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11AI - CLEANING
Clean the cylinder head.
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a set ofshims.
The maximum deformation is 0.05 mm .
Test the cylinder head to detect any possible cracksusing a cylinder head testing equipment .
(see TN 3652A, 4-cylinder Cast Iron High Pressu-re Common Rail Diesel Engine, 10A, Engine andperipherals, Rebuilding the cylinder head) for thecylinder head stripping procedure.
REFITTING
Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.
Degrease the gasket faces.
Refit the cylinder head with a new cylinder head gas-ket.
Refit new cylinder head bolts.
Tighten the cylinder head (see 11A, Top and frontof engine, tightening the cylinder head) using aangular tightening wrench .
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter ).
Refit the timing belt (see 11A, Top and front of en-gine, Timing belt ).
Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt ).
Fill and bleed the cooling circuit (see 19A, Cooling,Bleeding the cooling circuit .
Reprime the diesel circuit (see 13B, Fuel supply,Diesel supply circuit ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mountingbolts. ( 4 Nm . )
IMPORTANT
Do not scratch the aluminium gasket faces.
Wear protective goggles.
Wear gloves during the operation.
Clean the gasket faces with DECAPJOINT clea-ning product to dissolve the part of the gasketwhich is stuck to the sump and cylinder cover.
Apply the product to the section to be cleaned;Wait approximately ten minutes, then remove theresidue using a wooden spatula.
WARNING
To prevent any foreign bodies from entering theoil pipes (pipes in both the cylinder block andcylinder head).
WARNING
Protect the oilway to prevent any foreign bodiesfrom entering the cylinder head oil supply pipes.
Failure to follow this instruction could lead to thepipes becoming blocked, causing rapid camshaftdamage.
WARNING
No regrinding is permitted.
WARNING
carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
11A-185
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
REMOVING - REFITTING
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Drain the engine cooling circuit (see 19A, Cooling,Cooling circuit: Draining-refilling ).
Always respect the repair precautions (see 13B,Diesel injection, Diesel injection: Precautionsduring repair ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine covers,
- the battery tray,
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting: Removal -Refitting ).
Remove the catalytic pre-converter (see 19B, Ex-haust, Catalytic Pre-converter: Removal - Refit-ting ).
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting) ,
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
Fit the engine support using the (Mot. 1672) .
Remove the (Mot. 1453) and (Mot. 1453-01) .
Special tooling required
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Equipment required
diagnostic tool
cylinder head testing equipment
angular tightening wrench
Tightening torquesm
battery cover mountingbolts
4 Nm
IMPORTANT
Before any operation:
- connect the diagnostic tool (After-Sales),
- establish dialogue with the injection computer,
- check that the injection rail is depressurised,
- be aware of the fuel temperature,
- order the special high-pressure injection circuitplug kit.
WARNING
Fit plugs in the openings.
105432
11A-186
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
Disconnect:
- the oil vapour rebreathing pipe (1) ,
- the air inlet duct (see 12A, Fuel mixture, Air inlet:Removal - Refitting ) (2) ,
- the turbocharging pressure connector (4) ,
- the throttle valve connector (5) ,
- the turbocharging pressure solenoid valve connec-tor (6) ,
- the air flowmeter sensor connector (7) ,
- the rail pressure sensor connector (8) ,
- the diesel pressure regulator connector (9) .
Remove:
- the injection rail protector (10) (see 13B, Diesel in-jection, Injection rail protector ).
Disconnect:
- the vacuum pipe from the vacuum pump (11) ,
- the air filter outlet duct (12) ,
- the exhaust gas recirculation connector (13) ,
- the coolant temperature sensor (14) ,
- the turbocharger vacuum pipes (15) .
Disconnect:
- the camshaft sensor connector (16) ,
- the injector connectors (17) .
Insert the blanking plugs.
Move the electric wiring harness to one side.
111887
111888
7
5
4
3
21
6
10
9
8
111886
111965
12
11
14
13
1515
1617171717
11A-187
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
Disconnect:
- the diesel return temperature sensor connector,
- the high-pressure pump pressure regulator con-nector,
- the heater plug connectors (18) ,
- the diesel return pipe (19) ,
- the diesel fuel supply pipe.
Remove:
- the starter motor (see 16A, Starting-charging,Starter motor: Removal - Refitting .
- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).
- the water hoses.
Disconnect the cylinder head outlet water unit ho-ses.
Remove:
- the high pressure pump rear mounting bolts (20) ,
- the windscreen wiper mounting,
- the bonnet,
- the cylinder head mounting bolts.
111889
19
18181818
102348
WARNING
When removing the cylinder head, take care notto cause any damage to its gasket face as it pas-ses the turbocharger above it.
2020
11A-188
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11A
Remove the mounting bolts (21) from the exhaustgas recirculation pipe.
Remove the mounting clip from the exhaust gas re-circulation pipe.
Remove the cylinder head mounting bolts.
Remove the cylinder head.
I - CLEANING
Clean the cylinder head.
Clean the gasket faces with DECAPJOINT to dissol-ve any part of the gasket which is attached to thelower cover and cylinder block.
Apply the product to the section to be cleaned; waitapproximately 10 minutes, then remove residueusing a wooden spatula.
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a feelergauge.
The maximum bow is 0.05 mm .
Test the cylinder head to detect any possible cracksusing a cylinder head testing equipment .
For the cylinder head stripping procedure (seeTechnical Note 3652A, 4-cylinder Cast Iron HighPressure Common Rail Diesel Engine, 10A, En-gine and peripherals, Rebuilding the cylinderhead) .
111861
111863
2121
2121
IMPORTANT
Do not scratch the aluminium sealing surfaces.
During the operation, wear:
- goggles,
- gloves.
WARNING
To prevent any foreign bodies from entering theoil pipes (pipes in both the cylinder block andcylinder head).
WARNING
Protect the oilway to prevent any foreign bodiesfrom entering the cylinder head oil supply galle-ries.
Failure to follow this instruction could lead to thepipes becoming blocked, causing rapid camshaftdamage.
WARNING
No regrinding is permitted.
11A-189
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
F9Q, and 804
11AREFITTING
Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.
Degrease the gasket faces.
Refit the cylinder head with a new cylinder head gas-ket.
Refit new cylinder head bolts.
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head) using aangular tightening wrench .
Refit the catalytic pre-converter (see 19B, Exhaust,Catalytic Pre-converter: Removal - Refitting ).
Refit the timing belt (see 11A, Top and front of en-gine, Timing belt: Removal - Refitting ).
Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt: Removal - Refitting).
Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining-refilling ).
Reprime the diesel circuit (see 13B, Fuel supply,Diesel fuel supply circuit ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
11A-190
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Special tooling required
Car. 1363 Trim removal lever
Ele. 1552 Tool for removing rearscreen wiper arm
Mot. 1672 Lower engine support
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Mot. 1453-01 Additional winder nuton engine lift supportMot. 1453
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
diagnostic tool
hydraulic crane
load positioner
cylinder head testing tool
angular tightening wrench
Tightening torquesm
rocker cover mountingbolts
10 Nm
alternator mountingbolts
21 Nm
hose clip on the stain-less steel pipe
5.5 Nm
turbocharger oil returnpipe
9 Nm
battery cover bolts 4 Nm
WARNING
Before starting work on the vehicle, obtain:
- a new plug kit ( PART NO. 77 01 476 857) ,
- some cleaning cloths ( PART NO. 77 11 211 707) ,
- cleaning product ( PART NO. 77 11 24 188) .
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injection rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, Cleanliness guidelines).
WARNING
Procedure for removing the air inlet duct (risk of leaking and dislodging if this procedure is not res-pected):
- detach the hose using the (Car. 1363) ,
- do not use degreaser, brake cleaning agents, orany other products,
- clean the bearing face on the intercooler with adry, lint-free cloth,
- always replace the clip with a new one,
- place the clip in the same position if the hose isnot replaced,
- it is essential to replace the hose and/or the rigidpipe in the event of damage.
11A-191
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11ARemove the engine undertray.
Unclip the trim (1)
Remove:
- the seal (2) ,
- the plastic rivets (3) ,
- the wiper arms (4) using the (Ele. 1552) ,
- the scuttle panel grille.
- the scuttle panel partition.
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- the timing belt (see 11A, Top and front of engine,Timing belt ),
- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ).
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter ).
Remove the turbocharger oil return pipe (5) .
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Draining-refilling ).
Remove:
- the alternator upper mounting bolt (26) ,
- the alternator lower mounting bolt (27) ,
102101
102100
104175
102267
11A-192
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11A
Remove:
- the inner timing cover mounting bolts (6) ,
- the inner timing cover.
Fit the engine stand (Mot. 1672) .
Remove the (Mot. 1453) fitted with the (Mot. 1453-01) .
Disconnect the air inlet pressure sensor connector(7) .
Loosen the clips (8) and (9) .
Remove the air inlet duct (10) .
19710
19626
112815
102473
11A-193
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11A
Pull out the clip.
Make a mark (11) on the air inlet duct between thestainless steel pipe and the hose using an indeliblepen.
Detach the hose from the stainless steel pipe.
Remove:
- the mounting bolt (12) from the stainless steel pipe,
- the stainless steel pipe (13) .
Unclip the injection rail protector cover (14) .
Remove:
- the injection rail protector cover,
- the injection rail protector cover mounting bolt andmounting nut (15) ,
- the dipstick,
- the dipstick guide tube mounting bolts (16) .
Remove the dipstick guide tube.
Disconnect:
- the heater plug connectors (17) ,
112811
112991
112992
112993
11A-194
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11A- the injector connectors (18) ,
Disconnect:
- the connector (19) from the damper valve,
- the cylinder reference sensor connector (20) ,
- the pressure regulation solenoid valve connector(21) ,
- the flow regulation solenoid valve connector (22) ,
- the diesel temperature sensor connector (23) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (24) .
Remove the wiring harness clip mounting nut (25) .
Remove the wiring harness.
Tilt the alternator against the radiator assembly.
Clean the fuel return and supply pipe unions (see13A, Diesel injection, Repair precautions ).
Disconnect:
- the fuel supply pipe (28) ,
- the fuel return pipe (29) .
Fit plugs.
112994
112656
WARNING
Do not blast compressed air once the fuel circuitis open, otherwise impurities may enter the sys-tem. Use wipes if necessary.
Note:
Make preparations for fuel outflow. Clean withnew wipes.
11A-195
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11A
Remove:
- the retaining bracket mounting bolts from the ex-haust gas recirculation cooler,
- the bracket from the exhaust gas recirculation coo-ler.
Remove the injection rail protector cover supportmounting bolt and mounting nuts (30) .
Unclip the drain pipe from the injection rail protectorcover support.
Remove:
- the injection rail protector cover support,
- the damper valve (see 12A, Damper valve: Re-moval - Refitting .
Disconnect the oil vapour rebreathing pipe on therocker cover side (31) .
Remove the air inlet duct (32) .
Disconnect:
- the exhaust gas recirculation solenoid valve con-nector,
- the scuttle panel hoses (33) using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the brake servo vacuum pipe (34) on the vacuumpump side,
- the temperature sensor connector from the scuttlepanel,
- the radiator top hose from the cylinder head outletwater unit (35) using the (Mot. 1202-01) or (Mot.1202-02) or (Mot. 1448) ,
- the turbocharging pressure regulation solenoid val-ve hose on the vacuum pump side,
- the turbocharging pressure regulation solenoid val-ve hose on the pressure regulation valve side.
113475
111748
112996
112997
11A-196
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11A
Remove:
- the rocker cover mounting bolts (36) ,
- the rocker cover.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the cylinder head mounting bolts (37) ,
- the cylinder head using a hydraulic crane fittedwith a load positioner .
REFITTING
I - CLEANING
Clean the cylinder head.
Clean the gasket faces with DECAPJOINT to dissol-ve any parts of the seal still attached.
Apply the product to the part to be cleaned. Wait ap-proximately ten minutes, then remove the residueusing a wooden spatula.
II - CHECKING THE GASKET FACE
Check for gasket face bow using a ruler and a feelergauge.
The maximum bow is 0.05 mm .
For the cylinder head stripping procedure see Tech-nical Note 6006A, 4-cylinder cast iron High Pres-sure Common Rail Diesel Engine, 10A, Engineand peripherals, Rebuilding the cylinder head . .
Test the cylinder head to detect any possible cracksusing the cylinder head testing tool .
113476
19712
IMPORTANT
Do not scratch the aluminium sealing surfaces.
Wear goggles.
Wear gloves during the operation.
WARNING
Please make sure, during this operation, that noforeign bodies enter the oil pipes (pipes in boththe cylinder block and the cylinder head).
WARNING
Protect the oil duct to prevent any foreign bodiesfrom entering the cylinder head oil supply pipes.
Failure to follow this procedure could lead to theoil supply pipes becoming blocked, quicklydamaging the camshaft.
WARNING
No regrinding of the cylinder head is permitted.
11A-197
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11AIII - REFITTING OPERATION FOR PART CONCERNED
Bring the pistons to mid-stroke position to preventany risk of contact with the valves when tighteningthe cylinder head.
Fit the new cylinder head gasket, centred by twodowels.
Refit the cylinder head using the hydraulic crane fit-ted with the load positioner .
Tighten the cylinder head (see 11A, Top and frontof engine, Tightening the cylinder head ) usingangular tightening wrench .
IV - FINAL OPERATION
Fit the new rocker cover gasket.
Apply beads (38) of SILICONE ADHESIVE SEAL 2mm in diameter.
Refit the rocker cover.
Tighten to torque and in order the rocker covermounting bolts ( 10 Nm ) .
Connect:
- the turbocharging pressure regulation solenoid val-ve hose on the pressure regulation valve side.
- the turbocharging pressure regulation solenoid val-ve hose on the vacuum pump side,
- the radiator top hose from the cylinder head wateroutlet unit using the (Mot. 1202-01) or (Mot. 1202-02) or (Mot. 1448) ,
- the temperature sensor connector to the scuttle pa-nel,
- the brake servo vacuum pipe on the vacuum pumpside,
- the scuttle panel hoses using the (Mot. 1202-01) or(Mot. 1202-02) or (Mot. 1448) ,
Refit:
- the air inlet duct between the air filter unit outletand the turbocharger inlet,
- the oil vapour rebreathing pipe;
- the damper valve (see 12A, Damper valve: Re-moval - Refitting ).
- the injection rail protector cover support,
- the injection rail protector cover support mountingbolt and mounting nuts.
Clip the drain pipe onto the injection rail protector co-ver support.
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
19712-1
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Applying excess sealant could cause it to besqueezed out when parts are tightened. A mix-ture of sealant and fluid could damage certaincomponents (engine, radiator, etc.)
113476
11A-198
TOP AND FRONT OF ENGINECylinder head gasket : Removal - Refitting
K9K, and 732
11ARefit:
- the injection rail protector cover mounting bracket,
- the injection rail protector cover retaining bracketmounting bolts,
Remove the blanking plugs.
Connect:
- the fuel supply pipe,
- the fuel return pipe.
Torque tighten the alternator mounting bolts ( 21Nm ) .
Connect:
- the rail pressure sensor connector,
- the diesel fuel temperature sensor connector.
- the flow regulation solenoid valve connector,
- the pressure regulation solenoid valve connector,
- the cylinder reference sensor,
- the connector on the damper valve,
- the heater plugs connector,
- the injector connectors,
Position the wiring harness.
Refit the mounting nut of the wiring harness clip.
Clip the retaining clip of the wiring harness.
Refit:
- the dipstick guide tube mounting bolts to the injec-tion rail protector cover support,
- the diesel anti-splash device cover,
- the injection rail protector cover bolt and nuts,
Clip on the injection rail protector cover.
Refit:
- the clip to the stainless steel pipe,
- the stainless steel pipe between the intercoolerhose and the turbocharger, aligning the marks,
- the pipe between the intercooler and the dampervalve.
Tighten to torque the hose clip on the stainlesssteel pipe ( 5.5 Nm )
Clip the stainless steel pipe to the turbocharger.
Refit the air duct between the damper valve and theintercooler
Tighten the clips.
Connect:
- the air pressure sensor,
- the exhaust gas recirculation solenoid valve con-nector.
Fit the (Mot. 1453) with the (Mot. 1453-01) .
Remove the (Mot. 1672) .
Refit:
- the inner timing cover,
- the alternator upper mounting bolt,
- the alternator lower mounting bolt,
- the turbocharger oil return pipe.
Tighten to torque the turbocharger oil return pipe( 9 Nm ) .
Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter ),
- the timing belt (see 11A, Top and front of engine,Timing belt ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ),
- the engine undertray,
- the battery,
Fill and bleed the cooling circuit (see 19A, Cooling,Bleeding the cooling circuit ).
Reconnect the battery (see 80A, Battery, Removal- Refitting ).
Refit the engine covers.
Tighten to torque the battery cover bolts ( 4 Nm ) .
11A-199
TOP AND FRONT OF ENGINETightening the cylinder head
K4J, and 730 or 732 – K4M, and 760 or 761
11ACYLINDER HEAD TIGHTENING PROCEDURE
Tighten to torque and in order the cylinder headmounting bolts ( 20 Nm ) .
Check that all of the cylinder head mounting boltsare tightened to the correct torque of 20 Nm .
Angle-tighten in order the cylinder head mountingbolts ( 240˚ ±±±± 6˚ ) .
Tightening torquesm
cylinder head moun-ting bolts
20 Nm
cylinder head moun-ting bolts
240˚ ±±±± 6˚
14500
WARNING
Reuse the bolts if the length under the headdoes not exceed 117.7 mm (otherwise replaceall the bolts with new ones).
In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil whichmay be in the cylinder head mounting holes.
Do not oil the new bolts. The bolts must be oiledif reused.
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Do not retighten the cylinder head bolts afterapplying this procedure.
11A-200
TOP AND FRONT OF ENGINETightening the cylinder head
K9K, and 722 or 728 or 729
11A
CYLINDER HEAD TIGHTENING PROCEDURE
Tighten to torque and in order the cylinder headmounting bolts ( 25 Nm ) .
Check that all of the cylinder head mounting boltsare tightened to the correct torque (25 Nm) .
Angle-tighten in order the cylinder head mountingbolts ( 255˚ ±±±± 10˚ ) .
Tightening torquesm
cylinder head moun-ting bolts
25 Nm
cylinder head moun-ting bolts
255˚ ±±±± 10˚
19712
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Always replace all of the cylinder head bolts withnew ones after removal.
In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil thatmay be in the cylinder head mounting holes.
Do not oil the new bolts.
WARNING
Do not retighten the cylinder head bolts afterapplying this procedure.
3
4
102
918
7 6
5
11A-201
TOP AND FRONT OF ENGINETightening the cylinder head
F9Q, and 800 or 804 or 808
11ACYLINDER HEAD TIGHTENING PROCEDURE
Tighten to torque and in order the cylinder headmounting bolts ( 30 Nm ) .
Check that all of the cylinder head mounting boltsare tightened to the correct torque (30 Nm) .
Angle-tighten in order the cylinder head mountingbolts ( 230˚ +/- 6˚ ) .
Tightening torquesm
cylinder head moun-ting bolts
30 Nm
cylinder head moun-ting bolts
230˚ +/- 6˚
16189
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Systematically replace all cylinder head boltsafter removal.
To ensure correct tightening, use a syringe toremove any oil that may be in the cylinder headmounting holes.
Do not oil the new bolts.
WARNING
Do not retighten the cylinder head bolts afterapplying this procedure.
1
2 3
45
6 7
89
10
11A-202
TOP AND FRONT OF ENGINETightening the cylinder head
F4R, and 770 or 771 or 776
11ACYLINDER HEAD TIGHTENING PROCEDURE
Tighten to torque and in order the cylinder headmounting bolts ( 20 Nm ) .
Check that all of the cylinder head bolts are tighte-ned to the correct torque (20 Nm) .
Step 1
Angle-tighten in order the cylinder head mountingbolts ( 100˚ ±±±± 6˚ )
Tightening torquesm
cylinder head moun-ting bolts
20 Nm
cylinder head moun-ting bolts
100˚ ±±±± 6˚
cylinder head moun-ting bolts
100˚ ±±±± 6˚
15153
2
1 10
9
8
7
6
5
4
3
WARNING
Always replace all of the cylinder head bolts withnew ones after removal.
In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil thatmay be in the cylinder head mounting holes.
Do not oil the new bolts.
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
11A-203
TOP AND FRONT OF ENGINETightening the cylinder head
F4R, and 770 or 771 or 776
11AStep 2
Angle-tighten in order the cylinder head mountingbolts ( 100˚ ±±±± 6˚ )
WARNING
Do not retighten the cylinder head bolts afterapplying this procedure.
11A-204
TOP AND FRONT OF ENGINETightening the cylinder head
K9K, and 732
11ACYLINDER HEAD TIGHTENING PROCEDURE
Tighten to torque and in order the cylinder headmounting bolts ( 25 Nm ) with the low torquewrench .
Check that all of the cylinder head mounting boltsare tightened to the correct torque (25 Nm) .
Angle-tighten in order the cylinder head mountingbolts ( 255˚ ±±±± 10˚ ) using the angular tighteningwrench .
Equipment required
low torque wrench
angular tightening wrench
Tightening torquesm
cylinder head moun-ting bolts
25 Nm
cylinder head moun-ting bolts
255˚ ±±±± 10˚
19712
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Always replace all of the cylinder head bolts withnew ones after removal.
In order to ensure that the bolts are correctlytightened, use a syringe to remove any oil whichmay be in the cylinder head mounting holes.
Do not oil the new bolts.
WARNING
Do not retighten the cylinder head bolts afterapplying this procedure.
11A-205
TOP AND FRONT OF ENGINECylinder head: Removal - Refitting
M9R, and 700
11AREMOVAL
Removing the cylinder head requires the engine andgearbox assembly to be removed (see 10A, Engineand peripherals, Engine and gearbox assembly:Removal - Refitting ).
To remove the cylinder head (see Technical Note6017A, M9R Diesel engine ).
REFITTINGTo refit the cylinder head (see Technical Note6017A, M9R Diesel engine ).
Refit the engine and gearbox assembly (see 10A,Engine and peripherals, Engine and gearbox as-sembly: Removal - Refitting ).
12A-1
FUEL MIXTURESpecifications
F4R, and 770 or 771 or 776
12A
(1)for a coolant temperature above 80˚C and after theengine speed has stabilised at 2,500 rpm for approxi-mately 30 seconds .
(2)octane rating 91 unleaded compatible
(3)for the legal values, see specifications by country
(4)at 2,000 rpm CO should be a maximum of 0.3 %
Equipment required
diagnostic tool
VehicleGear-
box
Engine
Type Suffix Bore
(mm)
Stroke
(mm)
Cubiccapacity
(cc)
Compression
ratio
XM0UND0
F4R
770
82.7 93 1,998 9.8/1
DP0 771
XN0W ND0 776 9.5 ± 0.3
EngineTest carried out at idle speed(1)
Fuel (2)
(minimum
octane
rating)
Pollutant emissions(3)
Type Suffix Idlingspeed
(rpm)
CO (%)(4) CO2 (%) HC (ppm) Lambda (λ)
F4R 770 /771 /776
750 ±±±± 50 0.5
maximum
14.5
maximum
100
maximum
0.97< λ <1.03 Superunleaded(Octanerating 95)
Temperatures in ˚C ±±±± 1 - 10 25 50 80 110 120
Negative temperature coefficient air tem-perature sensor (resistance in Ω)
10,454to 8,623
2,174 to1,928
857 to763
326 to292
143 à127
112 to98
Negative temperature coefficient coolanttemperature sensor (resistance in Ω)
13,588t o 11,332
2,364 to2,140
850 to772
290 to275
117 to111
90 to 86
12A-2
FUEL MIXTURESpecifications
F4R, and 770 or 771 or 776
12A
Description Brand-Type Special notes
Injection computer SAGEM 3000 Ignition and sequential multipoint injection computer
128-track computer
- connector A: 48-track
- connector B: 32-track
- connector C: 48-track
Fuel pump - It is part of a « pump - sender - filter » assemblyincorporating the pressure regulator
Pressure: 3.5 ±±±± 0.06 bar
Minimum flow: 80 to 120 l/h
Ignition coils SAGEM Four coils
Primary resistance: tracks 1 and 2 approximately 0.5Ω
Secondary resistance: track 1 and high voltage out-put: 10.5 +/- 1.5 kΩ
2-track connector:
- 1: + 12 V supply
- 2: earth control
Ignition coils BERU (F4R 776) only Four coils
Primary resistance: tracks 1 and 2 approximately 0.5Ω
Secondary resistance: track 1 and high voltage out-put: 6.70 +/- 0.7 kΩ
2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors
SIEMENS - DEKA 4 Bi-jet solenoid injector
Resistance: 14.5 +/- 0.7 Ω at 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth control
SIEMENS - DEKA 7(F4R 776) only
Bi-jet solenoid injector
Resistance: 12 ±±±± 0.5 Ω at 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth control
12A-3
FUEL MIXTURESpecifications
F4R, and 770 or 771 or 776
12A
Manifold pressure sensor
SIEMENS - MAP03 Piezoelectric type sensor
Replace the seal each time it is removed.
3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
BOSCH (F4R 776) only Piezoelectric type sensor
Replace the seal each time it is removed.
3-track connector:
- 1: + 5 V supply
- 2: earth
- 3: signal
Injection order - 1-3-4-2
no. 1 flywheel end
Fault finding diagnostic tool CLIP only
Accelerator pedal potentio-meter
CTS Dual gang potentiometer
Resistance values:
- circuit 1: tracks 3 and 5: 1,700 ±±±± 900 Ω
- gang 2: tracks 2 and 6: 2,850 ±±±± 2,050 Ω
6-track connector:
- 1: gang 2 signal
- 2: 5 V supply, gang 2
- 3: 5 V supply, gang 1
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Pinking sensor SAGEM Piezoelectric type sensor
Tightening torque: 20 Nm
Engine speed and positionsensor
SIEMENS Variable reluctance type sensor
Resistance: 200 to 270 Ω at 23˚C
Tightening torque: 8 Nm
Description Brand-Type Special notes
12A-4
FUEL MIXTURESpecifications
F4R, and 770 or 771 or 776
12A
Upstream and downstreamoxygen sensors
BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaustgas temperature rises above 850˚C .
Heating resistor: 9 Ω at 20˚C
4-track connector:
- A: + heating resistor
- B: - heating resistor
- C: + signal
- D: - signal
Warm engine:
- Rich mixture > 800 mV
- Lean mixture < 50 mV
Fuel vapour absorber sole-noid valve
SAGEM Resistance: 26 ±±±± 4 Ω to 23˚C
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-vious table)
Coolant temperature sensor JAEGER ELTH
or SILEA
Negative temperature coefficient thermistor (see pre-vious table)
Refrigerant sensor TEXAS
INSTRUMENTS
3-track connector:
- A: earth
- B: + 5 V supply
- C: signal
Description Brand-Type Special notes
12A-5
FUEL MIXTURESpecifications
F4R, and 770 or 771 or 776
12A
Throttle valve
VDO EGAS 5
Diameter 60 mm (F4R770 and 771)
Direct current geared electric motor.
6-track connector:
- 1: potentiometer gang no. 1 signal
- 2: 5 V potentiometer supply
- 3: + motor
- 4: potentiometer gang no. 2 signal
- 5: - motor
- 6: common earth
Engine resistance: approximately 2.3 Ω at 23˚C
Potentiometer resistance:
tracks 2 and 6: 1000 ±±±± 250 Ω
VDO EGAS - T
Diameter 40 mm (F4R776) only
Direct current geared electric motor.
6-track connector:
- 1: earth
- 2: potentiometer gang no. 1 signal
- 3: + motor
- 4: - motor
- 5: 5 V potentiometer supply
- 6: potentiometer gang no. 2 signal
Engine resistance: approximately 1.57 Ω to 23˚C
Potentiometer resistance:
tracks 1 and 5: 1,000 ±±±± 250 Ω
Camshaft dephaser solenoidvalve
AISIN (F4R 770 and771)
It is controlled by the opening cyclic ratio.
Resistance: 7.2 ±±±± 0.5 Ω to 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth
Spark plug
CHAMPION
RC 87 YCL (F4R 770and 771
Single electrode spark plugs
Gap: 0.90 ±±±± 0.05 mm
Torque: 25 to 30 Nm
NGK PFR6G - 9
(F4R 776) only
Single electrode spark plugs
Gap: 0.900--0.1mm
Torque: 25 to 30 Nm
Catalytic converter EBERSPÄCHER C175
Description Brand-Type Special notes
12A-6
FUEL MIXTURESpecifications
K4J, and 730 or 732 – K4M, and 760 or 761
12A
(1)for a coolant temperature above 80˚C and after theengine speed has stabilised at 2,500 rpm for approxi-mately 30 seconds .
(2)octane rating 91 unleaded compatible
(3)for the legal values, see specifications by country
(4)at 2,000 rpm CO should be a maximum of 0.3 %
Equipment required
diagnostic tool
VehicleGear-
box
Engine
Type Suffix Bore
(mm)
Stroke
(mm)
Cubiccapacity
(cc)
Compression
ratio
XM0B JH3 K4J730
79.5 70 1390
10 / 1732
XM0CJH3
K4M760
79.5 80.5 1,598 DP0 761
EngineTest carried out at idle speed(1)
Fuel (2)
(minimum
octane
rating)
Pollutant emissions(3)
Type Suffix Idlingspeed
(rpm)
CO (%)(4) CO2 (%) HC (ppm) Lambda (λ)
K4J 730 /732
750 ±±±± 50 0.5
maximum
14.5
maximum
100
maximum0.97<λ<1.03
Superunleaded(Octanerating 95)
K4M 760 /761
700 ±±±± 40
Temperatures in ˚C ±±±± 1 - 10 25 50 80 110 120
Negative temperature coefficient air tem-perature sensor (resistance in Ω)
10,454to 8,623
2,174 to1,928
857 to763
326 to292
143 à127
112 to98
Negative temperature coefficient coolanttemperature sensor (resistance in Ω)
13,588t o 11,332
2,364 to2,140
850 to772
290 to275
117 to111
90 to 86
12A-7
FUEL MIXTURESpecifications
K4J, and 730 or 732 – K4M, and 760 or 761
12A
Description Brand -Type Special notes
Injection computer SAGEM 3000 Ignition and sequential multipoint injection computer
128-track computer
- connector A: 48-track
- connector B: 32-track
- connector C: 48-track
Fuel pump - It is part of a « pump - sender - filter » assemblyincorporating the pressure regulator
Pressure: 3.5 ±±±± 0.06 bar
Minimum flow: 80 to 120 l/h
Ignition coils SAGEM Four coils
Primary resistance: tracks 1 and 2 approximately 0.5Ω
Secondary resistance: track 1 and high voltage out-put: 10.5 +/- 1.5 kΩ
2-track connector:
- 1: + 12 V supply
- 2: earth control
Injectors SIEMENS - DEKA 4 Bi-jet solenoid injector
Resistance: 14.5 +/- 0.7 Ω at 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth control
Manifold pressure sensor SIEMENS - MAP03 Piezoelectric type sensor
Replace the seal each time it is removed.
3-track connector:
- A: earth
- B: signal
- C: + 5 V supply
Injection order - 1-3-4-2
no. 1 flywheel end
Fault finding diagnostic tool CLIP only
12A-8
FUEL MIXTURESpecifications
K4J, and 730 or 732 – K4M, and 760 or 761
12A
Accelerator pedal potentio-meter
CTS Dual gang potentiometer
Resistance values:
- gang 1: tracks 3 and 5: 1,700 ±±±± 900 Ω
- gang 2: tracks 2 and 6: 3,875 ±±±± 1,025 Ω
6-track connector:
- 1: gang 2 signal
- 2: 5 V supply, gang 2
- 3: 5 V supply, gang 1
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Pinking sensor SAGEM Piezoelectric type sensor
Tightening torque: 20 Nm
Engine speed and positionsensor
SIEMENS Variable reluctance type sensor
Resistance: 200 to 270 Ω at 23˚C
Tightening torque: 8 Nm
Upstream and downstreamoxygen sensors
BOSCH - LSF 4.2 The sensor heating is interrupted when the exhaustgas temperature rises above 850˚C .
Heating resistor: 9 Ω at 20˚C
4-track connector:
- A: + heating resistor
- B: - heating resistor
- C: + signal
- D: - signal
Warm engine:
- Rich mixture > 800 mV
- Lean mixture < 50 mV
Fuel vapour absorber sole-noid valve
SAGEM Resistance: 26 ±±±± 4 Ω to 23˚C
2-track connector:
- 1: + 12 V supply
- 2: earth control
Air temperature sensor JAEGER Negative temperature coefficient thermistor (see pre-vious table)
Description Brand -Type Special notes
12A-9
FUEL MIXTURESpecifications
K4J, and 730 or 732 – K4M, and 760 or 761
12A
Coolant temperature sensor JAEGER ELTH
or SILEA
Negative temperature coefficient thermistor (see pre-vious table)
Refrigerant sensor TEXAS
INSTRUMENTS
3-track connector:
- A: earth
- B: + 5 V supply
- C: signal
Description Brand -Type Special notes
K4J
Description Brand-Type Special notes
Throttle valve VDO EGAS T
60 mm diameter
6-way connector
- 1: common earth
- 2: potentiometer gang no. 1 signal
- 3: - motor
- 4: + motor
- 5: 5 V potentiometer supply
- 6: potentiometer gang no. 2 signal
Engine resistance: approximately 1.6Ω to 23˚C
Potentiometer resistance; tracks 1 and 5: 1,000 ±±±± 250 Ω
K4M
Description Brand-Type Special notes
Throttle valve VDO EGAS 5
57 mm diameter
Direct current geared electronic motor
6-way connector
- 1: potentiometer gang no. 1 signal
- 2: 5 V potentiometer supply
- 3: + motor
- 4: potentiometer gang no. 2 signal
- 5: - motor
- 6: common earth
Potentiometer resistance; tracks 2 and 6: 1,000 ±±±± 250 Ω
12A-10
FUEL MIXTURESpecifications
K4J, and 730 or 732 – K4M, and 760 or 761
12A
K4M
Description Brand-Type Special notes
Camshaft dephaser solenoid valve DELPHI It is controlled by the opening cyclic ratio.
Resistance: 7.2 ±±±± 0.5 Ω to 20˚C
2-track connector:
- 1: + 12 V supply
- 2: earth
Camshaft position sensor SAGEM Hall effect sensor
3-track connector:
- 1: earth
- 2: signal
- 3: + 12 V supply
Description Brand-Type Special notes
Spark plug EYQUEM RFN 58 LZ
or CHAMPION RC 87 YCL
Single electrode spark plugs
Gap: 0.95 ±±±± 0.05 mm
Torque: 25 to 30 Nm
Catalytic converter EBERSPÄCHER C150
12A-11
FUEL MIXTUREAir inlet
K4J, and 730 or 732
12ADiagram of the air inlet circuit
102071
(1) Air inlet sleeve
(2) Air resonator
(3) Air filter unit
(4) Air unit
(5) Throttle valve
(6) Inlet manifold
(7) Injector holder plate
(8) Air inlet
12A-12
FUEL MIXTUREAir inlet
K4M, and 760 or 761
12ADiagram of the air intake circuit
101190
7
2
22
6
5 4
3
1
(1) Air intake sleeve
(2) Air resonators
(3) Air filter unit
(4) Throttle valve
(5) Inlet manifold
(6) Injector holder shim
(7) Air inlet
12A-13
FUEL MIXTUREAir inlet
K9K, and 722
12ADiagram of the air intake circuit
102070
3
2
1
8
7
6
54
(1) Air intake sleeve
(2) Air filter unit
(3) Exhaust gas recirculation unit
(4) Air resonator
(5) Metal air intake tube
(6) Intercooler
(7) Turbocharger
(8) Air inlet
12A-14
FUEL MIXTUREAir inlet
F9Q, and 800
12AAir intake circuit diagram
102482
1
2
34 5
6
7
(1) Air inlet
(2) Air filter
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Engine shut-off flap
(7) Air-to-air intercooler
12A-15
FUEL MIXTUREAir inlet
F4R, and 770 or 771
12AAir intake circuit diagram
102744
1
2
23
45
6
7
(1) Air intake trunking
(2) Resonators
(3) Air filter unit
(4) Throttle body
(5) Intake manifold
(6) Injector mounting plate
(7) Air intake
12A-16
FUEL MIXTUREAir inlet
F4R, and 776
12A
107841
6
5
4
3
2
1
(1) Air intake
(2) Air resonator
(3) Air filter unit
(4) Turbocharger
(5) Intercooler
(6) Inlet manifold
12A-17
FUEL MIXTUREAir inlet
K9K, and 728 or 729
12A
110316
1
2
34
5
6
7
8
(1) Air inlet sleeve
(2) Air filter unit
(3) Exhaust gas recirculation unit
(4) Air resonator
(5) Metal air inlet tube
(6) Intercooler
(7) Turbocharger
(8) Air inlet
12A-18
FUEL MIXTUREAir inlet
F9Q, and 804
12ADiagram of the air inlet circuit
112269
(1) Air inlet
(2) Air filter unit
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Throttle valve
(7) Intercooler
(8) Air filter
(9) EGR unit
12A-19
FUEL MIXTUREAir inlet
K9K, and 732
12A
112302
1
2
3
4
56
7
8
(1) Air inlet
(2) Air filter unit
(3) Flowmeter
(4) Turbocharger
(5) Damper flap
(6) Air filter
(7) Intercooler
(8) Air resonator
12A-20
FUEL MIXTUREAir inlet
F9Q, and 808
12ADiagram of the air inlet circuit
114617
(1) Air inlet
(2) Air filter
(3) Flowmeter
(4) Turbocharger
(5) Inlet manifold
(6) Engine stop flap
(7) Intercooler
12A-21
FUEL MIXTUREAir inlet
M9R, and 700
12ADiagram of the air inlet circuit
114472
(1) Air inlet scoop
(2) Noise-reducing air duct
(3) Air resonator
(4) Air filter unit
(5) Air filter
(6) Air flowmeter
(7) Turbocharger
(8) Intercooler
(9) Damper flap
(10) EGR solenoid valve
12A-22
FUEL MIXTUREAir resonator: Removal - Refitting
M9R, and 700
12AREMOVAL
I - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the front bumper (see MR 365, Bodywork,55A, Exterior protection, Front bumper ).
Remove:
- the left-hand headlight upper mounting bolt (1) ,
- the left-hand headlight lower mounting bolt (2) .
Disconnect the left-hand headlight connectors.
Remove the left-hand headlight.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the air resonator (3) starting with the endpiece side of the duct that is upstream of the air filter.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the air resonator starting with the end pieceside of the duct that is upstream of the air filter.
II - FINAL OPERATION
Refit the left-hand headlight.
Tighten:
- the left-hand headlight upper mounting bolt,
- the left-hand headlight lower mounting bolt.
Disconnect the left-hand headlight connectors.
Refit the front bumper (see MR 365, Bodywork,55A, Exterior protection, Front bumper ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
115726
115725
114659
12A-23
FUEL MIXTUREAir filter: Replacement
K4J, and 730 or 732
12AREPLACING THE FILTER ELEMENT
Remove:
- the air resonator mounting bolt (1) ,
- the air resonator housing.
Disconnect brake servo vacuum pipe (2) from the in-let manifold.
Remove:
- the two air filter cover mounting bolts (3) ,
- the filter element.
101103
1
101104
WARNING
Do not damage the vacuum outlet on the inletmanifold. If it is broken the inlet manifold willneed to be replaced.
2
3
12A-24
FUEL MIXTUREAir filter: Replacement
F4R, and 770 or 771 or 776 – F9Q, and 800 or 804 or 808 – K4M, and 760 or 761 – K9K, and 722 or 728 or 729 or732
12A
REPLACING THE FILTER ELEMENT
Remove the mounting bolts (1) from the air filter co-ver.
Remove:
- the cover (2) ,
- the filter element.
.
REFITTING
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
battery cover mountingbolts
4 Nm
106277
11 106276
2
12A-25
FUEL MIXTUREAir filter: Removal - Refitting
F4R or F9Q or K4M or K9K or M9R
12AREMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the mounting bolts (1) from the air filter co-ver.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the cover (2) ,
- the air filter.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Clean the air filter unit.
Refit:
- the air filter,
- the cover.
II - FINAL OPERATION
Tighten the air filter unit mounting bolts.
106277
106276
12A-26
FUEL MIXTUREAir filter unit: Removal - Refitting
K4J, and 730 or 732
12A
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the seal (1) ,
- the plastic rivets (2) .
Unclip the trim (3) .
Remove wiper arms (4) using tool (Ele. 1294-01) .
Remove the scuttle panel grille.
Special tooling required
Ele. 1294-01 Windscreen wiper armremoving tool
Tightening torquesm
air filter unit mountingbolts
9 Nm
battery cover mountingbolts
4 Nm
102100
12
102101
102105
3
4
12A-27
FUEL MIXTUREAir filter unit: Removal - Refitting
K4J, and 730 or 732
12A
Remove:
- the bulkhead soundproofing mountings (5) ,
- the bulkhead soundproofing material.
Remove:
- the air resonator mounting bolt (6) ,
- the air resonator.
Disconnect brake servo vacuum pipe (7) from the in-let manifold.
Remove:
- air filter cover mounting bolts (8) ,
- the filter element.
101487
101103
5
5
55
6
101104
WARNING
Do not damage the vacuum outlet on the inletmanifold. If it is damaged, the inlet manifold willneed to be replaced.
7
8
12A-28
FUEL MIXTUREAir filter unit: Removal - Refitting
K4J, and 730 or 732
12A
Disconnect the oxygen sensor connector. (9)
Remove the retaining bracket (10) .
Remove:
- air filter mounting bolts (11) ,
- the air filter unit.
REFITTING
Replace:
- the throttle valve seal each time it is removed usinggrease to make fitting easier,
- the plastic rivets and clips every time they are re-moved.
Proceed in the reverse order to removal.
Torque tighten the air filter unit mounting bolts ( 9Nm ) .
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm ) .101494
101488
9
10
11
WARNINGcarry out the necessary programming (see 80A,Battery: Removal - refitting ).
12A-29
FUEL MIXTUREAir filter unit: Removal - Refitting
M9R, and 700
12A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove
- the engine protectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine undertray,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
Remove:
- the Protection and Switching Unit cover mountingbolts (1) ,
- the Protection and Switching Unit cover.
Disconnect the connectors (2) .
Unpick the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) .
Special tooling required
Mot. 1608 Torque screwdriver
Tightening torquesm
air flowmeter mountingbolts
4 Nm
air duct clip mountingbolt between the air fil-ter unit and the turbo-charger
5.5 Nm
front end panel lowermounting bolts
44 Nm
front end panel uppermounting bolts
21 Nm
battery tray mountingbolts
21 Nm
wiring harness moun-ting nut
8 Nm
112658
102504
12A-30
FUEL MIXTUREAir filter unit: Removal - Refitting
M9R, and 700
12A
Disconnect the injection computer connectors (6) .
Remove:
- the battery tray mounting bolts (7) ,
- the wiring harness mounting nut (8) .
Move the electric wiring harness to one side.
Unpick the battery negative terminal wiring harness(9) .
Remove the battery tray and the injection computer.
Move the turbocharger regulation solenoid valve(10) to one side.
Remove the air duct between the air filter unit andthe turbocharger.
Unclip the air inlet scoop (11) .
112659 104555
114933
12A-31
FUEL MIXTUREAir filter unit: Removal - Refitting
M9R, and 700
12A
Remove:
- the lower front end panel mounting bolts (12) .
- the front end panel.
Remove the air resonator (13) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the air inlet duct (14) .
Remove the air filter unit (15)
102365
114659
115019
115020
12A-32
FUEL MIXTUREAir filter unit: Removal - Refitting
M9R, and 700
12A
Remove
- the air flowmeter mounting bolts (16) ,
- the air flowmeter (17) .
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the air flowmeter onto the air filter unit.
Tighten to torque the air flowmeter mounting bolts( 4 Nm ) using the (Mot. 1608) .
Refit the air filter unit.
II - FINAL OPERATION
Refit:
- the air inlet duct,
- the air resonator,
- the front end panel mounting bolts,
- the front end panel clips,
- the front end panel mounting bolts.
Tighten to torque:
- the air duct clip mounting bolt between the airfilter unit and the turbocharger ( 5.5 Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) ,
- the front end panel upper mounting bolts ( 21Nm ) .
Clip on:
- the air inlet scoop to the front end panel,
- the bonnet opening cable
Fit the turbocharger regulation solenoid valve ontothe air filter unit.
Refit the battery tray and the computer.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Refit the wiring harness mounting nut.
Tighten to torque the wiring harness mounting nut( 8 Nm ) .
Connect:
- the injection computer connectors,
- the air flowmeter connector,
- the connectors to the Protection and Switching Unitbox.
Refit:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
- the engine undertray,
- the engine protectors.
114993
12A-33
FUEL MIXTUREAir filter unit: Removal - Refitting
K4M, and 760 or 761 – F4R, and 770 or 771 or 776
12A
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the battery (see 80A, Battery: Removal -Refitting ).
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
- the wiring harness strap (3) .
Unclip the wiring harnesses from the battery tray.
Remove the battery tray.
Remove the injection computer (4) and its mounting.
Remove:
- the air inlet sleeve (5) ,
- the air ducts (6) ,
- the air filter unit.
Tightening torquesm
battery tray mountingbolts
21 Nm
battery cover mountingbolts
4 Nm
101822
21
3
1122
101811
101737
4
6
5
6
12A-34
FUEL MIXTUREAir filter unit: Removal - Refitting
K4M, and 760 or 761 – F4R, and 770 or 771 or 776
12AREFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-35
FUEL MIXTUREAir filter unit: Removal - Refitting
K9K, and 722 or 728 or 729
12A
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the battery (see 80A, Battery: Removal -Refitting ).
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
- the wiring harness strap (3) .
Unclip the wiring harnesses from the battery tray.
Remove the battery tray.
Remove the injection computer (4) and its mounting.
Remove:
- the air inlet sleeve (5) ,
- the air ducts (6) ,
- the air filter unit.
Tightening torquesm
battery tray mountingbolts
21 Nm
battery cover mountingbolts
4 Nm
101822
101811
101737
12A-36
FUEL MIXTUREAir filter unit: Removal - Refitting
K9K, and 722 or 728 or 729
12AREFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-37
FUEL MIXTUREAir filter unit: Removal - Refitting
F9Q, and 800 or 804 or 808 – K9K, and 732
12A
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the battery (see 80A, Battery: Removal -Refitting ).
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
- the wiring harness strap (3) .
Unclip the wiring harnesses from the battery tray.
Remove the battery tray.
Remove the injection computer (4) and its mounting.
Remove:
- the air inlet sleeve (5) ,
- the air ducts (6) ,
- the air filter unit.
Tightening torquesm
battery tray mountingbolts
21 Nm
battery cover mountingbolts
4 Nm
101822
101811
101737
12A-38
FUEL MIXTUREAir filter unit: Removal - Refitting
F9Q, and 800 or 804 or 808 – K9K, and 732
12AREFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-39
FUEL MIXTUREAir flowmeter: Removal - Refitting
M9R, and 700
12A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Unclip:
- the turbocharger regulation solenoid valve hose (1)from the turbocharger - air filter unit air inlet duct,
- the oil vapour rebreathing duct (2) from the turbo-charger - air filter unit air inlet duct.
Unpick the turbocharger regulation solenoid valveon the air filter unit.
Disconnect the air flowmeter connector.
Move the turbocharger regulation solenoid valveand air flowmeter connector aside.
Loosen:
- the air inlet duct clip (3) on the air filter unit side,
- the air inlet duct clip on the turbocharger side.
Remove the turbocharger - air filter unit duct.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the air flowmeter mounting bolts (4) from the air fil-ter unit,
Special tooling required
Mot. 1608 Torque screwdriver
Tightening torquesm
air flowmeter mountingbolts on the air filter unit
4 Nm
air inlet duct clip on theair filter unit side
5.5 Nm
air inlet duct clip on theturbocharger side
5.5 Nm
114846
114990
114993
12A-40
FUEL MIXTUREAir flowmeter: Removal - Refitting
M9R, and 700
12A- the air flowmeter (5) .
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the air flowmeter,
- the bolts securing the air flowmeter.
Tighten to torque the air flowmeter mounting boltson the air filter unit ( 4 Nm ) using the (Mot. 1608) .
II - FINAL OPERATION
Refit the air filter unit - turbocharger air inlet duct.
Tighten to torque:
- the air inlet duct clip on the air filter unit side (5.5 Nm ) ,
- the air inlet duct clip on the turbocharger side (5.5 Nm ) .
Clip:
- the oil vapour rebreathing duct onto the air filter unit- turbocharger air inlet duct,
- the turbocharger regulation solenoid valve hoseonto the air filter unit - turbocharger air inlet duct,
Refit the turbocharger regulation solenoid valve ontothe air filter unit.
Connect:
- the air flowmeter connector,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Note:
Be sure not to damage the air flowmeter seal.
Replace the seal if necessary.
12A-41
FUEL MIXTUREAir inlet flap: Removal - Refitting
K9K, and 732
12A
REMOVAL
I - REFITTING PREPARATION OPERATION
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip and (2) and move the air inlet duct(3) to one side.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect:
- the connector (4) from the damper flap,
- the vacuum pipe from the brake servo.
Remove:
- the damper flap mounting nuts (5) ,
- the damper flap,
- the damper flap seal.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the damper flap with a new seal,
- the damper flap mounting nuts.
Tighten to torque the damper flap mounting nuts (12 Nm ) .
Connect:
- the vacuum pipe from the brake servo,
- the connector to the damper flap.
II - FINAL OPERATION
Refit the air inlet duct onto the damper flap.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Tightening torquesm
damper flap mountingnuts
12 Nm
112815
112810
12A-42
FUEL MIXTUREAir inlet flap: Removal - Refitting
K9K, and 732
12ARefit the engine covers.
12A-43
FUEL MIXTUREAir inlet flap: Removal - Refitting
F9Q, and 804
12A
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Loosen the air inlet hose clip (1) .
Disconnect the air inlet hose,
Move the air inlet hose to one side,
Disconnect:
- the connector (2) from the damper flap,
- the turbocharging pressure sensor connector (3) .
Remove the damper flap.
REFITTING
Proceed in the reverse order to removal.
Replace the seal.
Tighten to torque the damper flap mounting bolts( 8 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
damper flap mountingbolts
8 Nm
battery cover mountingbolts
4 Nm
111887
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-44
FUEL MIXTUREAir inlet flap: Removal - Refitting
M9R, and 700
12A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine protectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine undertray,
- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ).
Remove:
- the Protection and Switching Unit cover mountingbolts (1) ,
- the Protection and Switching Unit cover.
Disconnect the Protection and Switching Unit con-nectors (2) .
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the upper front end panel mounting bolts (5) ,
Disconnect the screen washer pipes.
Tightening torquesm
damper flap retainingstrut mounting bolts onthe inlet manifold
12 Nm
damper flap retainingstrut mounting bolts onthe exhaust gas recircu-lation solenoid valve
12 Nm
downstream intercoo-ler duct clip on the inter-cooler
5.5 Nm
downstream intercoo-ler duct clip on the dam-per flap
5.5 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
battery tray mountingbolts
21 Nm
wiring harness moun-ting nut on the batterytray
8 Nm
112658
115585
12A-45
FUEL MIXTUREAir inlet flap: Removal - Refitting
M9R, and 700
12A
Disconnect the injection computer connectors (6) .
Remove:
- the battery tray mounting bolts (7) ,
- the wiring harness mounting nut (8) .
Move the electric wiring harness to one side.
Unpick the battery negative terminal wiring harness(9) .
Remove the battery tray.
Unclip the air inlet scoop (10) .
Disconnect the turbocharger pressure sensor con-nector (11) .
Remove the turbocharger pressure sensor mountingnut (12) on the damper flap strut.
Remove:
- the lower front end panel mounting bolts (13) .
- the front end panel.
112659
114933
115701
102365
12A-46
FUEL MIXTUREAir inlet flap: Removal - Refitting
M9R, and 700
12A
Remove the mounting bolt (14) from the intercoolerduct (downstream) on the cooling radiator.
Loosen:
- the downstream intercooler duct clip (15) on the in-tercooler,
- the downstream intercooler duct clip (16) on thedamper flap.
Remove the downstream intercooler duct.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the damper flap connector (17) .
Remove:
- the mounting bolts (18) from the damper flap retai-ning strut on the inlet manifold,
- the mounting bolts (19) from the damper flap retai-ning strut on the exhaust gas recirculation solenoidvalve,
- the damper flap,
- the seal between the damper flap and the exhaustgas recirculation solenoid valve
REFITTING
I - REFITTING PREPARATION OPERATION
Replace the seal between the damper flap and theexhaust gas recirculation solenoid valve.
114649
115702
114406
12A-47
FUEL MIXTUREAir inlet flap: Removal - Refitting
M9R, and 700
12AII - REFITTING OPERATION FOR PART CONCERNED
Finger tighten until contact:
- the damper flap retaining strut mounting bolts onthe inlet manifold,
- the damper flap retaining strut mounting bolts onthe exhaust gas recirculation solenoid valve,
Tighten to torque:
- the damper flap retaining strut mounting boltson the inlet manifold ( 12 Nm ) ,
- the damper flap retaining strut mounting boltson the exhaust gas recirculation solenoid valve( 12 Nm ) .
12A-48
FUEL MIXTUREAir inlet flap: Removal - Refitting
M9R, and 700
12AIII - FINAL OPERATION
Refit:
- the downstream intercooler duct clip onto the inter-cooler and the damper flap,
- the downstream intercooler duct mounting boltonto the cooling radiator.
Tighten to torque:
- the downstream intercooler duct clip on the in-tercooler ( 5.5 Nm ) ,
- the downstream intercooler duct clip on thedamper flap ( 5.5 Nm ) .
Refit:
- the front end panel,
- front end panel mounting bolts.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) ,
Clip:
- the air inlet scoop,
- the bonnet opening cable.
Refit:
- the battery tray,
- the battery tray mounting bolts,
- the wiring harness mounting nut onto the batterytray.
Tighten to torque:
- the battery tray mounting bolts ( 21 Nm ) ,
- the wiring harness mounting nut on the batterytray ( 8 Nm )
Clip the battery negative terminal wiring harness.
Connect:
- the screen washer pipes,
- the Protection and Switching Unit connectors,
- the injection computer connectors.
Refit:
- the clips,
- the Protection and Switching Unit cover mountingbolts,
- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ),
- the engine undertray,
- the engine protectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Carry out programming by following command sce-nario SC036 if replacing or removing - refitting thedamper flap (see MR 366 Fault finding, 13B, Faultfinding - Interpretation of commands ) and (seeMR 366 Fault finding, 13B, Fault finding - Repla-cement of components ).
12A-49
FUEL MIXTUREAir inlet duct: Removal - Refitting
F9Q, and 800 or 808
12A
REMOVAL
Disconnect:
- the battery, starting with the negative terminal,
- the turbocharging pressure sensor (1) .
Loosen the clip (2) .
Disconnect the air inlet hose.
Separate the air inlet hose.
Disconnect the vacuum hose from the (3)diaphragm.
Remove:
- inlet duct mounting bolts (4) ,
- the air inlet duct mounting nut (5) ,
- the air inlet duct.
Tightening torquesm
inlet duct mountingbolts
8 Nm
inlet duct nut 21 Nm
battery cover mountingbolt
4 Nm
101893
1
101892
101884
2
3
4
5
12A-50
FUEL MIXTUREAir inlet duct: Removal - Refitting
F9Q, and 800 or 808
12AREFITTING
Replace the seal.
Refit the inlet duct.
Tighten to torque in order:
- the inlet duct mounting bolts ( 8 Nm ) ,
- the inlet duct nut ( 21 Nm ) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolt ( 4Nm ) .
101884
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
6
7
8
12A-51
FUEL MIXTUREAir inlet duct: Removal - Refitting
F9Q, and 804
12A
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Disconnect:
- the throttle valve connector (1) ,
- the pressure sensor connector (2) ,
- the inlet duct air duct (3) (4) ,
- the oil vapour rebreather pipe (5) :
• on the oil separator,
• on the turbocharger upstream air duct.
Remove:
- the inlet duct mounting bolts (6) ,
- the air inlet duct.
REFITTING
Replace the seals.
Refit the inlet duct.
Tighten to torque and in order:
- the inlet duct mounting bolts ( 25 Nm ) ,
- the inlet duct mounting nut ( 21 Nm ) ,
To refit, proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
inlet duct mountingbolts
25 Nm
inlet duct mounting nut 21 Nm
battery cover mountingbolts
4 Nm
111887
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-52
FUEL MIXTUREInlet manifold: Removal - Refitting
K4J, and 730 or 732
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove:
- the air filter unit (see 12A, Fuel mixture, Air filterunit ),
- the throttle valve (see 12A, Fuel mixture, Throttlevalve ).
Disconnect:
- the manifold pressure sensor (1) ,
- the ignition coils (2) ,
- the air temperature sensor (3) .
Move the wiring harness to one side.
Remove:
- the plenum chamber mounting bolts,
- the plenum chamber.
REFITTING
Always replace all of the seals.
Proceed in the reverse order to removal.
Tightening torquesm
plenum chamber moun-ting bolts
9 Nm
throttle valve bolts 13 Nm
air unit bolts 9 Nm
battery cover mountingbolts
4 Nm
101100
3
221
101794
12A-53
FUEL MIXTUREInlet manifold: Removal - Refitting
K4J, and 730 or 732
12A
Tighten to torque and in order the plenum chambermounting bolts ( 9 Nm )
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air unit bolts ( 9 Nm ) ,
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
101794
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting
7
1
4
6
3
5
2
12A-54
FUEL MIXTUREInlet manifold: Removal - Refitting
F4R, and 770 or 771 – K4M, and 760 or 761
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- air duct (1) .
Disconnect:
- throttle valve connector (2) ,
- brake servo vacuum pipe (3) to the inlet manifold.
Disconnect fuel vapour recirculation pipe (4) to thethrottle valve.
Tightening torquesm
inlet manifold bolts 9 Nm
motorised throttle valvebolts
13 Nm
battery cover mountingbolts
4 Nm
101807
1
102735
Note:
Do not damage the vacuum outlet on the inletmanifold. If it is damaged, the inlet manifold willneed to be replaced.
4
3
2
12A-55
FUEL MIXTUREInlet manifold: Removal - Refitting
F4R, and 770 or 771 – K4M, and 760 or 761
12A
Disconnect electrical wiring harness (5) .
Pull the electric wiring harness to one side.
Disconnect fuel inlet pipe (6) from the injector rail.
Unclip fuel vapour recirculation pipe (7) from the in-let manifold.
Remove the inlet manifold bolts.
ON THE WORKBENCH
Remove the throttle valve.
REFITTING
Always replace all of the seals with new ones.
Proceed in the reverse order to removal.
Tighten to torque and in order the inlet manifoldbolts ( 9 Nm ) .
Tighten to torque the motorised throttle valvebolts ( 13 Nm ) , tightening each bolt evenly.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
101795
IMPORTANT
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
102726
55
6
7
102726
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
1
8
7
3
6
2
5
4
12A-56
FUEL MIXTUREInlet manifold: Removal - Refitting
F4R, and 776
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove the engine covers.
Remove air duct (1) .
Remove petrol vapour rebreathing pipe (2) .
Disconnect the motorised throttle valve connector.
Remove air pipe (3) between the turbocharger andthe intercooler.
Remove:
- motorised throttle valve mounting bolts (4) ,
- the motorised throttle valve.
Disconnect:
- turbocharging pressure sensor connector (5) ,
- vacuum pipe (6) from the brake servo,
- oil vapour recirculation pipe (7) .
Tightening torquesm
inlet manifold mountingbolts
21 Nm
motorised throttle valvemounting bolts
21 Nm
battery cover mountingbolts
4 Nm
106270
106272
2
1
3
106633
106787
44
57
6
12A-57
FUEL MIXTUREInlet manifold: Removal - Refitting
F4R, and 776
12A
Disconnect:
- injection rail petrol supply pipe (8) ,
- the injector connectors.
Pull the electric wiring harness to one side.
Remove the inlet manifold bolts.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque and in order the inlet manifoldmounting bolts ( 21 Nm ) .
Tighten to torque the motorised throttle valvemounting bolts ( 21 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
106271
WARNING
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
106337
WARNING
Be sure to replace all the sealing joints with newones when they are removed.
8
106337
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
12A-58
FUEL MIXTUREInjector holder shim: Removal - Refitting
K4J, and 730 or 732
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove the inlet manifold (see 12A, Fuel mixture,Inlet manifold ).
Remove injector rail protector mounting nuts (1) .
Move the wiring harness to one side.
Disconnect:
- fuel supply union (2) ,
- injectors (3) ,
- pinking sensor (4) .
Remove the two injection rail bolts (5)
Pull the injection rail gently towards yourself to re-move it.
Remove:
- nut (6) securing the electrical wiring harness,
- oil gauge well (7) .
Tightening torquesm
injector holder shimmounting bolts 11 and12
25 Nm
injector holder shimmounting bolts 13 to 20
21 Nm
upper timing cover bolt 44 Nm
suspended mountingbolt
44 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from therail or supply duct.
101801
1
101802
101493
2
3 43
5
6
7
12A-59
FUEL MIXTUREInjector holder shim: Removal - Refitting
K4J, and 730 or 732
12A
Remove the injector holder shim mounting bolts.
REFITTING
The injector holder shim seal must always be repla-ced.
Insert all the mounting bolts.
Secure:
- the injector holder shim against the upper timingcover, by tightening bolt (8) by hand,
- the injector holder shim against the engine suspen-ded mounting by tightening bolt (9) by hand.
Position the injector mounting plate against thecross pieces (10) on the cylinder head cover.
Tighten to torque in order:
- injector holder shim mounting bolts 11 and 12( 25 Nm ) ,
- injector holder shim mounting bolts 13 to 20 (21 Nm ) .
Tighten to torque:
- the upper timing cover bolt ( 44 Nm ) ,
- the suspended mounting bolt ( 44 Nm ) .
Refit the inlet manifold (see 12A, Fuel mixture, Inletmanifold ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm ) .
101792
101792
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
8
9 10
11 12
1314
15
16
1718
19
20
12A-60
FUEL MIXTUREInjector holder shim: Removal - Refitting
K4M, and 760 or 761
12A
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove the inlet manifold (see 12A, Fuel mixture,Inlet manifold ).
Disconnect injectors (1) .
Move the wiring harness to one side.
Remove:
- injector rail mounting bolts (2) ,
- the injector rail, pulling it carefully towards you.
Remove injector mounting plate mounting bolts (3) .
Tightening torquesm
bolts 5 and 6 on theinjector holder shim
25 Nm
bolts 7 to 14 on theinjector holder shim
21 Nm
suspended mountingbolt
44 Nm
upper timing cover bolt 44 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from therail or supply duct.
101810
102303
11
2
33
3
33
12A-61
FUEL MIXTUREInjector holder shim: Removal - Refitting
K4M, and 760 or 761
12AREFITTING
The injector holder shim seal must always be repla-ced.
Insert all the mounting bolts.
Secure:
- the injector holder shim against the upper timingcover, by tightening bolt (3) by hand,
- the injector holder shim against the engine suspen-ded mounting by tightening bolt (4) by hand.
Tighten to torque in order:
- bolts 5 and 6 on the injector holder shim ( 25Nm ) ,
- bolts 7 to 14 on the injector holder shim (21 Nm ) .
Tighten to torque:
- the suspended mounting bolt ( 44 Nm ) ,
- the upper timing cover bolt ( 44 Nm ) .
Refit the inlet manifold (see 12A, Fuel mixture, Inletmanifold ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (
4 Nm ) .
102303
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
3
4
5 6
78
910
1112
13
14
12A-62
FUEL MIXTUREInjector holder shim: Removal - Refitting
F4R, and 770 or 771
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove the inlet manifold (see 12A, Fuel mixture,Inlet manifold ).
Remove injector rail protector mounting nuts (1) .
Move the wiring harness to one side.
Disconnect:
- fuel supply union (2) ,
- injection wiring harness (3) .
Remove:
- injector rail mounting bolts (4) ,
- the injector rail, pulling it carefully towards you.
Tightening torquesm
bolts 7 and 8 of theinjector holder shim
25 Nm
bolts 9 to 16 on theinjector holder shim
21 Nm
suspended mountingbolt 6
44 Nm
upper timing cover bolt5
44 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from therail or supply duct.
101801
1
102728
102730
3
2
4
12A-63
FUEL MIXTUREInjector holder shim: Removal - Refitting
F4R, and 770 or 771
12A
Remove the injector holder shim mounting bolts.
REFITTING
The injector holder shim seal must always be repla-ced.
Insert all the mounting bolts.
Secure:
- the injector holder shim against the upper timingcover, by tightening bolt (5) by hand
- the injector holder shim against the suspended en-gine mounting by tightening bolt (6) by hand.
Tighten to torque in order:
- bolts 7 and 8 of the injector holder shim ( 25Nm ) ,
- bolts 9 to 16 on the injector holder shim (21 Nm ) .
Tighten to torque:
- suspended mounting bolt 6 ( 44 Nm ) ,
- upper timing cover bolt 5 ( 44 Nm ) .
Refit the inlet manifold (see 12A, Fuel mixture, Inletmanifold ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm ) .
101792
101792
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
10 9
87
6
5
1615
14
13
1211
12A-64
FUEL MIXTUREManifolds: Removal - Refitting
F9Q, and 800 or 808
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
- the turbocharger (See 12B, Turbocharging, Tur-bocharger ).
Disconnect:
- the air inlet pipe from the damper (1) ,
- the engine stop solenoid valve (2) connector.
Remove:
- the pipe mountings (3) ,
- the vacuum canister (4) ,
- the engine stop solenoid valve (5) .
Disconnect the exhaust gas recirculation solenoidvalve.
Remove:
- the exhaust gas recirculation solenoid valve (6) ,
- the exhaust gas recirculation pipe (7)
- the engine lifting bracket (8)
- the manifold mounting nuts,
- the manifolds.
REFITTING
Proceed in the reverse order to removal.
Replace the gaskets:
- on the manifolds,
- the exhaust gas recirculation solenoid valve,
- on the air inlet duct.
Tighten to torque:
- the Manifold mounting stud ( 8 Nm ) ,
- the manifold mounting nuts, ( 28 Nm ) ,
- the exhaust gas recirculation valve mountingbolt ( 8 Nm ) .
Tighten to torque the engine cover mounting bolts( 4 Nm ) .
Tightening torquesm
Manifold mounting stud 8 Nm
manifold mounting nuts, 28 Nm
exhaust gas recircula-tion valve mounting bolt
8 Nm
engine cover mountingbolts
4 Nm
102486
1
2
3
4
5
102478
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
6
7
8
12A-65
FUEL MIXTUREManifolds: Removal - Refitting
F9Q, and 804
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Position the vehicle on a lift.
Remove:
- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting).
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
- the exhaust gas recirculation unit (see 14A, Emis-sion control, Exhaust gas recirculation unit ),
- the exhaust gas recirculation pipe,
- the catalytic pre-converter (see 19B, Exhaust, Ca-talytic pre-converter: Removal - Refitting ).
- the starter motor (see 16A, Starting-charging,Starter motor: Removal - Refitting ).
- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).
Disconnect the exhaust gas temperature before tur-bocharger sensor (1) .
Remove:
- the manifold mounting nuts
- the exhaust manifold (2) .
Remove the inlet manifold (3) .
Tightening torquesm
manifold mountingstuds
8 Nm
manifold mounting nuts 28 Nm
battery cover mountingbolts
4 Nm
111872
111873
12A-66
FUEL MIXTUREManifolds: Removal - Refitting
F9Q, and 804
12AREFITTING
Proceed in the reverse order to removal.
Replace the manifold gaskets.
Refit the manifolds.
Tighten to torque:
- the manifold mounting studs ( 8 Nm ) ,
- the manifold mounting nuts ( 28 Nm ) ,
Refit:
- the inlet duct (see 12A, Fuel mixture, Inlet duct ),
- the exhaust gas recirculation solenoid valve (see14A, Emission control, Exhaust gas recircula-tion unit ),
- the turbocharger (see 12B, Turbocharging, Tur-bocharger ).
Connect the battery, starting with the positive termi-nal.
Refit the engine lifting bracket.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-67
FUEL MIXTUREExhaust manifold: Removal - Refitting
M9R, and 700
12A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).
Disconnect:
- the injection computer connectors (1) ,
- the air flowmeter connector,
- the turbocharger regulation solenoid valve connec-tor.
Unclip:
- the battery negative terminal wiring harness (2) ,
- the injection computer connector wiring harness,
- the turbocharger regulation solenoid valve wiringharness.
Remove:
- the battery tray mounting bolts (3) ,
- the wiring harness mounting nut (4) .
Unpick the wiring harness from the injection compu-ter connectors.
Remove the battery tray with the injection computermounting.
Tightening torquesm
exhaust manifold studs 9 Nm
exhaust manifoldmounting nuts
30 Nm
EGR duct mountingbolts on the EGR cooler
30 Nm
EGR duct mountingbolts on the exhaustmanifold
30 Nm
EGR duct mountingbolt on the cylinderhead
10 Nm
EGR duct heat shieldmounting bolt on thecylinder head
10 Nm
EGR duct heat shieldmounting bolt on theexhaust manifold
10 Nm
lower mounting bolts ofthe front end panel
44 Nm
upper mounting bolts ofthe front end panel
21 Nm
air inlet duct clip 5.5 Nm
battery tray mountingbolts
21 Nm
IMPORTANT
Wear protective gloves during all operations.
112659
12A-68
FUEL MIXTUREExhaust manifold: Removal - Refitting
M9R, and 700
12A
Loosen the air inlet duct clip (5) on the air flowmeterside.
Remove:
- the air inlet duct on the air flowmeter side,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ).
Unclip the air inlet scoop (6) .
Remove:
- the Protection and Switching Unit cover mountingbolts (7) ,
- the Protection and Switching Unit cover.
Disconnect the Protection and Switching Unit con-nectors (8) .
Unfasten the bonnet opening cable (9) .
Remove:
- the clips (10) ,
- the upper mounting bolts (11) .
Disconnect the screen washer pipes.
114990
114933
112658
102504
12A-69
FUEL MIXTUREExhaust manifold: Removal - Refitting
M9R, and 700
12A
Remove:
- the front end panel mounting bolts (12) ,
- the front end panel.
Remove:
- the EGR duct heat shield mounting bolt (13) on theexhaust manifold,
- the EGR duct heat shield mounting bolt (14) on thecylinder head,
- the EGR duct mounting bolts (15) on the cylinderhead.
Move the EGR duct heat shield to one side.
Remove the EGR duct mounting bolts (16) on theEGR cooler.
Remove the EGR duct mounting bolts (17) on theexhaust manifold.
Move the EGR duct to one side.
Remove:
- the gasket between the EGR cooler and the EGRduct,
- the gasket between the EGR duct and the exhaustmanifold.
102365
113280
113295
113311
113281
12A-70
FUEL MIXTUREExhaust manifold: Removal - Refitting
M9R, and 700
12AII - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the exhaust manifold mounting nuts,
- the exhaust manifold spacers,
- the exhaust manifold,
- the exhaust manifold gasket.
REFITTING
I - REFITTING PREPARATION OPERATION
Clean and degrease the bearing faces:
- the exhaust manifold in case of reuse,
- the cylinder head face,
- the EGR duct,
Check that the exhaust manifold studs are correctlytorque tightened (9 Nm) ; if not, replace any looseexhaust manifold studs.
Tighten to torque the exhaust manifold studs ( 9Nm ) .
Refit the new seal on the exhaust manifold.
II - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the exhaust manifold,
- the spacers.
Finger tighten the new mounting nuts until they arein contact with the exhaust manifold.
Tighten to torque and in order the exhaust manifoldmounting nuts (18 Nm) .
Tighten to torque and in order the exhaust manifoldmounting nuts ( 30 Nm ) .
113279
113279
Note:
Check that the manifold gasket is positioned cor-rectly.
The tab must be positioned as (18) .
113279
12A-71
FUEL MIXTUREExhaust manifold: Removal - Refitting
M9R, and 700
12AIII - FINAL OPERATION
Refit:
- the new gasket between the EGR duct and the ex-haust manifold,
- the new gasket between the EGR cooler and theEGR duct.
Finger tighten until contact:
- the EGR duct mounting bolts on the exhaust mani-fold,
- the EGR duct mounting bolts on the EGR cooler,
- the EGR duct mounting bolts on the cylinder head.
Tighten to torque:
- the EGR duct mounting bolts on the EGR cooler( 30 Nm ) ,
- the EGR duct mounting bolts on the exhaustmanifold ( 30 Nm ) ,
- the EGR duct mounting bolt on the cylinderhead ( 10 Nm ) .
Fit the heat shield.
Refit:
- the EGR duct heat shield mounting bolt to the cylin-der head,
- the EGR duct heat shield mounting bolt to the ex-haust manifold.
Tighten to torque:
- the EGR duct heat shield mounting bolt on thecylinder head ( 10 Nm ) ,
- the EGR duct heat shield mounting bolt on theexhaust manifold ( 10 Nm ) .
Refit:
- the front end panel,
- the upper mounting bolts of the front end panel,
- the lower mounting bolts of the front end panel.
Tighten to torque:
- the lower mounting bolts of the front end panel( 44 Nm ) ,
- the upper mounting bolts of the front end panel( 21 Nm ) .
Clip on the air inlet scoop.
Connect the screen washer pipes.
Refit the clips.
Fit the bonnet opening cable.
Connect the Protection and Switching Unit connec-tors.
Refit:
- the Protection and Switching Unit cover,
- the Protection and Switching Unit cover mountingbolts,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ),
- the air inlet duct to the air flowmeter,
- the air inlet duct clip on the air flowmeter side.
Tighten to torque the air inlet duct clip ( 5.5 Nm ) .
Refit the battery tray with the injection computermounting.
Fit the computer connector wiring harness.
Refit:
- the wiring harness mounting nut,
- the battery tray mounting bolts.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Fit:
- the turbocharger regulation solenoid valve wiringharness,
- the battery negative terminal connector wiring har-ness,
- the injection computer connector wiring harness.
Connect:
- the turbocharger regulation solenoid valve connec-tor,
- the air flowmeter connector,
- the injection computer connectors.
Refit:
- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
12A-72
FUEL MIXTUREExhaust manifold: Removal - Refitting
K9K, and 722 or 728 or 729
12A
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the lifting eye (2) ,
- the air inlet metal tube (3) ,
- the turbocharger (see 12B, Turbocharging, Tur-bocharger ),
- the exhaust gas recirculation metal tube (1) ,
- the exhaust gas recirculation unit mounting bolts(4) ,
- the exhaust gas recirculation unit,
- the manifold mounting nuts (5) ,
- the manifold.
Special tooling required
Mot. 1567 Remote operationpliers for EGR clips
Tightening torquesm
exhaust manifold studs 9 Nm
exhaust manifoldmounting nuts
26 Nm
exhaust gas recircula-tion unit mounting bolts
21 Nm
air inlet metal tubemounting bolts
21 Nm
lifting eye 21 Nm
battery cover mountingbolts
4 Nm
102074
1
2
3
4
55
55
12A-73
FUEL MIXTUREExhaust manifold: Removal - Refitting
K9K, and 722 or 728 or 729
12AREFITTING
Replace the manifold gasket.
Tighten to torque the exhaust manifold studs ( 9Nm ) .
Refit the manifold.
Tighten to torque and in order the exhaust manifoldmounting nuts ( 26 Nm ) .
Fit:
- the exhaust gas recirculation unit,
- the new exhaust gas recirculation unit tube,
- the new clips on the new exhaust gas recirculationunit tube.
Tighten the new clips using the (Mot. 1567) .
Tighten to torque:
- the exhaust gas recirculation unit mountingbolts ( 21 Nm ) ,
- the air inlet metal tube mounting bolts ( 21 Nm ),
- the lifting eye ( 21 Nm ) .
Proceed in the reverse order to removal.
Refit the turbocharger (see 12B, Turbocharging,Turbocharger ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
20848-1
3
2
1
8
76
5
4
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-74
FUEL MIXTUREExhaust manifold: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
12A
REMOVALPosition the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the air filter unit (see 12A, Fuel mixture,Air filter unit ).
Remove the inlet manifold (see 12A, Fuel mixture,Inlet manifold ).
Disconnect downstream oxygen sensor (1) .
Remove:
- exhaust bracket mounting nuts (2) ,
- exhaust manifold strut (3) .
Special tooling required
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Tightening torquesm
manifold nuts. 23 ±±±± 3 Nm
heat shield bolts 10 Nm
oxygen sensors 45 Nm
mounting bolts for theexhaust pipe brackets tothe body
21 Nm
bolt on the inlet mani-fold strut
8 Nm
exhaust bracket nuts 20 Nm
battery cover mountingbolts
4 Nm
K4J
K4M
101501
101793
Note:
Mark with a pen the position of the exhaustsilentbloc supports on the vehicle body.
1
2333
12A-75
FUEL MIXTUREExhaust manifold: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
12A
Remove mounting bolt (4) from the exhaust pipe si-lentbloc supports on the body.
Remove mounting bolt (5) from the silencer silent-bloc bracket on the body.
Withdraw the exhaust pipe towards the rear of thevehicle.
Remove oxygen sensor (6) using tool (Mot. 1495-01) .
Remove upper heat shield (7) from the exhaust ma-nifold.
Remove:
- the nine exhaust manifold securing nuts,
- the exhaust manifold.
102116
102117
4
5
101798
101797
6
77
777
12A-76
FUEL MIXTUREExhaust manifold: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
12AON THE WORKBENCH
Remove the lower heat shield.
REFITTING
Always replace:
- the manifold gaskets,
- the exhaust bracket gaskets,
- the manifold nuts.
Proceed in the reverse order to removal.
Tighten to torque and in order:
- the manifold nuts. ( 23 ±±±± 3 Nm ) ,
- the heat shield bolts ( 10 Nm ) ,
- the oxygen sensors ( 45 Nm ) ,
- the mounting bolts for the exhaust pipe brac-kets to the body ( 21 Nm ) ,
- the bolt on the inlet manifold strut ( 8 Nm ) ,
- the exhaust bracket nuts ( 20 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
101502
101797
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
5
4
9
8
17
6
32
12A-77
FUEL MIXTUREExhaust manifold: Removal - Refitting
F4R, and 770 or 771
12A
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Disconnect downstream oxygen sensor (1) .
Remove:
- exhaust bracket mounting nuts (2) ,
- the exhaust manifold strut (3) .
Remove mounting bolt (4) from the exhaust pipe si-lentbloc supports on the body.
Special tooling required
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Tightening torquesm
manifold nuts 18 Nm
heat shield bolts 10 Nm
oxygen sensors 45 Nm
mounting bolts for theexhaust pipe brackets tothe body
21 Nm
bolt on the exhaustmanifold strut on thegearbox
21 Nm
exhaust bracket nuts 20 Nm
battery cover mountingbolts
4 Nm
101501
1
101793
Note:
Mark with a pen the position of the exhaustsilentbloc supports on the vehicle body.
102116
2
3
22
4
12A-78
FUEL MIXTUREExhaust manifold: Removal - Refitting
F4R, and 770 or 771
12A
Remove mounting bolt (5) from the silencer silent-bloc bracket on the body.
Withdraw the exhaust pipe towards the rear of thevehicle.
Remove oxygen sensor (6) using tool (Mot. 1495-01) .
Remove upper heat shield (7) from the exhaust ma-nifold.
Remove:
- the exhaust manifold mounting nuts,
- the exhaust manifold.
ON THE WORKBENCH
Remove the lower heat shield.
REFITTING
Always replace:
- the manifold gaskets,
102117
101798
5
7
6
7
101797
101502
12A-79
FUEL MIXTUREExhaust manifold: Removal - Refitting
F4R, and 770 or 771
12A- the exhaust bracket gaskets,
- the manifold nuts.
Proceed in the reverse order to removal.
Tighten to torque and in order:
- the manifold nuts ( 18 Nm ) ,
- the heat shield bolts ( 10 Nm ) ,
- the oxygen sensors ( 45 Nm ) ,
- the mounting bolts for the exhaust pipe brac-kets to the body ( 21 Nm ) ,
- the bolt on the exhaust manifold strut on thegearbox ( 21 Nm ) ,
- the exhaust bracket nuts ( 20 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
101797
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
3
97
25
14
6
8
12A-80
FUEL MIXTUREExhaust manifold: Removal - Refitting
F4R, and 776
12A
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove:
- the engine and transmission assembly (see 10A,Engine and peripherals, Engine - gearbox ),
- the turbocharger (see 12B, Turbocharging, Tur-bocharger ).
Remove:
- the exhaust manifold mounting nuts,
- the exhaust manifold.
REFITTING
Proceed in the reverse order to removal.Tightening torquesm
exhaust manifoldmounting nuts
20 Nm
the battery cover moun-ting bolts
4 Nm
21936
WARNING
Always replace:
- the exhaust manifold sealing ring,
- the exhaust manifold mounting nuts.
12A-81
FUEL MIXTUREExhaust manifold: Removal - Refitting
F4R, and 776
12A
Tighten to torque and in order the exhaust manifoldmounting nuts ( 20 Nm ) .
Refit:
- the turbocharger (see 12B, Turbocharging, Tur-bocharger ).
- the engine and transmission assembly (see 10A,Engine and peripherals, Engine - gearbox ),
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mountingbolts ( 4 Nm ) .
21936
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING
Strict adherence to the repair procedures isrequired for the removal and refitting of the turbo-charger in order to seal the system FAILURE TOCOMPLY WITH THESE INSTRUCTIONS MAYHAVE SERIOUS SAFETY-RELATED CONSE-QUENCES .
87
65
43
2
1
12A-82
FUEL MIXTUREExhaust manifold: Removal - Refitting
K9K, and 732
12A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Put the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip (2) .
Move aside the air inlet duct between the intercoolerand the damper valve on the damper valve.
Remove the mounting bolt (3) from the damper val-ve.
Remove:
- the engine undertray,
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).
- the lifting eye mounting bolts on the timing end,
- the lifting eye on the timing end.
Special tooling required
Mot. 1567 Remote operationpliers for EGR clips
Tightening torquesm
exhaust manifoldmounting studs
9 Nm
exhaust manifoldmounting nuts
26 Nm
exhaust gas recircula-tion unit mounting bolts
25 Nm
exhaust gas recircula-tion rigid pipe mountingbolts
35 Nm
112815
112810
12A-83
FUEL MIXTUREExhaust manifold: Removal - Refitting
K9K, and 732
12A
Remove the mounting bolts (4) from the injection railcover mounting bracket.
Remove:
- the clip (5) from the EGR rigid pipe using the (Mot.1567) ,
- the mounting bolts (6) from the exhaust gas recir-culation pipe,
- the exhaust gas inlet pipe .
Loosen the mounting bolts (7) on the EGR unit by afew turns.
Move the EGR unit to one side without removing it.
II - REMOVAL OF PART CONCERNED
Remove:
- the mounting nuts (8) from the exhaust manifold,
- the exhaust manifold.
REFITTING
I - REFITTING PREPARATION OPERATION
Always clean the joint faces thoroughly.
113475
113842
113558
113561
12A-84
FUEL MIXTUREExhaust manifold: Removal - Refitting
K9K, and 732
12AII - REFITTING OPERATION FOR PART CONCERNED
Tighten to torque and in order the exhaust manifoldmounting studs ( 9 Nm ) .
Position the new exhaust manifold gasket.
Refit:
- the exhaust manifold,
- the exhaust manifold mounting nuts.
Tighten to torque the exhaust manifold mountingnuts ( 26 Nm ) .
III - FINAL OPERATION
Fit the exhaust gas recirculation unit.
Torque tighten the exhaust gas recirculation unitmounting bolts ( 25 Nm ) .
Refit:
- the new exhaust gas recirculation rigid pipe with anew seal,
- the mounting bolts on the exhaust gas recirculationpipe,
Fit the new snap-on clip.
Tighten the bolts of the exhaust gas recirculation ri-gid pipe on the manifold until they make contact.
Adjust the exhaust gas recirculation rigid pipe in re-lation to the cooler support.
Lock the snap-on clip of the exhaust gas recircula-tion rigid pipe using the (Mot. 1567) .
Tighten to torque the exhaust gas recirculation ri-gid pipe mounting bolts ( 35 Nm ) .
Refit:
- the lifting eye mounting bolts on the timing end,
- the timing end lifting eye,
- the injection rail protector cover retaining bracketmounting bolts,
20848-1
WARNING
Ensure that you do not constrain the exhaust gasrecirculation rigid pipe before fitting the snap-onclip.
12A-85
FUEL MIXTUREExhaust manifold: Removal - Refitting
K9K, and 732
12A- the inlet throttle valve mounting bolt,
- the turbocharger (see 12B, Turbocharging, Tur-bocharger: Removal - Refitting ).
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the engine undertray.
Connect the damper valve connector.
Refit the air inlet duct between the intercooler andthe inlet throttle valve on the inlet throttle valve.
Tighten the clip on the air inlet duct.
Connect the air inlet pressure sensor connector.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Refit the engine covers.
12A-86
FUEL MIXTUREThrottle valve: Removal - Refitting
K4J, and 730 or 732
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove air filter unit (1) (see 12A, Fuel mixture,Air filter unit ).
Disconnect:
- throttle valve connector (2) ,
- fuel vapour recirculation pipe (3) on the control so-lenoid valve.
Remove:
- mounting bolts (4) ,
- the throttle valve.
Equipment required
diagnostic tool
Tightening torquesm
throttle valve bolts 13 Nm
air filter unit bolts 9 Nm
battery cover mountingbolts
4 Nm
101489
1
2
3
101800
44
12A-87
FUEL MIXTUREThrottle valve: Removal - Refitting
K4J, and 730 or 732
12AREFITTING
Proceed in the reverse order to removal.
Replace the throttle valve seal each time it is remo-ved (use grease to make it easier to fit).
Tighten to torque:
- the throttle valve bolts ( 13 Nm ) ,
- the air filter unit bolts ( 9 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
In the event of a throttle valve replacement, use thediagnostic tool « CLIP » to reinitialise the stop pro-g r a m m i n g u s i n g c o m m a n d RZ005« Programming » .
When the ignition is switched on, the throttle valveshould go through a cycle of programming the MINand MAX throttle stop positions.
Using the diagnostic tool « CLIP » , check that theprogramming has been performed correctly ET051« Throttle stop programming » .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
12A-88
FUEL MIXTUREThrottle valve: Removal - Refitting
F9Q, and 800 or 808
12A
REMOVAL
Disconnect:
- the battery, starting with the negative terminal,
- turbocharging pressure sensor (1) .
Unscrew air inlet hose clip (2) .
Disconnect the air inlet hose.
Separate the air inlet hose.
Disconnect vacuum hose (3) from the diaphragm.
Remove:
- the three mounting bolts (4) ,
- the « throttle valve / diaphragm » assembly.
REFITTING
Proceed in the reverse order to removal.
Replace the seal.
Tighten to torque the throttle valve mounting bolts( 8 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
throttle valve mountingbolts
8 Nm
battery cover mountingbolts
4 Nm
101893
1
101892
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
2
3
44
12A-89
FUEL MIXTUREThrottle valve: Removal - Refitting
K4M, and 760 or 761
12A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove air duct (1) .
Disconnect:
- throttle valve connector (2) ,
- fuel vapour recirculation pipe (3) on the control so-lenoid valve.
Remove:
- the four throttle valve mounting bolts (4) ,
- the throttle valve.
Equipment required
diagnostic tool
Tightening torquesm
throttle valve mountingbolts
13 Nm
battery cover mountingbolts
4 Nm
101807
1
102735
4
3
2
4
4
4
12A-90
FUEL MIXTUREThrottle valve: Removal - Refitting
K4M, and 760 or 761
12AREFITTING
Replace the throttle valve seal with a new one eachtime it is removed.
Proceed in the reverse order to removal.
Tighten to torque the throttle valve mounting bolts( 13 Nm ) , tightening them evenly.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
In the event of a throttle valve replacement, use thediagnostic tool « CLIP » to reinitialise the stop pro-g r a m m i n g u s i n g c o m m a n d RZ005« Programming » .
When the ignition is switched on, the throttle valveshould go through a cycle of programming the MINand MAX throttle stop positions.
Check using the diagnostic tool « CLIP » that theprogramming has been performed correctly ET051« Throttle stop programming » .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
12A-91
FUEL MIXTUREThrottle valve: Removal - Refitting
F4R, and 770 or 771 or 776
12A
REMOVAL
Remove the engine covers.
Remove air duct (1) .
Remove fuel vapour recirculation pipe (2) .
Disconnect the motorised throttle valve connector.
Remove:
- motorised throttle valve mounting bolts (3) ,
- the motorised throttle valve.
Disconnect the battery, starting with the negativeterminal.
Remove air duct (4) .
Equipment required
diagnostic tool
Tightening torquesm
throttle valve mountingbolts (F4R 776)
10 Nm
throttle valve mountingbolts
13 Nm
battery cover mountingbolts
4 Nm
F4R, and 776
106270
2
1
106633
101807
333
4
12A-92
FUEL MIXTUREThrottle valve: Removal - Refitting
F4R, and 770 or 771 or 776
12A
Disconnect:
- throttle valve connector (5) ,
- fuel vapour recirculation pipe (6) on the control so-lenoid valve.
Remove:
- the four throttle valve mounting bolts (7) ,
- the throttle valve.
REFITTING
Replace the throttle valve seal each time it is remo-ved.
Proceed in the reverse order to removal.
Tighten to torque the throttle valve mounting bolts(F4R 776) ( 10 Nm ) , tightening them evenly.
Tighten to torque the throttle valve mounting bolts( 13 Nm ) , tightening them evenly.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
In the event of a throttle valve replacement, use thediagnostic tool « CLIP » to reinitialise the stop pro-g ramming us ing command R Z 0 0 5« Programming » .
When the ignition is switched on, the throttle valveshould go through a cycle of programming the MINand MAX throttle stop positions.
Using the diagnostic tool « CLIP » , check that theprogramming has been performed correctly ET051« Throttle stop programming » .
102735
5
6
7
7
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
12A-93
FUEL MIXTUREThrottle valve: Removal - Refitting
F9Q, and 804
12A
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Undo the air inlet hose clip (1) .
Disconnect the air inlet hose,
Move the air inlet hose to one side,
Disconnect:
- the throttle valve connector (2) ,
- the turbocharging pressure sensor connector (3) .
Remove the throttle valve.
REFITTING
Proceed in the reverse order to removal.
Replace the seal.
Torque tighten the throttle valve mounting bolts (8 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
throttle valve mountingbolts
8 Nm
battery cover mountingbolts
4 Nm
111887
1
32
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-94
FUEL MIXTUREThrottle valve: Cleaning
F4R or K4J or K4M
12A
Remove the throttle valve (see 12A, Fuel mixture,Throttle valve ).
Remove the external O-ring seals from the throttlevalve.
Hold the throttle valve flap open manually.
Spray the cleaning product onto the inside of the val-ve until all traces of clogging disappear.
Remove the cleaning product residue and the dirt re-sidue using a cloth, part number 77 11 211 707
Equipment required
diagnostic tool
WARNING
Wear protective goggles and gloves during the ope-ration. Be sure to work in a clean environment soas not to allow any contamination of the throttlevalve.
106899
Note:
The Renault carburettor cleaning agent, partnumber 77 11 171 437 can damage the seals.
106901
WARNING
Do not apply cleaning agent, part number 77 11171 437 , to the outside of the valve, in the springhousing or on the connector.
106900
12A-95
FUEL MIXTUREThrottle valve: Cleaning
F4R or K4J or K4M
12A
Use a nozzle to direct compressed air at the edgesand outside of the throttle valve.
Refit the throttle valve (see 12A, Fuel mixture,Throttle valve ).
Connect the battery, starting with the positive termi-nal.
Using tool diagnostic tool , reinitialise the program-ming of the throttle stops via the delete commandRZ005 « Programming » .
When the ignition is switched on, the throttle valveshould go through a cycle of programming the MINand MAX throttle stop positions.
Check, using the diagnostic tool , that this pro-gramming has been carried out using the commandET051 « Throttle stop programming » .
106902
WARNING
It is essential to replace the throttle valve O-ringseals.
Note:
If the throttle valve is dropped or receives anyother impact, it will need to be replaced.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12A-96
FUEL MIXTUREEngine stop device
F9Q, and 800 or 808
12AI - OBJECTIVE
The system is intended to stop the engine quickly afterthe ignition is switched off.
II - DESCRIPTION
The system consists of:
- a diaphragm (1) acting on the throttle,
- a throttle (2) ,
- a solenoid valve (3) ,
- a vacuum (4) .
III - OPERATING PRINCIPLE
When the ignition is switched off, the solenoid valveconnects the vacuum and the diaphragm.
The diaphragm is submitted to the vacuum; this closesthe air inlet flap.
The engine can no longer take in air and stops runningimmediately.
101892
101894
2
1
2
1
102486
3
4
12B-1
TURBOCHARGINGTurbocharging: Precautions for repair
F9Q
12BInstructions that must be followed when turbochargers are replaced due to mechanical damage:
- damage to the bearing system,
- broken shaft,
- compressor wheel rubbing against the turbochargercasing,
- broken compressor wheel.
Damage of the kind listed above can lead to impuritiesentering the circuits to which the turbocharger is con-nected.
FOR THE AIR CIRCUIT:
- Consequences:
• swarf and metal objects in the ducts upstream anddownstream of the turbocharger,
• large volumes of oil in the air circuit (collected in theintercooler).
- Risks (after replacing the turbocharger):
• metal objects found in the compressor wheel (des-truction of turbocharger),
• engine racing (oil sucked up in the intercooler).
FOR THE LUBRICATION CIRCUIT:
- Consequences:
• swarf found in the engine oil circuit,
• circulation of swarf within the circuit.
- Risks (after replacing the turbocharger):
• premature wear on the bearing system (destructionof turbocharger).
The following must be replaced:
- intercooler,
- turbocharger upstream air duct,
- engine oil,
- oil filter,
- turbocharger oil supply and return pipes,
- all seals that have been removed.
DESCRIPTION OF OPERATION
- Replace the intercooler
- Replace the turbocharger upstream duct (see dia-gram)
- Clean the turbocharger ducts
- Drain the engine oil
- Replace the oil filter
- Replace the oil return and supply pipes and theirseals
I - INSTRUCTIONS FOR THE AIR CIRCUIT
Diagram of the air circuit
Remove intercooler (3) if the vehicle is fitted with one(refer to the Workshop Repair Manual of the vehicle af-fected 12B, Turbocharging, Intercooler ).
WARNINGMetal objects may enter the oil and air circuits as aresult of a broken turbocharger.
Failure to follow the INSTRUCTIONS listed will leadto the turbocharger breaking again.
112666
(1) air filter
(2) compressor wheel
(3) intercooler
(4) turbocharger pressure sensor
(5) inlet manifold
(6) turbine wheel
WARNING
Always replace the intercooler.
5
4
3
2
1
C
B
A6
7
12B-2
TURBOCHARGINGTurbocharging: Precautions for repair
F9Q
12B
Damage to the compressor wheel results in metal ob-jects entering the air duct (A) between the air filter andthe turbocharger.
Replace the air duct (A) between the air filter and theturbocharger.
Check that there are no metal objects inside the flow-meter (7) .
Clean the ducts
Remove:
- the air circuit duct (between the turbocharger and theintercooler) for section (B) ,
- the air circuit duct (between the intercooler and the in-let manifold) for section (C) .
Remove the turbocharger pressure sensor (4) for sec-tion (C) , if the duct is fitted with one.
For ducts comprising several components:
- mark the duct (11) so that you can identify whereeach component should be positioned when refitting,
- separate all the duct components.
Clean the removed ducts one by one using a cleaning spray:
- brush as much of the duct interior as possible (onlyuse brushes with plastic bristles),
- wash the duct with plenty of cleaning liquid,
- let the cleaned duct drain by standing it up verticallyand then start cleaning the next duct.
110738 112772
112770
11
12B-3
TURBOCHARGINGTurbocharging: Precautions for repair
F9Q
12B
Dry the ducts one by one using a compressed air spraygun.
For ducts comprising several components:
- assemble the components in the correct order usingthe markings (11) that you have previously made.
Refit:
- the turbocharger pressure sensor (4) for section (C) ,if the duct is fitted with one.
- the air circuit duct (between the turbocharger and theintercooler) for section (B) ,
- the air circuit duct (between the intercooler and the in-let manifold) for section (C) ,
Refit the new intercooler (3) , if the vehicle is fitted withone (refer to the Workshop Repair Manual of the vehi-cle affected 12B, Turbocharging, Intercooler ,).
II - INSTRUCTIONS FOR THE LUBRICATION CIRCUIT
Drain the engine oil.
Replace the oil filter.
Replace:
- the turbocharger oil supply pipe,
- the turbocharger oil return pipe(s).
112771 102480
111870
WARNING
Always replace all seals that have been removed.
12B-4
TURBOCHARGINGTurbocharging: Precautions for repair
F9Q
12B
WARNING
When starting the engine:
- let the engine run at idle speed for 1 minute sothat the oil circuit pressure can reach the requiredlevel,
- accelerate several times under no load.
12B-5
TURBOCHARGINGTurbocharging: Precautions for repair
M9R, and 700
12B
WARNING
With a marker, mark the position of the exhaust rub-ber mounting bush supports on the bodywork.
WARNING
- Ensure that no foreign bodies enter the turbine orcompressor during the refitting operation.
- Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Checkthat it is not leaking; if it is, replace it.
12B-6
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 722 or 728 or 729
12B
REMOVALPut the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the engine undertray.
Disconnect air duct (1) .
Remove air duct (2) from the turbocharger.
Disconnect:
- the turbocharger pressure sensor (3) ,
- the exhaust gas recirculation solenoid valve (4) ,
- the turbocharging duct (5) on the turbocharger,
- the pipe (6) from the turbocharging pressure regu-lation valve on the air duct.
Equipment required
diagnostic tool
Tightening torquesm
turbocharger mountingstuds on the turbochar-ger
7 Nm
turbocharger mountingstuds on the exhaustmanifold
7 Nm
turbocharger mountingnuts on the exhaustmanifold
26 Nm
turbocharger oil inletpipe union on the cylin-der head
22.5 Nm
turbocharger oil inletduct socketed bolt onthe turbocharger
22.5 Nm
turbocharger oil returnpipe mounting bolts onthe turbocharger
12 Nm
exhaust gas recircula-tion solenoid valve heatshield mounting bolts
12 Nm
battery cover mountingbolts
4 Nm
K9K, and 722
102081
4
6
5
3
2
1
12B-7
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 722 or 728 or 729
12B
Pull out the clip.
Undo bolt (7) .
Remove the air duct (8) .
Disconnect:
- the turbocharging pressure sensor connector (9) ,
- the exhaust gas recirculation solenoid valve mani-fold (10) ,
- the turbocharging duct (11) on the turbocharger,
- the pipe from the turbocharging pressure regula-tion valve on the turbocharging pressure regulationsolenoid valve.
K9K, and 728 or 729
110325
110323
8
7
110326
11
10
9
12B-8
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 722 or 728 or 729
12B
Remove:
- the exhaust flange mountings (12) ,
- the stay mounting (13) on the catalytic converter.
Loosen the other stay mountings on the gearbox.
Remove stay (13) .
Remove mounting bolt (14) from the exhaust piperubber mounting bush support on the body.
Remove mounting bolt (15) from the silencer rubbermounting bush support on the body.
Withdraw the exhaust pipe towards the rear of thevehicle.
102076
Note:
Mark the position of the exhaust rubber mountingbush supports on the vehicle body with a pen.
13
1212
102116
102117
14
15
12B-9
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 722 or 728 or 729
12B
Remove:
- the catalytic converter stay (16) ,
- the four mounting nuts (17) securing the catalyticconverter to the turbocharger,
- the catalytic converter.
Remove:
- the bracket (18) ,
- the exhaust gas recirculation solenoid valve heatshield (19) .
Remove:
- the oil supply pipe (20) ,
- the oil return pipe (21) ,
- the two upper mounting nuts (22) from the turbo-charger,
- the lower mounting nut from below,
- the turbocharger.
102077
102119
16
17171717
19 18
102079
22
21
20
22
12B-10
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 722 or 728 or 729
12BREFITTING
Tighten to torque:
- the turbocharger mounting studs on the turbo-charger ( 7 Nm ) ,
- the turbocharger mounting studs on the ex-haust manifold ( 7 Nm ) .
Position the turbocharger on the exhaust manifold.
Tighten to torque the turbocharger mounting nutson the exhaust manifold ( 26 Nm ) .
Apply LOCTITE FRENTANCH to the threads of theturbocharger oil inlet pipe union on the cylinderhead.
Position the turbocharger oil supply pipe on the tur-bocharger and on the cylinder head, applying newseals in the process.
Tighten to torque:
- the turbocharger oil inlet pipe union on the cy-linder head ( 22.5 Nm ) ,
- the turbocharger oil inlet duct socketed bolt onthe turbocharger ( 22.5 Nm ) .
Position the turbocharger oil return pipe on the tur-bocharger and on the cylinder block, applying newseals in the process.
Torque tighten the turbocharger oil return pipemounting bolts on the turbocharger ( 12 Nm )
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter: Removal - Refitting ).
Proceed in the reverse order to removal.
Tighten to torque the exhaust gas recirculationsolenoid valve heat shield mounting bolts ( 12Nm ) .
Connect the battery, starting with the positive termi-nal.
Before starting, disconnect the 4 injectors (startingthe engine is prohibited).
Run the starter motor until the oil pressure warninglight goes out (wait for a few seconds).
Switch off the ignition.
Reconnect the 4 injector connectors.
Start the engine.
Let the engine idle then depress the accelerator se-veral times with no load.
Switch off the ignition.
Make sure that there are no oil leaks.
Connect the diagnostic tool and clear the storedfaults.
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Make sure that there is no contact with the underbo-dy.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Ensure that no impurities enter the turbine orcompressor during the refitting operation.
Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Alsocheck that the sealing is perfect; if not, replace it.
WARNINGCheck that the intercooler is not full of oil. If thisis the case, remove it, rinse with a cleaning agentand then let it dry.
WARNING
Always replace:
- all the O-rings and both copper seals on the tur-bocharger oil inlet duct,
- the exhaust flange seal.
- any damaged heat shield.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12B-11
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 800
12B
REMOVALPut the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).
Disconnect the turbocharger air inlet and outlet pi-pes.
Disconnect the tube (1) from the turbocharging pres-sure regulation valve control diaphragm.
Remove:
- the turbocharger oil supply pipe (2) ,
- the turbocharger oil return pipe (3) ,
- the turbocharger mounting nuts (4) ,
- the turbocharger.
Tightening torquesm
turbocharger mountingstuds
8 Nm
turbocharger union endpiece
26 Nm
turbocharger mountingnuts
26 Nm
oil supply pipe moun-ting nuts
22.5 Nm
oil supply pipe moun-ting bolt on the cylinderblock
12 Nm
turbocharger oil returnpipe mounting bolts
12 Nm
battery cover mountingbolts
4 Nm102481
102480
12B-12
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 800
12BREFITTING
Proceed in the reverse order to removal.
Be sure to replace the seals:
- on the turbocharger oil supply pipe,
- on the turbocharger oil return pipe,
- the turbocharger,
WARNINGEnsure that no impurities enter the turbine orcompressor during the refitting operation.
Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale.
check that the sealing is perfect; if not, replace it.
12B-13
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 800
12B
Always replace the end piece seal on the union (5) ,if the end piece has been removed.
Tighten to torque:
- the turbocharger mounting studs ( 8 Nm ) ,
- the turbocharger union end piece ( 26 Nm ) , ifthe studs have been removed.
Refit the turbocharger.
Tighten to torque the turbocharger mounting nuts( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply pipenuts,
- screw on (without tightening) the oil supply pipemounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
- the oil supply pipe mounting nuts ( 22.5 Nm ) ,
- the oil supply pipe mounting bolt on the cylin-der block ( 12 Nm ) ,
- the turbocharger oil return pipe mounting bolts( 12 Nm ) .
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter: Removal - Refitting ).
Proceed in the reverse order to removal.
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Refit the exhaust pipe, aligning it with the marks
made previously.
Make sure that there is no contact with the underbo-dy.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has goneout,
- let the engine run at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
114467
12B-14
TURBOCHARGINGTurbocharger: Removal - Refitting
F4R, and 776
12B
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Removal of the turbocharger requires the engine tobe removed (see 10A, Engine and peripherals,Engine - Gearbox ).
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter ).
Disconnect:
- the wastegate control solenoid valve pipe (1) ,
- the solenoid valve - turbocharger pipe (2) ,
- the braking solenoid valve pipe (3) .
Remove the air filter - turbocharger pipe (4) .
Fit hose clamps and remove the turbocharger coo-ling hoses (5) .
Equipment required
diagnostic tool
Tightening torquesm
bolts of the oil returnpipe towards the cylin-der block
12 Nm
turbocharger coolingduct bolts (initial torque)
12 Nm
turbocharger coolingduct bolts
27 Nm
turbocharger mountings 15 Nm + 75˚
oil supply pipe hollowmounting bolt
45 Nm
oil supply pipe union 25 Nm
oil return pipe mountingbolts
8 Nm
mounting bolts of the oilreturn and supply pipes
21 Nm
Note:
To loosen the turbocharger mounting nuts on theexhaust manifold, spray some releasing agentonto the nuts while they are still warm, justbefore removal.
21927
21928
32
1
4
55
12B-15
TURBOCHARGINGTurbocharger: Removal - Refitting
F4R, and 776
12B
Remove:
- the heat shield bolt (6) ,
- the engine cover mounting and the turbochargerstrut (7) ,
- the turbocharger - intercooler air pipe.
Remove the starter motor heat shield.
Remove:
- the turbocharger oil return pipe mounting bolts (8) ,
- the turbocharger oil return pipe (10) ,
- the turbocharger oil supply pipe (9) .
Remove:
- the nuts (11) securing the turbocharger to the ma-nifold,
- the turbocharger.
21929
21930
21931
21933
12B-16
TURBOCHARGINGTurbocharger: Removal - Refitting
F4R, and 776
12BREFITTING
The turbocharger mounting nuts and studs must bereplaced along with the seals.
On the workbench, refit and tighten to torque:
- the two bolts of the oil return pipe towards thecylinder block ( 12 Nm ) (13) ,
- the oil return pipe bolt (14) .
Pre-tighten the turbocharger cooling duct bolts(initial torque) ( 12 Nm ) (15) ,
Tighten to torque the turbocharger cooling ductbolts ( 27 Nm ) .
Fit and finger tighten:
- the turbocharger mountings on the exhaust mani-fold,
- the oil supply pipe mountings on the turbocharger,
- the return pipe to the cylinder block,
- the turbocharger - intercooler air pipe,
- the turbocharger strut mounting.
Tighten:
- the clip (16) from the intercooler - turbochargerpipe to position the turbocharger,
- the turbocharger strut (17) .
WARNING
Ensure that no impurities enter the turbine orcompressor during the refitting operation.
If there has been a fault in the turbocharger,check that the intercooler is not full of oil. If this isthe case, remove it, rinse with a cleaning agentand then let it dry.
Check that the turbocharger oil return pipe is notpartially or completely blocked by scale. Alsocheck that it is perfectly sealed. If not, replace it.
22809
14
13
15
13
1521931
106273
17
16
12B-17
TURBOCHARGINGTurbocharger: Removal - Refitting
F4R, and 776
12B
Tighten to torque:
- the turbocharger mountings ( 15 Nm + 75˚ ) (18),
- the oil supply pipe hollow mounting bolt ( 45Nm ) (19) ,
- the oil supply pipe union ( 25 Nm ) (20) ,
- the oil return pipe mounting bolts ( 8 Nm ) (21) ,
- the mounting bolts of the oil return and supplypipes ( 21 Nm ) (22) .
Proceed in the reverse order to removal.
All removed seals must be replaced including thoseon the cooling pipe as well as the intercooler - turbo-charger air pipe.
Fill and bleed the cooling circuit (see 19A, Cooling,Filling - Bleeding ).
Connect the battery, starting with the positive termi-nal.
21933
21931
181818
18
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING- Before starting the engine, connect the dia-
gnostic tool and lock the injection system.
- Run the starter motor until the oil pressure war-ning light goes out (wait a few seconds) thenunlock the injection system.
- Start the engine then accelerate with no loadseveral times.
- Switch off the ignition and check that there areno oil leaks.
- Run the engine at idle speed until the enginecooling fan starts up:
- Accelerate several times with no load then per-form a road test.
- Clear the faults using the diagnostic tool .
- Switch off the ignition and check that there areno oil leaks.
12B-18
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 804
12B
REMOVALPut the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the battery.
Remove:
- the battery tray mounting bolts (1) ,
- the nut (2) ,
- the battery tray.
Bleed the cooling system (see 19A, Cooling, Coo-ling system: Draining - filling ).
Remove the catalytic pre-converter (see 19B, Ex-haust, Catalytic Pre-converter: Removal - Refit-ting ).
Special tooling required
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Equipment required
diagnostic tool
Tightening torquesm
turbocharger mountingnuts
37 Nm
turbocharger oil supplypipe hollow mountingbolts
22.5 Nm
oil supply pipe hollowmounting bolt on thehousing
44 Nm
oil supply pipe moun-ting bolt on the housing
25 Nm
turbocharger oil returnpipe
12 Nm
battery cover mountingbolts
4 Nm
112659
12B-19
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 804
12B
Remove, using the (Mot. 1448) :
- the « hose - rigid pipe assembly » (3) . betweenthe EGR cooler (4) and the water outlet unit,
- the « hose - rigid pipe assembly » (5) between theEGR coolant and the heater matrix hose.
Disconnect the upper cooling hose on the turbochar-ger.
Remove the air duct (6) from the turbocharger.
Remove the duct between the turbocharger and theair filter.
Disconnect the turbocharger (7) vacuum pipe.
Remove the turbocharger oil return pipe (8) .
111866
111860
111869
111865
12B-20
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 804
12B
Remove the starter motor (see 16A, Starting-Char-ging, Starter motor: Removal - Refitting ).
Remove the heat shield (9) .
Remove the turbocharger oil supply pipe (10) .
Remove the turbocharger mounting nuts (11) .
111868
111867
111870
111871
12B-21
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 804
12B
Remove the turbocharger (12) .
REFITTING
Proceed in the reverse order to removal.
Always replace:
- the turbocharger oil supply pipe,
- the oil supply pipe hollow mounting bolts,
- the seals on the turbocharger oil return pipe,
- the seal between the turbocharger and the exhaustmanifold,
Tighten to torque:
- the turbocharger mounting nuts ( 37 Nm ) ,
- the turbocharger oil supply pipe hollow moun-ting bolts ( 22.5 Nm ) ,
- the oil supply pipe hollow mounting bolt on thehousing ( 44 Nm ) ,
- the oil supply pipe mounting bolt on the hou-sing ( 25 Nm ) ,
- the turbocharger oil return pipe ( 12 Nm ) .
Refit:
- the starter motor (see 16A, Starting-charging,Starter motor: Removal - Refitting ).
- the catalytic pre-converter (see 19B, Catalyticpre-converter: Removal - Refitting ).
112457
112458
WARNINGEnsure that no impurities enter the turbine orcompressor during the refitting operation.
Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Alsocheck that it is perfectly sealed. If not, replace it.
Note:
Pay attention to the direction of fitting of themanifold - turbocharger seal.
The seal tab must be on the turbocharger side.
12B-22
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 804
12BMake sure that all the exhaust pipe heat shields arein place and properly secured.
Make sure that there is no contact with the underbo-dy.
Connect the battery, starting with the positive termi-nal.
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has goneout,
- let the engine run at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
Connect the diagnostic tool and clear the storedfaults.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Fill the cooling circuit (see 19A, Cooling, Coolingcircuit: Draining - filling ).
Bleed the cooling circuit (see 19A, Cooling, Coo-ling circuit: Bleeding ).
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
12B-23
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 732
12B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Put the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove the engine undertray.
Pull out the clip.
Loosen the mounting bolt (1) on the air inlet rigidduct.
Move the air inlet rigid duct to one side (see (2) .
Disconnect:
- the oil vapour rebreathing pipe (3) ,
- the air inlet duct (4) on the turbocharger,
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter ).
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the turbocharging pressure regulationvalve hose on the regulation valve side.
Tightening torquesm
turbocharger mountingstuds
9 Nm
turbocharger mountingnuts
26 Nm
bolts mounting the oilinlet pipe on the turbo-charger
22.5 Nm
bolts mounting the oilinlet pipe on the cylinderhead
22.5 Nm
bolts mounting the oilreturn pipe on the turbo-charger
12 Nm
112811
112991
112816
12B-24
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 732
12B
Remove:
- the bolt (6) mounting the oil inlet pipe on the turbo-charger,
- the bolt mounting the oil inlet pipe on the cylinderhead,
- the oil supply pipe ,
- the oil return pipe mounting bolts,
- the oil return pipes (5) ,
- the upper mounting nuts (7) from the turbocharger,
- the lower mounting nut from the turbocharger,
- the turbocharger.
REFITTING
I - REFITTING PREPARATION OPERATION
Always clean the joint faces thoroughly.
102079
WARNING
Ensure that no foreign bodies enter the turbine orcompressor during the refitting operation.
Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale. Checkthat there are no leaks. If there are, replace thepart.
WARNING
Check that the intercooler is not full of oil. If it is,remove and rinse it with the cleaning agent, thenlet it dr ip dry.
WARNING
Replace any damaged heat shield.
12B-25
TURBOCHARGINGTurbocharger: Removal - Refitting
K9K, and 732
12BII - REFITTING OPERATION FOR PART CONCERNED
Tighten to torque the turbocharger mountingstuds ( 9 Nm )
Fit the new turbocharger seal.
Refit:
- the turbocharger.
- the turbocharger mounting nuts.
Tighten to torque the turbocharger mounting nuts( 26 Nm ) .
Refit:
- the new oil inlet pipe,
- the oil inlet pipe mounting bolt on the turbocharger
- the bolt mounting the oil inlet pipe on the cylinderhead.
Tighten to torque:
- the bolts mounting the oil inlet pipe on the tur-bocharger ( 22.5 Nm ) ,
- the bolts mounting the oil inlet pipe on the cy-linder head ( 22.5 Nm )
Fit new seals on the oil return pipe.
Refit:
- the oil return pipe,
- the oil return pipe mounting bolts.
Tighten to torque the bolts mounting the oil returnpipe on the turbocharger ( 12 Nm ) .
Connect the vacuum pipe to the pressure regulationsolenoid valve on the turbocharger.
Refit:
- the oil inlet pipe on the turbocharger,
- the turbocharger oil inlet pipe union on the turbo-charger,
III - FINAL OPERATION
Connect:
- the turbocharging pressure regulation valve hose,
- the air inlet duct on the turbocharger side,
- the oil vapour rebreathing pipe on the rocker coverside.
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter: Removal - Refitting ).
Refit the clip on the air inlet duct if necessary.
Clip the air inlet rigid pipe on the turbocharger.
Refit the air inlet rigid duct mounting bolt.
Connect:
- the air inlet duct on the turbocharger,
- the oil vapour rebreathing pipe.
Refit the engine undertray.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Refit the engine covers.
Note:
Make sure there is no contact between the cata-lytic converter and the turbocharger oil returnpipe.
12B-26
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 808
12B
REMOVAL
Put the vehicle on a two-post lift.
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Disconnect:
- the oil vapour rebreathing pipe (1) ,
- the turbocharging pressure regulation valve (2) pi-pe.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Tightening torquesm
turbocharger mountingstuds
8 Nm
turbocharger mountingnuts
26 Nm
hollow mounting bolt onthe turbocharger oil sup-ply pipe
22.5 Nm
nut mounting the oilsupply pipe on the cylin-der block
22.5 Nm
bolt mounting the oilsupply pipe on the cylin-der block
25 Nm
turbocharger oil returnpipe mounting bolts
12 Nm
turbocharger mountingstuds
8 Nm
turbocharger union endpiece
26 Nm
turbocharger mountingnuts
26 Nm
oil supply pipe moun-ting nut on the turbo-charger side
22.5 Nm
oil supply pipe moun-ting nut on the cylinderblock
22.5 Nm
turbocharger oil returnpipe mounting bolts
12 Nm
battery cover mountingbolts
4 Nm
104424
12B-27
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 808
12B
Disconnect the turbocharger air inlet and outlet pi-pes (3) .
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).
I - OIL SUPPLY PIPE WITH HOLLOW BOLT UNION (TURBOCHARGER SIDE)
Remove:
- the mounting bolt (4) from the oil supply pipe,
- the hollow mounting bolt (5) from the oil supply pipeunion on the turbocharger.
Loosen the union (6) on the cylinder block.
Remove the oil supply pipe by passing it through theturbocharger wheels.
Remove:
- the oil return pipe mounting bolts,
- the oil return pipe,
- the turbocharger bracket mounting nuts,
- the turbocharger.
104421
Note:
During factory fitting, 2 types of oil supply pipecan be fitted to the turbocharger.
The way in which a turbocharger is removeddepends on the type of pipe.
114207
12B-28
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 808
12BII - THE OIL SUPPLY PIPE WITH NUT UNION (TURBOCHARGER SIDE)
Remove the bolt (7) mounting the oil supply pipe tothe cylinder block.
Undo the oil supply pipe unions on:
- the cylinder block,
- the turbocharger (8) using the (Mot. 1566) .
Remove the turbocharger oil supply pipe.
Remove:
- the oil return pipe mounting bolts,
- the oil return pipe,
- the turbocharger bracket mounting nuts,
- the turbocharger.
In the event that the oil supply pipe is replaced:
- remove the oil supply union end piece (9) . Thisstep prepares the turbocharger for the supply pipeto be refitted with the hollow bolt union.
REFITTING
Proceed in the reverse order to removal.
Always replace:
- the oil supply pipe with hollow bolt union on the tur-bocharger side (depending on version),
- the oil supply pipe seals with nut unions on the tur-bocharger side (depending on version),
- the seals on the turbocharger oil return pipe,
104417
Note:
There is only one supply pipe part numberavailable as a replacement part. Only the oil sup-ply pipe with a hollow bolt union is available.
114467
Note:
During factory fitting, 2 types of oil supply pipecan be fitted to the turbocharger.
The way in which a turbocharger is refitteddepends on the type of pipe.
WARNING
Ensure that no impurities enter the turbine orcompressor during the refitting operation.
Check that the turbocharger oil return pipe is notcompletely or partially blocked by scale.
Also check that it is perfectly sealed. If not,replace it.
12B-29
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 808
12B- the turbocharger seals.
I - THE OIL SUPPLY PIPE WITH HOLLOW BOLT UNION (TURBOCHARGER SIDE)
Tighten to torque the turbocharger mountingstuds ( 8 Nm ) .
Refit the turbocharger.
Tighten to torque the turbocharger mounting nuts( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply unionmounting nut on the cylinder block,
- screw on (without tightening) the supply pipe hol-low mounting bolt,
- screw on (without tightening) the oil supply pipemounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
- the hollow mounting bolt on the turbochargeroil supply pipe ( 22.5 Nm ) ,
- the nut mounting the oil supply pipe on the cy-linder block ( 22.5 Nm ) ,
- the bolt mounting the oil supply pipe on the cy-linder block ( 25 Nm )
- the turbocharger oil return pipe mounting bolts( 12 Nm ) .
II - THE OIL SUPPLY PIPE WITH NUT UNION (TURBOCHARGER SIDE)
Always replace the end piece seal on the union (10), if the end piece has been removed.
Tighten to torque:
- the turbocharger mounting studs ( 8 Nm ) ,
- the turbocharger union end piece ( 26 Nm ) , if ithas been removed.
Refit the turbocharger.
Tighten to torque the turbocharger mounting nuts( 26 Nm ) .
Fit the oil supply pipe:
- screw on (without tightening) the oil supply pipemounting nuts,
- screw on (without tightening) the oil supply pipemounting bolt on the cylinder block.
Refit the oil return pipe.
Tighten to torque:
- using the tool, the oil supply pipe mounting nuton the turbocharger side ( 22.5 Nm ) ,
- the oil supply pipe mounting nut on the cylinderblock ( 22.5 Nm ) ,
- the turbocharger oil return pipe mounting bolts( 12 Nm )
III - CONTINUATION OF REFITTING PROCEDURE
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter: Removal - Refitting ).
114467
12B-30
TURBOCHARGINGTurbocharger: Removal - Refitting
F9Q, and 808
12BTo refit, proceed in the reverse order to removal.
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Refit the exhaust pipe, aligning it with the marksmade previously.
Make sure that there is no contact with the underbo-dy.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Check that there are no leaks:
- start the engine,
- check that the oil pressure warning light has goneout,
- let the engine run at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there are no oil leaks.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
12B-31
TURBOCHARGINGTurbocharger: Removal - Refitting
M9R, and 700
12BREMOVAL
I - REMOVAL PREPARATION OPERATION
Put the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).
Remove:
- the bolts (1) mounting the oil pipe on the turbochar-ger,
- the oil pipe mounting bolts (2) on the cylinder block,
- the hollow bolt (3) securing the turbocharger oilpipe to the cylinder block,
- the turbocharger oil pipe.
Equipment required
roller-type stud removal tool
tweezers
diagnostic tool
Tightening torquesm
stud on the exhaustmanifold
9 Nm
studs on the turbochar-ger
14.5 Nm
turbocharger strutmounting bolt on theflywheel end
25 Nm
lower mounting nuts onthe turbocharger
28 Nm
upper mounting nut onthe turbocharger
28 Nm
turbocharger transversemounting bolt
25 Nm
turbocharger strutmounting bolt on thetiming side
25 Nm
air inlet duct mountingbolts
8 Nm
air inlet duct clip on theturbocharger side
5.5 Nm
bolts mounting the oilpipe on the turbochar-ger
10 Nm
hollow bolt securing theoil pipe on the cylinderblock
16 Nm
bolt mounting the oilpipe on the cylinderblock
25 Nm
IMPORTANT
Wear protective gloves during the operation.
114982
12B-32
TURBOCHARGINGTurbocharger: Removal - Refitting
M9R, and 700
12B
Remove the lower mounting nuts (4) from the turbo-charger.
Disconnect:
- the hose (5) from the turbocharging pressure regu-lator on the control diaphragm,
- the oil vapour rebreathing hose (6) on the oil sepa-rator.
Loosen the air duct clip on the turbocharger side.
Disconnect the air inlet duct on the turbocharger si-de.
Rotate the air duct retaining clip (7) on the turbo-charger.
Remove the mounting bolts (8) for the air duct on theinlet manifold.
Move to one side the air duct towards the intercoo-ler.
113277
114846
113282
113155
12B-33
TURBOCHARGINGTurbocharger: Removal - Refitting
M9R, and 700
12BII - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the turbocharger upper mounting nut (9) on the ex-haust manifold,
- the turbocharger mounting bolt (10) ,
- the turbocharger.
- the gasket between the turbocharger and the ex-haust manifold.
Remove:
- the mounting bolts (11) from the turbocharger strut,
- the turbocharger strut.
REFITTING
I - REFITTING PREPARATION OPERATION
Clean and degrease the bearing faces:
- of the exhaust manifold,
- of the turbocharger if reused.
Remove the stud on the exhaust manifold using aroller-type stud removal tool .
Refit a new stud to the exhaust manifold using a rol-ler-type stud removal tool .
Tighten to torque the stud on the exhaust mani-fold ( 9 Nm ) .
Remove the turbocharger studs in the event that theturbocharger is reused.
Refit the new studs on the turbocharger in the eventthat the turbocharger is reused.
Tighten to torque the studs on the turbocharger (14.5 Nm ) .
Remove the air inlet duct seal at the turbochargeroutlet using a tweezers .
113277
114471
115068
12B-34
TURBOCHARGINGTurbocharger: Removal - Refitting
M9R, and 700
12B
Refit the new seal to the turbocharger air inlet duct.
115069
Note:
Check that the turbocharger air inlet duct seal(12) is fitted in the correct direction.
12B-35
TURBOCHARGINGTurbocharger: Removal - Refitting
M9R, and 700
12BII - REFITTING OPERATION FOR PART CONCERNED
Fit the new turbocharger strut.
Finger tighten the mounting bolts (13) and (14) of theturbocharger strut.
Fit the turbocharger without its seal and hold the tur-bocharger flat against the exhaust manifold.
Move the turbocharger strut until it is against the tur-bocharger at the flywheel end.
Gently tighten the turbocharger strut mounting bolton the timing end (13) .
Move the turbocharger to one side.
Tighten to torque the turbocharger strut mountingbolt on the flywheel end ( 25 Nm ) (14) .
Fit a new seal between the turbocharger and the ex-haust manifold.
Refit the turbocharger.
Finger tighten the new turbocharger transversemounting bolt by a few turns.
Tighten until contact is made:
- the new upper mounting nut on the turbocharger,
- the new lower mounting nuts on the turbocharger.
Tighten to torque:
- the lower mounting nuts on the turbocharger (28 Nm ) ,
- the upper mounting nut on the turbocharger (28 Nm ) .
Undo the turbocharger strut mounting bolt on the ti-ming end (13) .
Tighten to torque:
- the turbocharger transverse mounting bolt ( 25Nm ) ,
- the turbocharger strut mounting bolt on the ti-ming side ( 25 Nm ) (13) .
III - FINAL OPERATION
Rotate the retaining clip of the air inlet duct to refitthe retaining clip in its recess.
Clip the air inlet duct on to the turbocharger.
Refit the air inlet duct mounting bolts on the inlet ma-nifold.
Tighten to torque the air inlet duct mounting bolts( 8 Nm ) .
Connect:
- the air inlet duct to the turbocharger,
- the oil vapour rebreathing hose to the oil separator.
Tighten to torque the air inlet duct clip on the tur-bocharger side ( 5.5 Nm ) .
Connect the turbocharging pressure regulator on thecontrol diaphragm.
114471
WARNING
The turbocharger strut must move freely.
WARNING
Do not tighten the bolt too quickly to prevent theturbocharger strut from rotating.
12B-36
TURBOCHARGINGTurbocharger: Removal - Refitting
M9R, and 700
12B
Lubricate the new turbocharger oil pipe O-ring onthe cylinder block side.
Remove the protective plug from the oil supply unionon the cylinder block side.
Fit the turbocharger oil pipe, first positioning it in thecylinder block (14) .
Finger tighten:
- the bolts (15) mounting the oil pipe on the turbo-charger,
- the oil pipe hollow bolt (16) on the cylinder block,
- the bolts (17) mounting the oil pipe on the cylinderblock.
Tighten to torque:
- the bolts mounting the oil pipe on the turbo-charger ( 10 Nm ) (15) ,
- the hollow bolt securing the oil pipe on the cy-linder block ( 16 Nm ) (16) ,
- the bolt mounting the oil pipe on the cylinderblock ( 25 Nm ) (17) .
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter: Removal - Refitting ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
114982
WARNING
Check for the gasket between the turbochargerand the turbocharger oil pipe.
WARNING
Do not rotate the turbocharger oil pipe O-ring onthe cylinder block side when inserting.
After fitting, check that the turbocharger oil pipeO-ring, on the cylinder block side, has not comeout of its housing.
Check for two copper seals on the oil supplyunion on the cylinder block side.
WARNING
Disconnect the injection rail pressure regulatorconnector (disables engine starting).
Run the starter motor until the oil pressure war-ning light goes out (do this for a few seconds).
Switch off the ignition.
Connect the injection rail pressure regulator con-nector.
Start the engine.
Let the engine idle then depress the acceleratorseveral times under no load.
Switch off the ignition.
Make sure that there are no oil leaks.
Connect the diagnostic tool and clear the sto-red faults.
12B-37
TURBOCHARGINGPressure regulator: Checking
K9K, and 722 or 724 or 728 or 729 or 732
12B
TURBOCHARGING PRESSURE REGULATION VALVE
1 - Check
Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger ).
Use a magnetic holder fitted with a dial gauge loca-ted at the end of the regulation valve rod (as far aspossible on the rod shaft).
Gradually apply pressure to the regulation valveusing the pressure and vacuum pump.
2 - Value
For a pressure value of 1.4 bar , the rod movementmust be 4.3 mm .
3 - Check
Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger ).
Use a magnetic holder fitted with a dial gauge loca-ted at the end of the regulation valve rod (as far aspossible on the rod shaft).
Gradually apply pressure to the regulation valveusing the pressure and vacuum pump.
4 - Value
For a vacuum value of 0.6 bar , the rod movementmust be 7 mm ±±±± 0.5 .
WARNING
It is strictly prohibited to adjust the turbochargingpressure regulation valve rod in the turbocharger.
K9K, and 722
21869
Note:
The check cannot be carried out with the turbo-charger in place.
K9K, and 724
21869
Note:
The check cannot be carried out with the turbo-charger in place.
12B-38
TURBOCHARGINGPressure regulator: Checking
K9K, and 722 or 724 or 728 or 729 or 732
12B
5 - Check
Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger ).
Use a feeler gauge between the regulation valve rodand the stop (as far as possible into the rod shaft).
Gradually apply pressure to the regulation valveusing the pressure and vacuum pump.
6 - Value
For a vacuum value of 0.5 bar , the rod movementmust be 1.7 mm .
K9K, and 728 or 729 or 732
110748
Note:
The check cannot be carried out with the turbo-charger in place.
12B-39
TURBOCHARGINGPressure regulator: Checking
F9Q, and 800 or 808
12B
TURBOCHARGING PRESSURE CONTROL VALVE
1 - CHECKING
Remove the turbocharger (See 12B, Turbochar-ging, Turbocharger ).
Use a magnetic holder fitted with a dial gauge pla-ced on the end of the control valve stem (as far aspossible in the axis of the stem).
Gradually apply pressure to the regulation valveusing a vacuum/pressure pump.
2 - Value
For a pressure value of 265 mbar , the stem move-ment must be between 0.5 and 3.5 mm .
For a vacuum value greater than 600 mbar , thestem is at the stop.
WARNING
Adjusting the turbocharger pressure regulationvalve rod is strictly prohibited.
21869
Note:
The turbocharger cannot be tested in situ.
12B-40
TURBOCHARGINGPressure regulator: Checking
F4R, and 776
12B
TURBOCHARGING PRESSURE CONTROL VALVE
1 - CHECKING
Remove the turbocharger (See 12B, Turbochar-ging, Turbocharger ).
Use a magnetic holder fitted with a dial gauge pla-ced on the end of the control valve stem (as far aspossible in the axis of the stem).
Gradually apply pressure to the regulation valveusing a vacuum/pressure pump.
2 - Value
For a pressure value of 331 mbar , the stem move-ment should be 1 mm .
For a pressure value of 544 mbar , the stem move-ment must be 5 mm .
WARNING
Adjusting the turbocharger pressure regulationvalve rod is strictly prohibited.
22807
Note:
The turbocharger cannot be tested in situ.
12B-41
TURBOCHARGINGPressure regulator: Checking
F9Q, and 804
12B
TURBOCHARGING PRESSURE CONTROL VALVE
1 - Checking
Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger ).
Connect a pressure and vacuum pump (1) to thepressure regulator (2) .
Use a magnetic holder fitted with a dial gauge loca-ted at the end of the regulation valve rod (as far aspossible on the rod shaft).
Gradually apply a vacuum to the pressure regulatorusing the pressure and vacuum pump.
2 - Value
Test points:
- For a pressure value of 200 mbar , the rod move-ment should be between 2 and 4 mm .
- for a pressure value of 550 mbar , the rod move-ment should be between 8 and 11 mm. .
WARNING
It is strictly prohibited to adjust the turbochargingpressure regulation valve rod in the turbocharger.
21869
Note:
The check cannot be carried out with the turbo-charger in place.
12B-42
TURBOCHARGINGPressure regulator: Checking
M9R, and 700
12B
TURBOCHARGING PRESSURE REGULATOR
1 - Check
Remove the turbocharger (see 12B, Turbochar-ging, Turbocharger: Removal - Refitting ).
Connect a pressure-vacuum pump (1) to the pressu-re regulator (2) .
Use a magnetic holder fitted with a dial gauge loca-ted at the end of the regulation valve rod (as far aspossible on the rod shaft).
Gradually apply a vacuum to the pressure regulatorusing the pressure-vacuum pump.
2 - Value
Test points:
- For a vacuum value of 250 mbar , the rod move-ment should be between 3 and 6 mm .
- for a vacuum value greater than 600 mbar , the rodshould not move.
WARNING
The turbocharging pressure regulator rod must notbe adjusted.
21869
Note:
The check cannot be carried out with the turbo-charger in place.
12B-43
TURBOCHARGINGTurbocharging pressure regulation valve
F9Q, and 800 or 808
12B
The turbocharging pressure regulation valvediaphragm (1) is controlled by a solenoid valve (2)which is in turn controlled by the injection computer.This solenoid valve varies the vacuum as a function ofthe engine operating ranges, which allows the turbo-charging pressure to be regulated.
The turbocharging pressure regulation valve is open inthe rest position. The engine operates as normally as-pirated.
The solenoid valve, closed in the rest position, is sup-plied after the engine is started following a delay whichvaries according to the coolant temperature.
WARNING
If the turbocharger solenoid valve is removed, it isessential to mark the supply and return pipes onthe solenoid valve.
102480
101889
2
1
2
103128
Shaft Description
X Time in seconds
Y Coolant temperature in ˚C
12B-44
TURBOCHARGINGTurbocharging pressure regulation valve
F4R, and 776
12B
Pressure regulation valve diaphragm (1) is controlledby a solenoid valve (2) , which is in turn controlled bythe injection computer.
The pressure adjustment valve is closed at rest posi-tion.
Solenoid valve (2) is open in the rest position.
In the open position, solenoid valve (2) compares theturbocharger outlet (turbocharging pressure) anddiaphragm (1) .
Because of this, the turbocharging pressure acts di-rectly on the diaphragm and the pressure adjustmentvalve opens.
When solenoid valve (2) is controlled, the turbochar-ging pressure signal (taken at the turbocharger outlet)is diverted to the turbocharger inlet. Consequently, thediaphragm is not submitted to turbocharging pressure,the pressure adjustment valve closes.
The solenoid valve is open at rest and is energisedwhen the engine is started. However, during a timedperiod which depends on coolant temperature, the tur-bocharging pressure is limited and the engine speedcannot exceed 2500 rpm.
This ensures that the oil has sufficient time to reach theturbocharger bearings.
21927
2
1
107010
Shaft Description
X Time in seconds
Y Coolant temperature in ˚C
12B-45
TURBOCHARGINGTurbocharging pressure regulation valve
K9K, and 728 or 732
12B
The turbocharging pressure regulation valvediaphragm (1) is controlled by a turbocharging pressu-re regulator solenoid valve (2) attached to a bracketfixed onto the air filter unit. This solenoid valve is con-trolled by the injection computer.
This solenoid valve may, according to engine operatingranges, vary the vacuum pressure used to regulate theturbocharging pressure delivered by a variable geo-metry turbocharger.
The pressure regulation valve is open in the rest posi-tion; the engine is therefore naturally aspirated.
The turbocharging pressure regulation solenoid valveis closed in the rest position; it is powered once the en-gine is started and a delay according to the coolanttemperature.
114184
114185
WARNING
When removing the turbocharging pressure regula-tion solenoid valve, it is essential to mark the supplyand return pipes on the solenoid valve.
12B-46
TURBOCHARGINGIntercooler: Removal - Refitting
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
12BREMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine protectors,
- the engine undertray,
- the front bumper (see MR 365, Bodywork, 55A,Exterior protection, Front bumper ).
Remove the Protection and Switching Unit covermounting bolts (1) .
Special tooling required
Car. 1363 Trim removal lever
Tightening torquesm
intercooler downs-tream duct clip on theintercooler
5.5 Nm
intercooler upstreamhose clip
5.5 Nm
intercooler downs-tream duct clip on thedamper valve
5.5 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
battery tray mountingbolts
21 Nm
wiring harness moun-ting nut on the batterytray
8 Nm
WARNING
Procedure for removing the air inlet duct on the intercooler:
- detach the hose using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product orany other product,
- clean the intercooler bearing face and the hoseusing a dry, lint-free cloth,
- replace the clip in the same position if the hose isnot replaced,
- always replace the clip with a new one,
- always replace the hose and/or the intercooler ifthey have been damaged.
There is a danger of leakage and dislocation if thisprocedure is not followed.
F9Q, and 804 – K9K, and 732 – M9R, and 700
112658
12B-47
TURBOCHARGINGIntercooler: Removal - Refitting
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
12B
Remove the Protection and Switching Unit cover.
Disconnect the Protection and Switching Unit con-nectors (2) .
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the upper mounting bolts (5) of the front end panel,
- the lower mounting bolts of the front end panel.
Disconnect the screen washer pipes.
Unclip the air inlet scoop (6) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the front end panel lower mounting bolts (7) .
- the front end panel.
Undo the hose clip (8) upstream of the intercooler.
Disconnect the hose upstream of the intercooler.
102504
M9R, and 700
114933
102473
12B-48
TURBOCHARGINGIntercooler: Removal - Refitting
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
12B
Remove the intercooler downstream duct mountingbolt (9) on the cooling radiator.
Loosen:
- the intercooler downstream duct clip (10) on the in-tercooler,
- the intercooler downstream duct clip on the dampervalve.
Loosen the intercooler downstream duct clip (11) onthe intercooler.
Move the intercooler downstream duct away fromthe intercooler.
Remove the intercooler.
REFITTING
I - REFITTING PREPARATION OPERATION
M9R, and 700
114649
102474
WARNING
If there has been a fault in the turbocharger,check that the intercooler is not full of oil.
In this is the case:
- remove the intercooler.
- rinse the intercooler with a cleaning agent,
- allow the intercooler to drain.
12B-49
TURBOCHARGINGIntercooler: Removal - Refitting
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – F4R, and 776 – M9R, and 700
12BII - REFITTING OPERATION FOR PART CONCERNED
Connect:
- the intercooler upstream hose,
- the intercooler downstream duct onto the intercoo-ler.
Tighten to torque:
- the intercooler downstream duct clip on the in-tercooler ( 5.5 Nm ) ,
- the intercooler upstream hose clip ( 5.5 Nm ) .
Refit the intercooler downstream duct mounting boltonto the cooling radiator.
Tighten to torque the intercooler downstream ductclip on the damper valve ( 5.5 Nm ) .
III - FINAL OPERATION
Refit:
- the front end panel,
- the front end panel mounting bolts.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) ,
Clip on the air inlet scoop.
Clip on the bonnet opening cable.
Refit:
- the battery tray,
- the battery tray mounting bolts,
- the wiring harness mounting nut on the battery tray.
Tighten to torque:
- the battery tray mounting bolts ( 21 Nm ) ,
- the wiring harness mounting nut on the batterytray ( 8 Nm )
Clip on the battery terminal wiring harness.
Connect:
- the screen washer pipes,
- the Protection and Switching Unit connectors,
- the injection computer connectors.
Refit the Protection and Switching Unit cover.
Refit the Protection and Switching Unit cover moun-ting bolts.
Refit:
- the clips,
- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ),
- the engine undertray,
- the engine protectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Adjust the headlights (see 80B, Headlights,Halogen headlights: Adjustment ).
M9R, and 700
M9R, and 700
M9R, and 700
Note:
You must initialise the xenon bulb system (if fittedto the vehicle).
12B-50
TURBOCHARGINGIntercooler: Removal - Refitting
B84 or C84, and F4R, and 774
12B
REMOVAL
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the front bumper,
- the headlights.
Remove the air deflectors (1) .
Disconnect the inlet (2) and outlet (3) ducts from theintercooler.
Tightening torquesm
battery cover mountingbolts
4 Nm
102476
102474
102473
12B-51
TURBOCHARGINGIntercooler: Removal - Refitting
B84 or C84, and F4R, and 774
12B
Lift the intercooler upwards to release it from themounting brackets (4) .
REFITTING
Check that the intercooler is not full of oil.
If it is, it must be rinsed with a cleaning agent andthen left to drain properly.
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
102475
13A-1
FUEL SUPPLYPetrol supply circuit
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
13AOperating diagram of the fuel supply circuit
The fuel system does not have a return.
The fuel pressure does not vary with engine load.
The circuit comprises:
- a rail (1) without a union to return pipes and without asupply pressure regulator,
- a single pipe (2) coming from the tank,
- from a supply assembly « pump - dipstick - fuel filter »fitted with a pressure regulator (3) , pump (4) and fuelfilter (5) (all located in the reservoir),
- a fuel vapour recirculation tank (6) .
19310
3
2
1
6
5
4
13A-2
FUEL SUPPLYDiesel fuel supply circuit
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
13AOperating diagram of the diesel fuel supply circuit
The circuit comprises:
- a gauge (1) ,
- a manual priming pump (2) ,
- a fuel filter (3) that may be fitted with a water detectionsensor,
- a high-pressure pump (4) with a built-in mechanicallow-pressure pump (transfer pump),
- a fuel flow actuator (5) ,
- an injector rail (6) fitted with a diesel pressure sensor(7) ,
- four solenoid injectors (8) fitted with discharge valves,
- a Venturi tube (9) ,
- various sensors,
- an injection computer.
102847
IMPORTANT
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
It is not permitted to remove the pressure sensorfrom the fuel rail (because this may cause circuitcontamination problems). If the pressure sensorfails, the pressure sensor, the rail and the five high-pressure pipes must be replaced.
K9K, and 722 or 728 or 729
WARNING
Dismantling the interior of the high-pressure pumpand the injectors is prohibited. DELPHI Only theflow actuator, the diesel fuel temperature sensorand the Venturi tube can be replaced.
13A-3
FUEL SUPPLYDiesel fuel supply circuit
C84 or G84 or S84, and K9K, and 722 or 728 or 729 or 732
13A
K9K, and 732
WARNING
Removing the flow regulator solenoid valve and thepressure regulating solenoid valve from the high-pressure pump is prohibited. SIEMENS .
13A-4
FUEL SUPPLYDiesel fuel supply circuit
F9Q, and 800
13AOperating diagram of the fuel supply circuit
The circuit comprises:
- a priming bulb (1) (located in the engine compart-ment),
- a fuel filter (2) that may be fitted with a water detectionsensor,
- a high-pressure regulator (3) mounted on the pump,
- a high-pressure pump (4) ,
- an injection rail (5) fitted with a diesel pressure sensorand a pressure limiter (6) ,
- four solenoid injectors (7) ,
- various sensors,
- an injection computer.
100821
654321 7
IMPORTANT
It is strictly forbidden to uncouple a high-pressurepipe union when the engine is running.
WARNING
Dismantling the interior of a high-pressure pump orthe injectors is prohibited.
13A-5
FUEL SUPPLYDiesel fuel supply circuit
F9Q, and 800 or 804 or 808
13AOperating diagram of the diesel fuel supply circuit
The circuit comprises:
- a gauge (1)
- a manual priming pump, (2)
- a diesel filter (3) consisting of:
• a fuel heater,
• a water detection sensor (4) , depending on the ver-sion,
- a high-pressure pump (5) consisting of:
• a mechanical low-pressure pump,
• a pressure regulator, (6)
- an injector rail (7) fitted with a pressure regulator (8) ,
- four solenoid injectors (9) ,
- a diesel fuel temperature sensor (10) for the diesel re-turn circuit,
- an injection computer.
102307
IMPORTANT
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
Dismantling the interior of the high-pressure pumpand the injectors is prohibited.
Outside the warranty period for the pump, only thepump pressure regulator can be replaced.
During the pump warranty period, the high-pressurepump should be completely replaced if the pressureregulator fails.
13A-6
FUEL SUPPLYPetrol filter: General information
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
13A
The fuel filter is located in the fuel tank; it is built intothe « pump-sender-filter » assembly and cannot be re-moved.
The filter is intended to have a long service life.
Checking the fuel supply pressure and the pump deli-very rate is the equivalent of running fault finding on the« pump-sender-filter » assembly.
102299
WARNING
The « pump-sender-filter » assembly must be repla-ced if one of the components is faulty.
13A-7
FUEL SUPPLYDiesel filter: Removal - Refitting
K9K, and 722 or 728 or 729
13A
Order a set of blanking plugs, part number 77 01 206804 .
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove:
- the front right-hand wheel,
- the wheel arch liner mounting bolts (1) .
- the wheel arch liner clips using an unclipping tool,
- the wheel arch liner (2) ,
- the right-hand engine side cover,
- the diesel filter from its mounting by pushing itupwards.
Disconnect all the filter pipe unions.
Place blanking plugs over the open fuel supply pi-pes.
Remove the diesel filter.
REFITTING
Take the blanking plugs off the fuel supply pipes.
Reconnect the pipe unions.
Clip the diesel filter onto the mounting.
Tightening torquesm
wheel bolts 110 Nm
WARNING
Follow the cleanliness instructions closely (see13B, Diesel injection, Cleanliness guidelines ).
The cartr idge assembly must be replaced (the die-sel filter is contained in a non-removable cartridge).
101539
WARNING
Keep the pipe unions away from contaminatedareas.
13A-8
FUEL SUPPLYDiesel filter: Removal - Refitting
K9K, and 722 or 728 or 729
13A
Prime the fuel system with the priming pump (3)(automatic degassing).
Proceed in the reverse order to removal.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect the battery, starting with the positive termi-nal.
102124
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
21749
Regular ly bleed out the water in the diesel filtervia the bleed plug (4) .
Some vehicles have a sensor for detecting waterin the diesel fuel (5) , located on the filter. If wateris detected in the circuit, the injection fault war-ning light on the instrument panel comes on.
13A-9
FUEL SUPPLYDiesel filter: Removal - Refitting
F9Q, and 800 or 804 or 808
13A
The diesel filter is located behind the right-hand headli-ght. It is contained in a removable cartridge. This car-tridge has a built-in diesel fuel heater, comprising aresistor and temperature switch.
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove:
- the front right-hand wheel,
- the wheel arch liner mounting bolts (1) ,
- the wheel arch liner clips using an unclipping tool,
- the wheel arch liner (2) .
Unclip the diesel filter from its mounting by pushing itupwards.
Tightening torquesm
battery cover mountingbolts
4 Nm
wheel bolts 110 Nm
IMPORTANT
Before any operation:
- watch out for diesel fuel splashing when discon-necting the supply union,
- order the special high pressure injection circuitplug kit.
WARNING
- Protect sensitive areas from fuel leakage.
- Strictly observe the cleanliness guidelines.
Note:
Remove the diesel filter assembly to remove thecartr idge.
101539
104560
13A-10
FUEL SUPPLYDiesel filter: Removal - Refitting
F9Q, and 800 or 804 or 808
13A
Disconnect the diesel heater connector (3) from thediesel heater.
Disconnect from the diesel filter:
- the pipe (4) coming from the tank,
- the engine supply pipe (5) .
fit plugs to the pipes and filter.
Remove the diesel filter.
Mark the position of the diesel filter cover in relationto the bowl (6) .
Remove the mounting bolt (7) from the cover on thebowl.
Open the diesel filter and replace:
- the filter element,
- the seal,
REFITTING
Always replace the filter element O-ring.
Refit the cover over the bowl.
Tighten the mounting bolt on the cover over thebowl.
Clip the diesel filter onto the mounting.
Reconnect to the diesel filter:
- the fuel supply pipes,
- the diesel fuel heater connector,
102477
WARNING
Keep the pipe unions away from contaminatedareas.
19317
WARNING
Align the marking on the cover, fitted with blan-king plugs, with the marking on the bowl.
13A-11
FUEL SUPPLYDiesel filter: Removal - Refitting
F9Q, and 800 or 804 or 808
13A
Reprime the supply circuit:
- Turn the air bleed screw (8) 360 degrees,
- operate the manual priming pump (9) until the fuelruns without air bubbles,
- retighten the bleed screw (8) ,
- operate the manual priming pump (9) one last time.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tighten to torque the wheel bolts ( 110 Nm )
19317
102124
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
Note:
Regular ly bleed out water that has accumulatedin the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting waterin the diesel fuel, located in the diesel filter. Ifwater is detected in the circuit, the injection faultwarning light on the instrument panel comes on.
13A-12
FUEL SUPPLYDiesel filter: Removal - Refitting
K9K, and 724 or 732 – M9R, and 700
13A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the front right-hand wheel,
- the front right-hand wheel arch liner (1) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the diesel filter from its mounting on thebody by pushing the « filter - metal strap » assemblyupwards.
Disconnect all the fuel pipe unions on the diesel fil-ter.
Remove the diesel filter from the vehicle.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Connect the fuel pipes onto the new diesel filter.
Tightening torquesm
wheel bolts 110 Nm
WARNING
During this operation:
- refrain from smoking or bringing red hot objectsclose to the working area,
- beware of fuel splashes when disconnecting theunion,
- protect sensitive areas from fuel outflow.
Note:
Make sure you have a new diesel filter before ope-ning the fuel circuit.
104544
114559
Note:
Make preparations for the fuel outflow.
WARNING
Prevent the hose unions from coming into con-tact with a polluted environment.
Note:
Only use wipes part number 77 11 211 707 toclean the filter and pipes once the fuel circuit isopened.
13A-13
FUEL SUPPLYDiesel filter: Removal - Refitting
K9K, and 724 or 732 – M9R, and 700
13ARefit the « filter - metal strap » assembly on itsmounting on the body.
II - FINAL OPERATION
Prime the fuel circuit using the manual priming pump(2) (automatic degassing).
Check there are no leaks from the unions on the fil-ter.
Refit:
- the front right-hand wheel arch liner,
- the front right-hand wheel.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Note:
Check that the filter is correctly positioned andsecure in its mounting by shaking it: the filtermust not move.
If necessary, remove the filter and gentlysqueeze the metal strap retaining bracket on itsmounting.
102124
Note:
Regularly bleed out water that has accumulatedin the diesel filter through the bleed plug.
Some vehicles have a sensor for detecting waterin the diesel fuel, located at the bottom of the fil-ter. If water is detected in the circuit, a fault war-ning light on the instrument panel comes on.
13A-14
FUEL SUPPLYInjector rail - Injectors: Removal - Refitting
K4M, and 760 or 761
13A
The injectors are secured to the injector rail by clips.
The fuel circulates constantly around the circumferen-ce of the injector body. This sweeping by the fuel pre-vents the formation of petrol vapour bubbles and helpswarm starting.
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the inlet manifold (see 12A, Fuel mixture, Inletmanifold ).
Disconnect injector electrical harness (1) .
Remove:
- the two injector rail mounting bolts (2) ,
- the injector rail, pulling it carefully towards you.
ON THE WORKBENCH
Remove:
- injector clips (3) ,
- injectors (4) .
Tightening torquesm
injector rail mountingbolts
9 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from therail or supply duct.
101810
101816
2
1
34
13A-15
FUEL SUPPLYInjector rail - Injectors: Removal - Refitting
K4M, and 760 or 761
13AREFITTING
Fit the injector rail.
Torque tighten the injector rail mounting bolts ( 9Nm ) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm ) .
WARNINGThe O-rings and the injector mounting clips mustalways be replaced with new ones.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
13A-16
FUEL SUPPLYInjector rail - Injectors: Removal - Refitting
B84 or C84 or G84, and K4J, and 730 or 732
13A
The injectors are secured to the injector rail by clips.
The fuel circulates constantly around the circumferen-ce of the injector body. This sweeping by the fuel pre-vents the formation of petrol vapour bubbles and helpswarm starting.
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove the engine covers.
Remove mounting nuts (1) from the injection rail pro-tector.
Move the wiring harness to one side.
Disconnect:
- fuel supply pipe (2)
- injector and pinking sensor electrical harness (3) .
Remove:
- the two injector rail mounting bolts (4) ,
- the injector rail, pulling it carefully towards you.
Tightening torquesm
injector rail mountingbolts
9 Nm
battery cover mountingbolts
4 Nm
101801
1
101802
IMPORTANT
Be careful of petrol splashing when disconnec-ting the supply pipe union from the injector rail.
WARNING
Protect the alternator against fuel spills from therail or supply duct.
101493
332
4
13A-17
FUEL SUPPLYInjector rail - Injectors: Removal - Refitting
B84 or C84 or G84, and K4J, and 730 or 732
13AON THE WORKBENCH
Remove:
- injector clips (5) ,
- injectors (6) .
REFITTING
Fit the injector rail.
Torque tighten the injector rail mounting bolts ( 9Nm ) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm ) .
101492
WARNING
The O-rings and the injector mounting clips mustalways be replaced with new ones.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
56
13A-18
FUEL SUPPLYInjector rail - Injectors: Removal - Refitting
F4R, and 770 or 771 or 776
13A
The injectors are secured to the injector rail by clips.
The fuel circulates constantly around the circumferen-ce of the injector body. This sweeping by the fuel pre-vents the formation of petrol vapour bubbles and helpswarm starting.
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove the engine covers.
Remove the two injection rail guard mounting nuts(1) .
Move the wiring harness to one side.
Disconnect:
- fuel supply pipe (2) ,
- injector and pinking sensor electrical harness (3) .
Disconnect:
- turbocharging pressure sensor connector (4)
- the vacuum pipe from brake servo (5) ,
- oil vapour recirculation pipe (6) .
Tightening torquesm
injector rail mountingbolts
9 Nm
battery cover mountingbolts
4 Nm
F4R, and 770 or 771
101801
11
102728
F4R, and 776
106787
3
2
5
4
6
13A-19
FUEL SUPPLYInjector rail - Injectors: Removal - Refitting
F4R, and 770 or 771 or 776
13A
Disconnect fuel supply pipe (7) from the injector rail.
Remove:
- the two injector rail mounting bolts (8) ,
- the injector rail, pulling it carefully towards you.
ON THE WORKBENCH
Remove:
- injector clips (9) ,
- injectors (10) .
REFITTING
Fit the injector rail.
Torque tighten the injector rail mounting bolts ( 9Nm ) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm )
106271
IMPORTANT
Be careful of petrol splashing out when discon-necting the fuel supply union.
WARNING
Protect sensitive areas from fuel spillage.
102730
7
88
102737
WARNING
The O-rings and the injector mounting clips mustalways be replaced with new ones.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
9
10
13A-20
FUEL SUPPLYElectric fuel: Checking
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
13A
Disconnect the petrol inlet pipe from the injectionrail.
Disconnect the petrol inlet pipe from the injectionrail.
Connect:
- pipe (1) fitted with a pressure gauge and located intest kit (Mot. 1311-01) , to the « T » union of tool(Mot. 1311-08) (2) ,
- the « T » union to the rail,
- petrol inlet pipe (3) to the « T » union.
Insert pipe (1) into a 2000 ml measuring cylinder.
Remove the Protection and Switching Unit cover.
Special tooling required
Mot. 1311-01 Fuel pressure test kit
Mot. 1311-08 Union for measuringfuel pressure
IMPORTANT
During this operation, be sure to:
- refrain from smoking or bringing hot objects closeto the working area,
- beware of fuel splashes when disconnecting theunion,
- protect sensitive areas from fuel outflow.
K4J, and 730 or 732 – F4R, and 770 or 771 or 776
101496
12
3
K4M, and 760 or 761
101803
IMPORTANT
This procedure must be carried out with the igni-tion off.
1
2
3
13A-21
FUEL SUPPLYElectric fuel: Checking
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
13A
Place the electrical connector (4) to one side withoutdisconnecting it.
Disconnect the brown connector (5) from the Protec-tion and Switching Unit.
Connect terminal (5) of the brown connector to thebattery positive feed
102502
102503
4
5
102501
Note:
The flow reading should be between 80 and 120l/h .
5
1
12
13B-1
DIESEL INJECTIONSpecifications
K9K, and 722 or 728 or 729
13B
Equipment required
diagnostic tool
Vehicle type
Engine Engine speed (rpm) Smoke opacity
Type Suffix Idlingspeed
Maximumunladen
Maximumladen
Homologa-tion value(m-1)
Legal maxi-mum (m-1)
XM0F
XM0T
K9K
722 805 ±±±± 50 5000 ±±±± 150 4800 ±±±± 100
1.5
3
XM1F 724 800 ±±±±50 4900 ±±±± 150 4900 ±±±± 150 2
XM02
XM13
728
805 ±±±± 50 4950 ±±±± 150 4800 ±±±± 100 3
XM02 729
Description Make - type Special notes
High pressure pump DELPHI Pressure from 0 to 1,400 bar
Low pressure pump DELPHI Integrated in the high pressurepump
Injection computer DELPHI 112-track computer (A 32, B 48, C32)
Diesel rail pressure sensor DELPHI Integrated in the rail
Resistance not measurable
Supply voltage: + 5 V
3-track connector:
- 1: signal
- 2: diesel rail pressure sensorearth
- 3: + 5 V supply
Injectors DELPHI / MNS HP Solenoid injector
Maximum pressure 1,600 bar
Resistance not measurable
Supply voltage: + 14 V
2-track connector:
- 1: injector + control
- 2: injector - control
13B-2
DIESEL INJECTIONSpecifications
K9K, and 722 or 728 or 729
13B
Diesel flow actuator DELPHI Located on the high pressurepump
Resistance: 5.3 Ω ± 0.5 at 20˚C
Supply voltage: + 5 V
2-track connector:
- 1: + battery feed via Protectionand Switching Unit
- 2: actuator control
Engine speed and position sensor MGI Var iable reluctance sensor
Resistance: 760 Ω (K9K 722)
Resistance: 680 Ω (K9K 724,728, 729)
2-track connector
- A: + signal
- B: - signal
Pre-postheating unit NAGARES BED 7-12 Pre-postheating function mana-ged by the computer
9-track connector
- 1: heater plug no. 3 supply
- 2: heater plug no. 4 supply
- 3: + battery supply
- 6: heater plug no. 1 supply
- 7: heater plug no. 2 supply
- 8: injection computer control
- 9: fault finding
Heater plugs CHAMPION or BERU Resistance: 0.6 Ω
Description Make - type Special notes
13B-3
DIESEL INJECTIONSpecifications
K9K, and 722 or 728 or 729
13B
Accelerator pedal potentiometer CTS Dual gang potentiometer
Resistance
- gang 1: tracks 3 and 5: 1700 ±900 Ω
- gang 2: tracks 2 and 6: 3875 ±1025 Ω
6-track connector:
- 1: gang 2 signal
- 2: gang 2 + 5 V supply
- 3: gang 1 + 5 V supply
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Cylinder reference sensor SAGEM Hall effect sensor
3-track connector:
- 1: cylinder reference sensorearth
- 2: signal
- 3: + battery feed via Protectionand Switching Unit
Diesel temperature sensor DELPHI Located on the high pressurepump
Negative temperature coefficientthermistor
Resistance: 2.2 kΩ at 25˚C
2-track connector:
- 1: signal
- 2: diesel temperature sensorearth
Accelerometer SAGEM Resistance not measurable
2-track connector:
- 1: signal
- 2: accelerometer earth
Description Make - type Special notes
13B-4
DIESEL INJECTIONSpecifications
K9K, and 722 or 728 or 729
13B
Engine coolant temperature sen-sor
ELTH Negative temperature coefficientthermistor
Resistance:
- 75780 ± 7000 Ω at - 40˚C
- 12460 ± 1128 Ω at - 10˚C
- 2252 ± 112 Ω at 25˚C
- 811 ± 38 Ω at 50˚C
- 282 ± 8 Ω at 80˚C
- 115 ± 3 Ω at 110˚C
- 88 ± 2 Ω at 120˚C
4-track connector:
- 3: signal
- 4: engine coolant temperaturesensor earth
Turbocharging air temperatureand pressure sensor
BOSCH / LDF6T 20-250 Pressure sensor with a negativetemperature coefficient thermistor
Supply voltage: + 5 V
Resistance:
- 20376 ± 1110.5 Ω at - 25˚C
- 15614 ± 829 Ω at - 20˚C
- 9426 ± 475 Ω at - 10˚C
- 5887 ± 281.5 Ω at 0˚C
- 3791 ± 172.5 Ω at 10˚C
- 2511 ± 109 Ω at 20˚C
- 1715.5 ± 71 Ω at 30˚C
- 1200 ± 47 Ω at 40˚C
- 851 ± 32 Ω at 50˚C
- 612 ± 22 Ω at 60˚C
- 446 ± 15 Ω at 70˚C
- 330 ± 11 Ω at 80˚C
4-track connector:
- 1: earth
- 2: air temperature sensor signal
- 3: + 5 V supply
- 4: pressure sensor signal
Exhaust gas recirculation sole-noid valve (K9K 722, 728 and729)
PIERBURG Supply voltage: + 13.5 V
Resistance: tracks 1 and 5: 8 ±0.5 Ω at 20˚C
Description Make - type Special notes
13B-5
DIESEL INJECTIONSpecifications
K9K, and 722 or 728 or 729
13B
Exhaust gas recirculation sole-noid valve (K9K 724)
PIERBURG Supply voltage: 13.5 V
Resistance: tracks 2 and 6: 2.3 Ωat 20˚C
Exhaust gas recirculation sole-noid valve position potentiometer(K9K 724)
PIERBURG Integrated in the exhaust gasrecirculation solenoid valve
Supply voltage: + 5 V
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: not used
- 5: potentiometer signal
- 6: solenoid valve earth
Exhaust gas recirculation sole-noid valve position potentiometer(K9K 722 728 and 729)
PIERBURG Integrated in the exhaust gasrecirculation solenoid valve
Supply voltage: + 5 V
Resistance:
- tracks 2 and 4: 4 ± 1.6 kΩ at20˚C
6-track connector:
- 1: solenoid valve + battery feedvia Protection and Switching unit
- 2: potentiometer supply + 5 V
- 3: not used
- 4: potentiometer earth
- 5: solenoid valve earth
- 6: potentiometer signal
Refrigerant pressure sensor TEXAS INSTRUMENTS Supply voltage: + 5 V
3-track connector:
- A: earth
- B: + 5 V supply
- C: signal
Description Make - type Special notes
13B-6
DIESEL INJECTIONSpecifications
K9K, and 722 or 728 or 729
13B
Fault finding - diagnostic tool : CLIP only
Turbocharging pressure regula-tion solenoid valve (K9K 724, 728and 729)
BITRON Proportional solenoid valve
Supply voltage: 13.5 V
Resistance: 16.5 Ω ±±±± 1.6 at 23˚C
2-track connector:
- 1: signal
- 2: supply
Description Make - type Special notes
13B-7
DIESEL INJECTIONSpecifications
F9Q, and 800 or 808
13B
Equipment required
diagnostic tool
Vehicles Gearbox
Engine
Type Suffix Bore(mm)
Stroke(mm)
Cubic capa-city (cc)
Compres-sion ratio
XM0G
XM1G ND0 F9Q
800
80 93 1870 19:1
XM00 808
Engine speed (rpm) Smoke opacity
Idling speed Maximum unladen Maximum laden Homologation
value (m-1)
Legal maximum
(m-1)
800 ± 50 4850 ± 150 4500 ± 100 1.9 (54%) 3 (70%)
Description Make - Type Special notes
High pressure pump BOSCH CP3 Pressure from 250 to 1,350 bar
Diesel fuel pressure sensor BOSCH Bolted onto the rail
Injectors BOSCH Solenoid injector
Operating pressure up to: 1300bar
Pressure regulator BOSCH Bolted onto the high pressurepump
Resistance: 3 ± 0.1 Ω at 20˚C
Injection computer BOSCH EDC 16 112-track computer
Pre-postheating unit (locatedbehind the front left-hand wheelarch liner)
NAGARES BED/7-12 With pre-postheating functionmanaged by computer
Heater plugs BERU ou CHAMPION Resistance: 0.6 Ω connector dis-connected
Engine speed sensor MGI Resistance: 720 at 880 Ω at 20˚C
Camshaft sensor ELECTRIFIL -
Accelerator potentiometer CTS Dual gang potentiometer
Resistance:
- gang 1: 1700 ± 900 Ω
- gang 2: 3875 ± 1025 Ω
13B-8
DIESEL INJECTIONSpecifications
F9Q, and 800 or 808
13B
Air inlet temperature sensor SIEMENS Integrated in the air flowmeter
Diesel fuel temperature sensor ELTH Resistance: 2,050 Ω at 25˚C
Engine coolant temperature sen-sor
ELTH Resistance: 2252 Ω ± 112 at 25˚C
Air flowmeter SIEMENS Air flowmeter with integrated airtemperature sensor
- track 1: air temperature
- track 2: earth
- track 3: 5 V reference feed
- track 4: + 12 V after injectionrelay feed
- track 5: air flow signal
- track 6: earth
Turbocharger pressure sensor BOSCH Output voltage with ignition on andengine stopped (between tracks 2and 3):
- = 1.6 V for an atmospheric pres-sure of 1,013 mbar
- > 1.6 V for an atmospheric pres-sure > 1,013 mbar
- < 1.6 V for an atmospheric pres-sure < 1,013 mbar
Replace the seal each time it isremoved
Atmospheric pressure sensor - Integrated in the computer
Exhaust gas recirculation solenoidvalve
PIERBURG Gang resistance: 8 ± 0.5 Ω at20˚C (tracks 1 and 5)
Sensor resistance: 4 kΩ at 20˚C(tracks 2 and 4)
Damper valve solenoid valve(engine stop solenoid valve)
BITRON ou EATON Resistance: 46 ± 3 Ω at 25˚C
Turbocharging pressure regulationsolenoid valve
PIERBURG Resistance: 15.4 ± 0.7 Ω at 20˚C
Fault finding diagnostic tool : CLIP only
Description Make - Type Special notes
13B-9
DIESEL INJECTIONSpecifications
F9Q, and 804
13B
Equipment required
diagnostic tool
Vehicle type
Engine Engine speed (rpm) Smoke opacity
Type Suffix Idlingspeed
Maximumunladen
Maximumladen
Homologa-tion value(m -1)
Legal maxi-mum (m-1)
XM0L
XM1D
XM17
XM14
F9Q 804 800 ± 50 4850 ±150
4500 ±100
1.9 (54%) 3 (70%)
Description Make - Type Special notes
High pressure pump BOSCH CP3.2 Pressure 1600 bar Max
Diesel fuel pressure sensor BOSCH Bolted onto the rail
Tightening torque: 3.5 ± 5 Nm
Injectors BOSCH Solenoid injector
Operating pressure up to: 1600 bar
Pressure regulator BOSCH Screwed onto the high pressurepump
Resistance: 3 ± 0.1 Ω at 20˚C
Injection computer BOSCH EDC 16 112-track computer
Pre-postheating unit (locatedbehind the front left-hand wheelarch liner)
NAGARES BED/7-12 With pre-postheating functionmanaged by computer
Heater plugs BERU ou CHAMPION Resistance: 0.6 Ω connector dis-connected
Engine speed and TDC sensor MGI Resistance: 800 Ω at 20˚C
Camshaft sensor ELECTRIFIL Hall effect type
Accelerator potentiometer CTS Dual gang potentiometer
Resistance:
- gang 1: 1700 ± 900 Ω
- gang 2: 2850 ± 2050 Ω
Air inlet temperature sensor SIEMENS Integrated in the air flowmeter
Engine coolant temperature sensor ELTH Resistance: 2252 Ω ± 112 at 25˚C
13B-10
DIESEL INJECTIONSpecifications
F9Q, and 804
13B
Air flowmeter SIEMENS Air flowmeter with integrated airtemperature sensor
- track 1: air temperature
- track 2: earth
- track 3: 5 V reference feed
- track 4: + 12 V after injection relayfeed
- track 5: air flow signal
- track 6: earth
Turbocharger pressure sensor BOSCH Output voltage with ignition on andengine stopped (between tracks 2and 3):
- = 1.6 V for an atmospheric pres-sure of 1,013 mbar
- > 1.6V for an atmospheric pres-sure > 1013 mbar
- < 1.6 V for an atmospheric pres-sure < 1013 mbar
Replace the seal each time it isremoved
Atmospheric pressure sensor - Integrated in the computer
Exhaust gas recirculation solenoidvalve
SIEMENS Gang resistance: 2.96 ± 10 % at20˚C (tracks 1 and 5)
Sensor resistance: 6.5 kΩ ± 40% at20˚C (tracks 2 and 4)
Turbocharging pressure regulationsolenoid valve
PIERBURG Resistance: 15.4 ± 0.7 Ω at 20˚C
Turbocharger GARRET Calibration
- For an underpressure 265 mbar ,the rod should have a stroke ofbetween 0.5 and 3.5 mm
- for a vacuum greater than 600mbar the rod should be at thestop
Fault finding diagnostic tool : CLIP only
Description Make - Type Special notes
13B-11
DIESEL INJECTIONDiesel injection: Specifications
K9K, and 732
13B
Equipment required
diagnostic tool
Vehicletype
Engine Engine speed (rpm) Smoke opacityDepollutionstan-dard
Type Suffix Idlingspeed
Maximumunladen
Maximumladen
Homo-loga-tionvalue
Legalmaxi-mum
X84 K9K 732 800 ± 50 5000 ±150
5000 ±150
1.5 m -1 2 m -1 EuroIV
Description Make - type Special notes
High pressure pump SIEMENS VDO Pressure from 0 to 1600 bar
Low pressure pump SIEMENS VDO Integrated in the high pressurepump
Injection computer SIEMENS VDO 128-track computer (A 32, B 48, C48)
Diesel rail pressure sensor SIEMENS VDO Integrated in the rail
Resistance not measurable
Supply voltage: + 5 V
3-track connector:
- 1: signal
- 2: diesel rail pressure sensorearth
- 3: supply +
Injectors SIEMENS VDO 6-hole piezoelectric injector
Resistance not measurable
Supply voltage: 150 V
2-track connector:
- 1: supply
- 2: earth
Flow regulation solenoid valve SIEMENS VDO Integrated in the high pressurepump
Cannot be removed
Supply voltage: + 12 V
13B-12
DIESEL INJECTIONDiesel injection: Specifications
K9K, and 732
13B
Pressure regulation solenoid valve SIEMENS VDO Integrated in the high pressurepump
Cannot be removed
Supply voltage: + 12 V
Engine speed and position sensor SIEMENS VDO Variable reluctance sensor
Resistance: 680 Ω ± 6.8 at 20˚C
2-track connector
- 1: + signal
- 2: - signal
Pre-postheating unit NAGARES With pre-postheating function con-trolled by the injection computer
8-track connector
- 1: heater plug no. 3 supply
- 2: spark plug no. 1 supply
- 3: fault finding
- 4: + battery supply
- 6: spark plug no. 4 supply
- 7: heater plug no. 2 supply
- 8: injection computer control
Heater plugs CHAMPION ou BERU Resistance: 0.6 Ω
Accelerator pedal potentiometer CTS Dual gang potentiometer
Resistance
- gang 1: tracks 3 and 5: 1700 Ω ±900
- gang 2: tracks 2 and 6: 3875 Ω ±1025
6-track connector:
- 1: gang 2 signal
- 2: gang 2 + 5 V supply
- 3: gang 1 + 5 V supply
- 4: gang 1 signal
- 5: gang 1 earth
- 6: gang 2 earth
Description Make - type Special notes
13B-13
DIESEL INJECTIONDiesel injection: Specifications
K9K, and 732
13B
Cylinder reference sensor JCAE Hall effect sensor
3-track connector:
- 1: earth
- 2: signal
- 3: supply
Diesel temperature sensor ELTH Located on the diesel return rail onthe high pressure pump outlet
2-track connector:
- 1: signal
- 2: earth
Atmospheric pressure sensor SIEMENS VDO Integrated in the computer
Air temperature sensor SIEMENS VDO Integrated in flowmeter
Negative temperature coefficientthermistor
Resistance:
- 44373 Ω ± 3118 at - 40˚C
- 15141 Ω ± 871 at - 20˚C
- 9202 Ω ± 486 at 10˚C
- 5774 Ω ± 276 at 0˚C
- 3714 Ω ± 161 at 10˚C
- 2448 Ω ± 95 at 20˚C
- 1671 Ω ± 58 at 30˚C
- 1150 Ω ± 36 at 40˚C
- 817 Ω ± 22 at 50˚C
- 583 Ω ± 14 at 60˚C
- 316 Ω ± 6 at 80˚C
- 183 Ω ± 2 at 100˚C
Turbocharger pressure sensor BOSCH / LDF6 20-300 Supply voltage: + 5 V
3-track connector:
- 1: supply
- 2: earth
- 3: signal
Damper valve JCAE Solenoid valve position potentiome-ter built into the damper valve
Solenoid valve supply voltage: +13.5V
Potentiometer supply voltage: + 5V
Description Make - type Special notes
13B-14
DIESEL INJECTIONDiesel injection: Specifications
K9K, and 732
13B
Engine coolant temperature sensor ELTH Negative temperature coefficientthermistor
Resistance:
- 75780 Ω ± 7000 at - 40˚C
- 12460 Ω ± 1128 at - 10˚C
- 2,252 Ω ± 112 at 25˚C
- 811 Ω ± 38 at 50˚C
- 282 Ω ± 8 at 80˚C
- 115 Ω ± 3 at 110˚C
- 88 Ω ± 2 at 120˚C
4-track connector:
- 1: not used
- 2: engine coolant temperaturesensor signal
- 3: engine coolant temperaturesensor earth
- 4: not used
Exhaust gas recirculation solenoidvalve
PIERBURG Supply voltage: + 13.5 V
Resistance: tracks 2 and 6: 2.3 Ω
Exhaust gas recirculation solenoidvalve position potentiometer
PIERBURG Integrated in the exhaust gas recir-culation solenoid valve
Supply voltage: + 5 V
6-track connector:
- 1: potentiometer supply
- 2: solenoid valve supply
- 3: potentiometer earth
- 4: not used
- 5: potentiometer signal
- 6: solenoid valve earth
Refrigerant pressure sensor TEXAS INSTRUMENT
BIRTON
Supply voltage: + 5 V
3-track connector:
- A: earth
- B: supply
- C: signal
Description Make - type Special notes
13B-15
DIESEL INJECTIONDiesel injection: Specifications
K9K, and 732
13B
Water in diesel sensor PRESSAC Located on the diesel filter
3-track connector:
- 1: supply
- 2: signal
- 3: earth
Air inlet flowmeter SIEMENS VDO Air flowmeter with integrated airtemperature sensor
6-track connector:
- 1: air temperature signal
- 2: earth
- 3: Not used
- 4: + 12 V supply
- 5: supply: + 5 V
- 6: air flow signal
Turbocharging pressure regulationsolenoid valve
BIRTON Proportional solenoid valve
supply voltage + 12 V
2-track connector:
- 1: computer output
- 2: supply
Fault finding - diagnostic tool : CLIP only
Description Make - type Special notes
13B-16
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13BI - RISKS LINKED TO CONTAMINATION
The high pressure direct injection system is highly sen-sitive to contamination. The risks caused by contami-nation are:
- damage to or destruction of the high pressure injec-tion system,
- a component seizing,
- a component not being properly sealed.
All After-Sales operations must be performed undervery clean conditions. Having carried out an operationin good conditions means that no impurities (particles afew microns in size) have penetrated the system duringdismantling.
The cleanliness principle must be applied from the filterto the injectors.
What are the sources of contamination?
- metal or plastic chips,
- paint,
- fibres from:
• cardboard,
• brushes,
• paper,
• clothing,
• cloth,
- foreign bodies such as hair,
- ambient atmosphere,
- etc.
1 - Cleaning cloths
Use lint free cleaning cloths (part number 77 11 211707 ).
The use of rags or ordinary paper towels is prohibited:these produce lint and lose fibres, which then contami-nate the fuel circuit.
Each cloth must only be used once.
2 - Blanking plugs
The blanking plugs are used to cap the fuel circuit onceit is opened and to therefore prevent contaminantsfrom entering.
A set of blanking plugs should be used once only andused plugs must be discarded after use: once used,the plugs are soiled and cleaning them is not sufficientto make them reusable.
Unused plugs must also be discarded and not usedagain for any other operation on an injection system.
Blanking plug set part number:
- F9Q: 77 01 208 229
- K9K ( DELPHI injection): 77 01 206 804
- K9K ( SIEMENS injection): 77 01 476 857
- M9R: 77 01 209 062
3 - Protective bags
Use hermetically-resealable plastic bags, using adhe-sive tape, for example, to store components which willbe refitted and reused. Stored parts will therefore beless subject to the risk of contamination.
These bags must be used once only: once they havebeen used, they are to be discarded.
4 - Cleaning products
Two cleaning products can be used:
- an injector cleaner (part number 77 11 224 188 ),
- an aerosol spray brake cleaner (part number 77 11226 128 ).
To use the injector cleaner, be sure to have a cleanbrush in good condition (the brush must not lose anybristles) as well as a clean container which has no im-purities in it.
II - ADVICE TO BE FOLLOWED BEFORE ANY OPERATION
1) Carry out the work in a clean working area and takecare to protect removed components from dust usingplastic bags which are hermetically-resealable, forexample.
WARNING
Cleaning the engine using a high pressure washeris prohibited because of the risk of damaging con-nections. In addition, moisture may collect in theconnectors and create electrical connection faults.
Note:
Use a new injector cleaner each time work is car-ried out (a used cleaning agent will contain impuri-ties).
13B-17
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B2) Always order the following from the Parts Depart-ment before carrying out work:
- une collection de bouchons de propreté neuve ,specific to the engine,
- a sufficient number of lint-free lingettes de nettoya-ge .
- one of the two produits de nettoyage for the fuelpipe unions,
- les pièces à remplacer systématiquement aftereach removal and which are mentioned in the workprocedures specific to each vehicle (see the relevantWorkshop Repair Manual).
3) Wear safety goggles fitted with side shields to pre-vent the cleaning product from splashing the eyes.
4) Wear latex safety gloves to avoid prolonged contactwith the skin.
5) Before any operation on the injection system protect (using plastic bags or clean cloths for example):
- the accessories and timing belts,
- the electrical accessories (starter motor, alternator,power-assisted steering pump, sensors and electricalconnectors),
- the flywheel face.
III - INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
Wash your hands before and while carrying out thework.
Change the latex safety gloves if they become soiled ordamaged.
All components removed from the injection systemmust be stored in a hermetically sealed plastic bagonce they have been capped.
Reseal the bag hermetically using adhesive tape, forexample, even if the bag must be opened shortly afte-rwards: ambient atmosphere can be a source of pollu-tion.
After opening the fuel circuit, the use of brushes, clea-ning agents, air blow guns, rifle-type brushes or stan-dard cloths is strictly prohibited: These items are likelyto allow impurities to enter the system.
When replacing a component with a new one or whenrefitting it after storing it in a plastic bag, do not unpackit until it is time to fit it on the vehicle.
IV - CLEANING
There are currently two procedures for cleaning thefuel circuit before opening it in order to carry out work inthe workshop.
These procedures enable the fuel circuit to be cleanedto prevent contamination: they both have the same endresult and neither is preferred over the other.
1 - Using the injector cleaning agent
Clear the access to the unions that need opening, fol-lowing the work procedures specific to the vehicle (seethe relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Pour the injector cleaning agent into a container whichis free from impurities.
Dip a clean brush, which is not shedding bristles, intothe container of injector cleaning agent.
Clean the unions carefully using the brush and the in-jector cleaning agent.
Blast the components that have been cleaned withcompressed air (tools, workbench, and also parts,unions and around the injection system). Make surethere are no brush bristles remaining and that the areais clean.
Wipe the sections that were cleaned with fresh clea-ning cloths.
Open the circuit at the unions and immediately fit therelevant blanking plugs.
Note:
If wearing leather protective gloves, cover thesewith latex protective gloves.
IMPORTANT
Wear latex safety gloves when using the cleaningagent.
IMPORTANT
Wear safety goggles fitted with side shields duringthis operation.
WARNINGDo not blast with compressed air once the fuel cir-cuit is open, otherwise impurities may enter the sys-tem. Use cleaning cloths only, if necessary.
13B-18
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B2 - Using the brake cleaning agent
Clear the access to the unions that need opening, fol-lowing the work procedures specific to the vehicle (seethe relevant Workshop Repair Manual).
Protect sections which are sensitive to fuel leaks.
Spray the brake cleaning agent onto the unions to beopened.
Clean the unions carefully using fresh cleaning cloths.
Blast the components that have been cleaned withcompressed air (tools, workbench, and also parts,unions and around the injection system). Make surethere are no brush bristles remaining and that the areais clean.
Open the circuit at the unions and immediately fit therelevant blanking plugs.
IMPORTANT
Wear latex safety gloves when using the cleaningagent.
IMPORTANT
Wear safety goggles fitted with side shields duringthis operation.
WARNING
Do not blast with compressed air once the fuel cir-cuit is open, otherwise impurities may enter the sys-tem. Use cleaning cloths only, if necessary.
13B-19
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13BV - INSTRUCTIONS FOR FITTING THE PLUGS
K9K, and 722 or 724 or 728
13B-20
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13Bpart no. 77 01 206 804
13B-21
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B20977
13B-22
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B
K9K, and 732
13B-23
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13Bpart no. 77 01 476 857
13B-24
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B113430
13B-25
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B
F9Q, and 804
13B-26
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13Bpart no. 77 01 208 229
13B-27
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B104561
13B-28
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B
M9R, and 700
13B-29
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13Bpart no. 77 01 209 062
13B-30
DIESEL INJECTIONDiesel injection: Precautions for repair
K9K, and 722 or 724 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808 – M9R, and 700
13B113737
13B-31
DIESEL INJECTIONDescription
F9Q, and 800 or 808
13BThe high pressure direct injection system is intended todeliver a specific volume of diesel fuel to the engine ata specific time.
The system comprises:
- a priming pump on the low pressure circuit,
- a diesel filter,
- a pressure regulator mounted on the pump,
- a high pressure pump,
- an injection rail fitted with a diesel fuel pressure sen-sor and a pressure limiter,
- four solenoid injectors,
- various sensors,
- an injection computer.
13B-32
DIESEL INJECTIONDescription
K9K, and 722 or 728 or 729
13BThe high pressure direct injection system is intended todeliver a specific volume of diesel fuel to the engine ata specific time.
The system comprises:
- a priming pump on the low pressure circuit,
- a diesel filter,
- a high pressure pump combined with a low pressurepump (transfer pump),
- a pressure regulator mounted on the pump,
- a spherical injection rail,
- a pressure sensor incorporated into the rail,
- four solenoid injectors,
- a diesel fuel temperature sensor,
- a coolant temperature sensor,
- a turbocharging air temperature and pressure sensor,
- a cylinder marking sensor,
- an engine speed sensor,
- an accelerometer,
- an exhaust gas recirculation solenoid valve,
- an accelerator pedal potentiometer,
- an atmospheric pressure sensor,
- an injection computer.
13B-33
DIESEL INJECTIONOperation
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
13B
The « common rail » high pressure injection systemoperates in sequential mode (based on the multipointinjection principle for petrol engines).
Through its pre-injection process, this injection system can provide:
- reduced operating noise,
- a reduction in the amount of pollutant gases and par-ticles,
- a high engine torque at low engine speeds.
The high pressure pump generates the high pressuretransmitted to the injection rail. The actuator on thehigh pressure pump controls the volume of diesel fuelsupplied according to the demand determined by theinjection computer. The rail supplies each injectorthrough a steel pipe.
The computer:
- determines the injection pressure value necessary forthe engine to operate correctly and then operates thefuel flow actuator. It checks that the pressure value iscorrect by analysing the value transmitted by thepressure sensor located on the rail,
- determines the injection time necessary to deliver theright volume of diesel fuel and the moment when in-jection should be started,
- electrically actuates each injector individually afterdetermining these two values.
The flow injected into the engine is determined accor-ding to:
- the duration of injector actuation,
- the injector opening and closing speed,
- the needle stroke (determined by a constant for an in-jector type),
- the nominal hydraulic flow of the injector (specific toeach injector),
- the high pressure rail pressure regulated by the com-puter.
The computer manages:
- idle speed regulation,
- the exhaust gas flow reinjected into the inlet,
- the fuel supply (timing, flow and rail pressure),
- the fan assembly actuation request (function: centra-lised coolant temperature management),
- the air conditioning,
- the cruise control-speed limiter function,
- the pre/postheating actuation.
The high pressure pump is supplied at low pressure bya mechanical low pressure pump (transfer pump).
The high pressure pump supplies the rail which is pres-sure-controlled:
- for loading by the fuel flow actuator,
- for discharge by the injector valves.
Drops in pressure may also be compensated for.
The fuel flow actuator allows the high pressure pump tosupply the exact volume of diesel fuel required to main-tain the pressure in the rail. This feature allows heatgeneration to be minimised and engine output to be im-proved.
To discharge the rail, the injection valves are controlled by small electrical pulses:
- short enough not to open the injector (passing throu-gh the return circuit from the injectors),
- long enough to open the valves and discharge therail.
The injection computer actuates the fan assembly andthe coolant temperature warning light on the instru-ment panel (function: centralised coolant temperaturemanagement).
The various vehicle computers communicate via multi-plex links. The fault warning lights on the instrumentpanel are therefore activated via the multiplex network.
In the event of an impact, the function that cuts off thediesel fuel supply circuit is managed by the airbagcomputer. It gives the command via the multiplexnetwork to the injection computer to lock the injectionlocking relay control.
Equipment required
diagnostic tool
IMPORTANT
Before carrying out any work on the injection circuit, check using the diagnostic tool :
- that the rail is not pressurised,
- that the fuel temperature is not too high.
Every time work is carried out, be sure to follow thesafety and cleanliness advice specified in this docu-ment.
Loosening a high pressure pipe union when theengine is running is strictly prohibited.
13B-34
DIESEL INJECTIONOperation
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
13BUnlocking is only enabled after the ignition is switchedoff for 10 seconds . This operation causes the faultwarning light to come on for longer than usual whenswitching on the ignition. The warning light will not re-turn to normal operation until the fault has been clearedusing the diagnostic tool .
The vehicle speed signal is transmitted to the instru-ment panel by the ABS computer or the gearbox (vehi-cle without ABS system) via the multiplex network.
Some vehicles have a sensor for detecting water in thediesel fuel, which is located in the filter. If there is waterpresent in the diesel fuel, the orange injection warninglight comes on.
Automatic configuration for cruise control - speed limi-ter operation and for air conditioning operation.
Injection computer actuating the air conditioning com-pressor clutch via the UPC.
A new electronics casing called the « UPC » has beenadded to the vehicles wiring diagram.
The UPC supplies the following with power:
- the air conditioning compressor,
- the fan assembly,
- the electrical heating resistors.
The UPC is located in the engine compartment nearthe battery. It contributes to the protection of certainelectrical components.
In this capacity, it comprises:
- fuses,
- several internal relays including:
• the « + after ignition feed » relay,
• the fan assembly control relays,
• the air conditioning compressor relay.
These relays cannot be removed.
If the UPC is replaced, it must be configured using thediagnostic tool (see 87G, Motor exchange unit,UPC: Configuration ).
The injection computer receives a continuous signalvia the multiplex network regarding the electrical poweravailable from the alternator. This therefore preventsthe vehicle's electrical consumption from being in ex-cess of the alternator's capacity. The aim is to givepriority to charging the battery.
Reprime the circuit using the priming pump.
The system can inject the diesel fuel into the engine upto a pressure of 1350 bar . Before each operationcheck that the injection rail is no longer pressurised.
Be sure to observe the tightening torque:
- for the high pressure pipes,
- for the injector on the cylinder head,
- for the pressure sensor and pressure regulator.
WARNING
- The engine must not be run with diesel fuel contai-ning more than 10% diester or petrol, even inminute quantities.
- Dismantling the interior of the high pressure pumpand the injectors is prohibited. Only the fuel flowactuator, the diesel fuel temperature sensor andthe Venturi tube can be replaced.
- It is prohibited to remove the pressure sensor fromthe injection rail as this could cause contaminationof the circuit. If the pressure sensor is faulty,replace the assembly consisting of the pressuresensor, rail, and the five high pressure pipes.
- It is strictly prohibited to remove any injectionpump pulley bearing the number 070 575. If thepump is being replaced also replace the pulley.
- Supplying any system component directly with the+ 12 V is prohibited.
- Ultrasonic decarbonisation and cleaning are prohi-bited.
- Never start the engine unless the battery is pro-perly connected.
- Never turn the engine against its operating direc-tion.
IMPORTANT
The engine should not be run with diesel fuel con-taining more than 10% diester.
Note:
After any operation, check that there is no dieselfuel leakage. Let the engine idle until the enginecooling fan starts up, then accelerate several timesat no load.
13B-35
DIESEL INJECTIONOperation
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
13BWhen the high pressure pump, injectors and high pres-sure supply, outlet and return unions are removed orrepaired, all apertures should be capped with suitablenew blanking covers to prevent contamination.
When replacing a high pressure pipe, follow the proce-dure below:
- remove the high pressure pipe, holding the filter rodon the injector with a lock spanner,
- fit anti-contamination plugs,
- loosen the high pressure rail,
- fit the new high pressure pipe,
- finger tighten the unions until they touch,
- torque tighten the high pressure rail mountings,
- torque tighten the union at the injector end,
- torque tighten the high pressure rail end union.
WARNING
Any pipe removed must be replaced.
WARNING
Dismantling the interior of the pump is prohibited.
The fuel return pipe fitted to the injectors must bereplaced when removed.
The diesel fuel temperature sensor cannot beremoved. It is part of the fuel return rail.
Loosening a high pressure pipe union when theengine is running is prohibited.
13B-36
DIESEL INJECTIONLocation of components
K9K, and 722
13B
102072
(1) Pr iming pump
(2) Cylinder reference sensor
(3) Turbocharger
(4) Exhaust gas recirculation sole-noid valve
(5) Injector
(6) Turbocharging air temperatureand pressure sensor
(7) Injection computer
(8) Air filter unit
(9) Protection and Switching Unit
(10) Coolant temperature sensor
(11) Engine speed and position sen-sor
(12) Rail pressure sensor
(13) Spherical injection rail
(14) Accelerometer
(15) Diesel temperature sensor
(16) Diesel flow actuator
(17) High pressure pump
101811
(18) Injection computer
13B-37
DIESEL INJECTIONLocation of components
K9K, and 722
13B
101105
(19) Protection and Switching Unit
102085
(20) High pressure pump
102084
(21) Venturi
(22) Flow actuator
(23) Diesel temperature sensor
(24) Rail pressure sensor
(25) Spherical injection rail
(26) Accelerometer
(27) Injector
102082
13B-38
DIESEL INJECTIONLocation of components
K9K, and 722
13B
(28) Turbocharging air temperatureand pressure sensor
(29) Exhaust gas recirculation sole-noid valve
(30) Wastegate valve
19654-1
(31) Cylinder reference sensor
13B-39
DIESEL INJECTIONLocation of components
K9K, and 722
13B
20796
(32) Coolant temperature sensor
(33) Engine speed and position sen-sor
102204
(34) Accelerator pedal potentiometer
102125
(35) Pre-postheating unit
102121
(36) Diesel filter
13B-40
DIESEL INJECTIONLocation of components
K9K, and 722
13B
102124
(37) Pr iming pump
102128
(38) Refrigerant pressure sensor
102077
(39) Turbocharger
(40) Catalytic converter
13B-41
DIESEL INJECTIONLocation of components
F9Q, and 800 or 808
13B
101883
(1) Diesel filter
(2) Manual priming pump
(3) Cylinder reference sensor
(4) Rail pressure sensor
(5) Solenoid injectors
(6) Engine stop system vacuumreserve
(7) Engine stop system solenoidvalve
(8) Exhaust gas recirculation sole-noid valve (F9Q 800)
(9) Turbocharger regulation sole-noid valve
(10) Flowmeter with air temperaturesensor
(11) Injection computer
(12) Protection and Switching Unit
(13) Engine stop valve diaphragm
(14) Engine stop valve
(15) Pressure limiter (on injectionrail)
(16) Turbocharging pressure sensor
(17) Diesel temperature sensor (fuelreturn)
(18) High pressure pump
(19) Diesel pressure regulator
13B-42
DIESEL INJECTIONLocation of components
F9Q, and 800 or 808
13B
18297-1
(20) High pressure pump
(21) Injection rail
(22) Injector
(23) Pressure regulator
(24) Pressure sensor
(25) Coolant temperature sensor
(26) Pressure limiter
102485
(27) TDC sensor
27
13B-43
DIESEL INJECTIONLocation of components
F9Q, and 800 or 808
13B
16181
(28) Cylinder reference sensor
102479
(29) Turbocharger
(30) Catalytic converter
28
29
30
101891
(31) Preheating unit
101889
(32) Turbocharging pressure regula-tion solenoid valve
31
32
13B-44
DIESEL INJECTIONLocation of components
F9Q, and 800 or 808
13B
101892
(33) Engine stop valve
(34) Engine stop valve controldiaphragm
102486
(35) Engine stop valve vacuumreserve
(36) Engine stop valve solenoid valve
(37) Exhaust gas recirculation sole-noid valve (F9Q 800)
34
33
37
36
35
101886
(38) Manual priming pump
102121
(39) Diesel filter
38
39
13B-45
DIESEL INJECTIONLocation of components
F9Q, and 800 or 808
13B
102352
(40) Turbocharging pressure sensor
102204
(41) Accelerator pedal potentiometer
40
13B-46
DIESEL INJECTIONLocation of components
K9K, and 728 or 729
13B
106343
(1) Pr iming pump
(2) Cylinder reference sensor
(3) Turbocharger
(4) Exhaust gas recirculation sole-noid valve
(5) Injector
(6) Turbocharging air temperatureand pressure sensor
(7) Injection computer
(8) Air filter unit
(9) UPC
(10) Coolant temperature sensor
(11) Engine speed and position sen-sor
(12) Rail pressure sensor
(13) Spherical injection rail
(14) Accelerometer
(15) Diesel fuel temperature sensor
(16) Diesel fuel flow actuator
(17) High pressure pump
(18) Turbocharging pressure sole-noid valve
101811
(19) Injection computer
13B-47
DIESEL INJECTIONLocation of components
K9K, and 728 or 729
13B
101105
(20) UPC
102085
(21) High pressure pump
102084
(22) Venturi
(23) Fuel flow actuator
(24) Diesel fuel temperature sensor
(25) Rail pressure sensor
(26) Spherical injection rail
(27) Accelerometer
(28) Injector
110327
13B-48
DIESEL INJECTIONLocation of components
K9K, and 728 or 729
13B
110319
(29) Turbocharging air temperatureand pressure sensor
(30) Exhaust gas recirculation sole-noid valve
(31) Engine speed and position sen-sor
(32) Turbocharging pressure regula-tion valve
101889
(33) Turbocharging pressure regula-tion solenoid valve
13B-49
DIESEL INJECTIONLocation of components
K9K, and 728 or 729
13B
19654-1
(34) Cylinder reference sensor
20796
(35) Coolant temperature sensor
102204
(36) Accelerator pedal potentiometer
13B-50
DIESEL INJECTIONLocation of components
K9K, and 728 or 729
13B
102125
(37) Pre-postheating unit
104954
(38) Diesel filter
102124
(39) Priming pump
102128
(40) Refrigerant pressure sensor
13B-51
DIESEL INJECTIONLocation of components
K9K, and 728 or 729
13B
102077
(41) Turbocharger
(42) Catalytic converter
13B-52
DIESEL INJECTIONLocation of components
F9Q, and 804
13B
101883
(1) Diesel filter
(2) Pr iming pump
(3) Cylinder reference sensor
(4) Rail pressure sensor
(5) Solenoid injectors
(6) Exhaust gas recirculation sole-noid valve unit
(7) Turbocharger regulation sole-noid valve
(8) Flowmeter with air temperaturesensor
(9) Injection computer
(10) UPC
(11) Pressure limiter
(12) Turbocharging pressure sensor
(13) Diesel fuel temperature sensor
(14) High pressure pump
(15) Diesel pressure regulator
13B-53
DIESEL INJECTIONLocation of components
F9Q, and 804
13B
18297-1
(16) High pressure pump
(17) Injection common rail
(18) Injectors
(19) Pressure regulator
(20) Pressure sensor
(21) Coolant temperature sensor
(22) Pressure limiter
102485
(23) TDC sensor
13B-54
DIESEL INJECTIONLocation of components
F9Q, and 804
13B
16181
(24) Cylinder reference sensor
111864
(25) Turbocharger
(26) Catalytic converter
101891
(27) Preheating unit
101889
(28) Turbocharging pressure regula-tion solenoid valve
13B-55
DIESEL INJECTIONLocation of components
F9Q, and 804
13B
111856
(29) Throttle valve.
(30) Exhaust gas recirculation sole-noid valve unit.
101886
(31) Pr iming pump
102121
(32) Diesel filter
102204
(33) Accelerator pedal potentiometer
13B-56
DIESEL INJECTIONLocation of components
K9K, and 732
13B
114186
(1) Manual priming pump
(2) High pressure pump
(3) Exhaust gas recirculation sole-noid valve
(4) Turbocharger
(5) Injectors
(6) Cylinder reference sensor
(7) Turbocharging air pressure sen-sor
(8) Air flowmeter
(9) Air filter unit
(10) Protection and Switching Unit
(11) Injection computer
(12) Turbocharging pressure regula-tion solenoid valve
(13) Coolant temperature sensor
(14) Injection rail
(15) Injection rail pressure sensor
(16) Diesel fuel temperature sensor
(17) Diesel filter
101811
(18) Injection computer
13B-57
DIESEL INJECTIONLocation of components
K9K, and 732
13B
101105
(19) Protection and Switching Unit
111748
(20) High pressure pump
112994
(21) Cylinder reference sensor
(22) Air inlet valve
(24) Pressure regulation solenoidvalve
(23) Flow regulation solenoid valve
13B-58
DIESEL INJECTIONLocation of components
K9K, and 732
13B
114348
(25) Diesel injector fuel return rail
(26) Diesel temperature sensor
(27) High pressure pipe between therail and injector
(28) High pressure pipe between thepump and rail
(29) High pressure rail
(30) Rail pressure sensor
(31) Diesel injector
(32) Injector bracket
(33) Spacer between the cylinderhead and injector bracket
102204
(34) Accelerator pedal potentiometer
13B-59
DIESEL INJECTIONLocation of components
K9K, and 732
13B
102125
(35) Pre-postheating unit
114559
(36) Diesel filter
102124
(37) Priming pump
113840
(38) Catalytic converter
(39) Turbocharger
13B-60
DIESEL INJECTIONLocation of components
K9K, and 732
13B
114185
(40) Turbocharging pressure regula-tion solenoid valve
13B-61
DIESEL INJECTIONImmobiliser function
K9K, and 722 or 728 or 729 – F9Q, and 800 or 804 or 808
13BThese vehicles are fitted with an engine immobilisersystem, controlled by a RENAULT card random rollingcode recognition system, which requires a special pro-cedure for replacing the computer.
REPLACEMENT
For the removal/refitting procedure, (see 13B, Die-sel injection, Diesel injection computer ).
For the engine immobiliser functions (see 82A, En-gine immobiliser, Operation ).
Injection computers are supplied without a code, butthey can all be programmed with one.
When replacing the computer, program it with thevehicle code, then check that the engine immobiliserfunction is operational.
Switch on the ignition for a few seconds without star-ting the engine.
Switch off the ignition.
Note:
The immobiliser function operates after roughly10 seconds (the red immobiliser warning lightblinks on the instrument panel).
WARNING
- The injection computer retains the immobilisercode for life.
- The system has no security code.
- Running tests with computers borrowed fromthe Parts Department or from another vehiclewhich must then be returned is prohibited.
- These computers are permanently coded.
13B-62
DIESEL INJECTIONInjection warning light
K9K, and 722 or 728 or 729 or 732
13B
Vehicles fitted with the Delphi DDCR high-pressurediesel fuel system use fault warning symbols and textwarning messages, depending on the level of severityof the faults detected, to inform the customer and de-termine the correct fault finding procedure.
The injection computer controls the illumination of war-ning lights and message displays on the instrument pa-nel. The fault warning lights come on:
- during the preheating phase,
- if there is an injection fault,
- if the engine is overheating.
The warning signals are sent to the instrument panelvia the multiplex network.
WARNING LIGHT ACTIVATION PRINCIPLE.
During the starting phase (press the « Start » button,the orange preheating symbol is lit during the prehea-ting phase, then goes out) (see 13C, Preheating, Pre-postheating control ).
In the event of an injection fault (level 1), the message« Check injection » is displayed and then the« Service » warning light comes on. This means a re-duced level of operation and a limited safety level.
Repairs should be carried out as soon as possible.
These faults are associated with:
- the engine immobiliser,
- a C2l (individual injector correction) coding error,
- an injector,
- the injector controls,
- the diesel fuel supply (injector leak, etc.),
- an engine speed sensor target fault,
- the injection locking relay,
- the exhaust gas recirculation solenoid valve or posi-tion sensor,
- the accelerator pedal potentiometer (gangs 1 and 2),
- the accelerator pedal potentiometer supply,
- the turbocharging pressure sensor (in the event ofoverpressure),
- water in the diesel fuel or a water detection sensorfault (if fitted on vehicle.
If there is a serious injection fault (level 2), the red en-gine symbol and the word « Stop » appears (only on in-formation display), with the message « Injectionfaulty » , followed by the « Stop » warning light andbuzzer.
The faults relate to:
- with delayed stop: the fuel flow actuator (loop discre-pancy and overpressure),
- with immediate stop:
• the engine speed sensor,
• the diesel flow actuator,
• the rail pressure sensor,
• the supply to all the injectors,
• the sensor supply voltage,
• an internal computer fault.
If the engine overheats, the engine temperature faultsymbol appears with the message « Engineoverheating » (only on information display) followed bythe « Stop » warning light and buzzer. If this happens,the vehicle will stop immediately.
« On Board Diagnostic » excess pollution orange warning light
The orange warning light, represented by an engine,comes on for approximately 5 seconds then goes out.It is never displayed when the engine is running (notoperational).
Note:
For vehicles fitted with K9K 732 engines (see MR370 Mechanics, Scénic II ).
13B-63
DIESEL INJECTIONInjection warning light
F9Q, and 800 or 804 or 808
13BVehicles fitted with the Bosch EDC16 high pressurediesel fuel system use fault warning symbols and textwarning messages, depending on the level of severityof the faults detected, to inform the customer and de-termine the correct fault finding procedure.
The injection computer controls the illumination of war-ning lights and message displays on the instrument pa-nel. The fault warning lights and error messages are visible:
- during the preheating phase,
- if there is an injection fault,
- if the engine is overheating.
The warning signals are sent to the instrument panelvia the multiplex network.
WARNING LIGHT PRINCIPLE
During the starting phase (press on the « Start » but-ton, the orange preheating symbol is lit during the pre-heating phase then it goes out) (see 13C, Preheating,Pre-postheating control ).
In the event of an injection fault (level 1), the message« Check injection » is displayed and then the« Service » warning light comes on. This means a re-duced level of operation and a limited safety level.
These faults are associated with:
- an internal computer fault,
- an immobiliser system fault,
- a speed synchronisation fault,
- an accelerator pedal potentiometer fault,
- an air flowmeter fault,
- a speed sensor fault (see ABS system),
- an EGR solenoid valve fault,
- a fault in the turbocharging pressure regulation sole-noid valve,
- a fault in the main relay of the Protection and Swit-ching Unit,
- an injector fault,
- an injector flow correction fault (IMA),
- a sensor power feed fault.
If there is a serious injection fault (level 2), the red en-gine symbol and the word « Stop » appears (only on in-formation display), with the message « Injectionfaulty » , followed by the « Stop » warning light andbuzzer.
These faults are associated with:
- an internal computer fault,
- an injector fault,
- a rail pressure sensor fault,
- a rail pressure regulator fault.
If the engine overheats, the engine coolant temperatu-re fault symbol appears with the message « Engineoverheating » (only on information display) followed bythe « Stop » warning light and buzzer. In this case thevehicle must be stopped immediately.
« On Board Diagnostic » excess pollution orange warning light
The orange engine symbol comes on when the ignitionis switched on for around 5 seconds then goes out. Itis never displayed when the engine is running (not ope-rational).
13B-64
DIESEL INJECTIONInjection / air conditioning programming
K9K, and 722 or 728 or 729
13B
The air conditioning management is shared betweenseveral computers that communicate via the multiplexnetwork.
It is of the « cold loop » type.
The injection computer is responsible for:
- managing the cooling request according to passengercompartment commands and the circuit pressure va-lue,
- calculating the power absorbed by the compressorfrom the circuit pressure value,
- authorising engine cooling fan control in accordancewith vehicle speed and circuit pressure,
- authorising or inhibiting engagement of the compres-sor clutch.
When the air conditioning is switched on, the air condi-tioning control panel requests authorisation to engagethe compressor clutch.
The injection computer authorises or inhibits compres-sor clutch engagement, controls the fan assembly viathe UPC and imposes an increased idle speed.
This engine speed is 900 rpm depending on how muchpower is absorbed by the compressor.
The injection computer authorises operation of the air conditioning compressor and the fan unit (both sup-plied by the UPC), according to the following condi-tions:
- engine coolant temperature,
- vehicle speed,
- climate control.
The signals used for the air conditioning function are transmitted via:
- track A A4 « CAN HIGH » multiplex connection,
- track A A3 « CAN LOW » multiplex connection.
The connections between the injection computer and the refrigerant pressure sensor are:
- C C3 refrigerant pressure sensor signal,
- C C4 refrigerant pressure sensor supply,
- C G3 refrigerant pressure sensor earth.
I - COMPRESSOR OPERATION PROGRAMMING
During certain operating phases, the injection compu-ter disables the operation of the compressor.
1 - Engine starting programming
The operation of the air conditioning compressor is in-hibited for 1 second after the engine has started.
2 - Thermal protection programming
The air conditioning compressor is not engaged if theengine temperature is above 115˚C or above 110˚C athigh engine speeds, 4500 rpm for more than 10 se-conds .
3 - Fan unit control programming
With the engine idling or when driving, with the air con-ditioning on, the fan unit is activated at high or lowspeed, according to the refrigerant pressure and thevehicle speed.
4 - Recovery of performance
If the accelerator pedal is depressed firmly (more than75 % of its travel), the compressor is disengaged for 5seconds .
5 - Recovery of power when moving off
To assist the vehicle moving away, the air conditioningcompressor is disengaged if the accelerator pedal tra-vel is greater than 30 % and the engine speed is lessthan 1250 rpm .
6 - Anti-stalling function
The air conditioning compressor is disengaged if theengine speed is less than 740 rpm .
Note:
For vehicles fitted with engine concerned (see MR370 Mechanics, Scénic II ).
Note:
The value of parameter ( PR044 ) « power absor-bed by the air conditioning compressor » is never 0,whatever the status of the air conditioning compres-sor. The minimum reading is approximately 250 W .
The air conditioning compressor is of the « variabledisplacement » type.
13B-65
DIESEL INJECTIONInjection / air conditioning programming
K9K, and 722 or 728 or 729
13B7 - Engine overspeed timed protection programming
The air conditioning compressor is disengaged if theengine speed is above 4500 rpm for more than 3 se-conds .
II - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING
To reduce the heating time, fit air heating resistorsknown as « passenger compartment heatingresistors » in the passenger compartment heating cir-cuit.
The UCH determines the need to actuate the heatingresistors, according to the user's request.
The injection computer determines:
- the number of heating resistors supplied (power con-trol limitation) depending on the alternator charge,
- whether resistor operation should be disabled, accor-ding to engine speed, load and vehicle speed.
The heating resistors are supplied by the UPC.
At the request of the resistors, the fast idle speed beco-mes 900 rpm .
III - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING
During certain operating phases, the injection compu-ter disables the passenger compartment heating resis-tors.
1 - Engine start programming
Operation of passenger compartment heating resistorsis prohibited for 20 seconds after the engine is started.
2 - Performance return programming under heavy load
Under heavy load at low engine speeds the heating re-sistors are temporarily disabled.
Input conditions:
- engine speed less than 3000 rpm ,
- and vehicle speed less than 78 mph (130 km/h) .
Output conditions:
- engine speed above 3500 rpm ,
- and vehicle speed greater than 90 mph (150 km/h)(by way of information).
3 - Performance return programming for hill starts
To assist hill starts, the heating resistors are tempora-rily disabled.
Input conditions:
- engine speed less than 900 rpm ,
- and vehicle speed less than 2.4 mph (4 km/h) ,
- and gearbox in neutral.
Output conditions:
- engine speed greater than 2500 rpm ,
- or vehicle speed greater than 3.6 mph (6 km/h)
- or a gear is engaged.
4 - Stalling prevention programming
When the engine speed falls below 760 rpm , opera-tion of passenger compartment heating resistors is in-terrupted. When engine speed rises above 750 rpm ,the passenger compartment heating resistors are re-enabled.
Note:
There is always a delay of more than 10 secondsafter the air conditioning compressor is disengagedbefore it can be disengaged again.
13B-66
DIESEL INJECTIONInjection / air conditioning programming
F9Q, and 800 or 804 or 808
13BThe air conditioning management is shared betweenseveral computers that communicate via the multiplexnetwork.
When the air conditioning is switched on, the air condi-tioning control panel requests authorisation to engagethe compressor clutch.
The injection computer authorises or inhibits the com-pressor clutch, and controls the fan assembly via theUPC.
When the air conditioning function is selected, theidling speed is not altered.
The signals used for the air conditioning function are transmitted via:
- track A A4 « CAN HIGH » multiplex connection,
- track A A3 « CAN LOW » multiplex connection.
This compressor is the variable output type.
I - AIR CONDITIONING COMPRESSOR OPERATION PROGRAMMING
During certain operating phases, the injection compu-ter disables the compressor.
1 - Engine start programming
Air conditioning compressor operation is inhibited for 2seconds after the engine has started.
2 - Thermal protection programming
The air conditioning compressor is not engaged if theengine coolant temperature is above 115 ˚C , it is re-engaged if the engine coolant temperature falls below115 ˚C .
This vehicle is equipped with heating resistors locatedin the air conditioning unit.
These heating resistors are designed to heat up the airwhich is then directed to the passenger compartment.
When the heating resistors are activated, the injectioncomputer adopts a fast idling speed. This enginespeed is 900 rpm .
3 - Recovery of power when moving off
To help the vehicle start moving, the air conditioningcompressor is engaged if the accelerator pedal posi-tion is above 25 % , the engine speed is below 1350rpm and the vehicle speed is below 3 mph (5 km/h) .
4 - Anti-stalling function
The air conditioning compressor is disengaged if theengine speed is below 750 rpm .
It is re-engaged if the engine speed exceeds 780 rpm .
II - PASSENGER COMPARTMENT HEATING RESISTORS OPERATION PROGRAMMING
During certain operating phases, the injection compu-ter disables the heating resistors.
1 - Engine start programming
The heating resistors are disabled while the heaterplugs are in operation.
When the engine starts, the heating resistor supply isauthorised after a delay that depends on the enginecoolant temperature.
2 - Stalling prevention programming
When the engine speed falls below 800 rpm , opera-tion of the heating resistors is interrupted. When theengine speed falls below 875 rpm , operation of theheating resistors is authorised.
Engine coolant tem-perature
(˚C +/- 1)
Delay
(s)
- 30 30
- 20 25
- 10 15
0 15
10 15
20 15
30 10
13B-67
DIESEL INJECTIONIdling speed
K9K, and 722 or 728 or 729 or 732
13B
The injection computer calculates the idling speed nee-ded to maintain it at the recommended level and tocompensate for any variation in the mechanical orelectrical torque as a function of:
- the coolant temperature,
- the battery voltage,
- the gear selected,
- the electrical consumers (climate control, fan unit,passenger compartment heating electrical resistors,etc.),
- any faults found.
I - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
X: Engine idle speed (rpm)
Y: Engine coolant temperature (˚C)
II - IDLE SPEED CORRECTION IN THE EVENT OF AN ACCELERATOR PEDAL POTENTIOMETER FAULT
- If one of the two accelerator pedal potentiometertracks is faulty, the injection computer forces an idlespeed of 1300 rpm . This defect mode limits perfor-mance. The « Check injection » message lights up,followed by the « Service » warning light.
- If the accelerator pedal potentiometer is jammed, nolonger supplied, or is no longer sending an output si-gnal, the injection computer imposes an idle speed of1300 rpm . This defect mode limits performance. The« Check injection » message lights up, followed bythe « Service » warning light.
- If there is inconsistency between the accelerator pe-dal potentiometer signal and the brake switch signal,the injection computer imposes an idle speed of 1300rpm .
III - IDLE SPEED CORRECTION IN THE EVENT OF AN INJECTOR C2I CODING ERROR
In the event of an injector C2I coding error (individualadjustment of the injector flow), the injection computerforces an idle speed of 1300 rpm . This defect mode li-mits performance. The « Check injection » message li-ghts up, followed by the « Service » warning light.
IV - IDLE SPEED CORRECTION WHEN THE VEHICLE IS BEING DRIVEN
At normal engine operating temperature, the idle speed is modified according to the gear engaged:
- in neutral, the speed is 805 rpm ,
- in 1stand 2ndgear, the speed is 875 rpm ,
- in 3rdand 4thgear, the speed is 900 rpm ,
- in 5thgear, the speed is 950 rpm .
Note:
For vehicles fitted with K9K 732 engines (see MR370 Mechanics, Scénic II ).
Note:
At normal engine operating temperature, withoutmajor electrical consumers, the engine idling speedis 805 ±±±± 50 rpm .
103122
13B-68
DIESEL INJECTIONIdling speed
B84 or C84 or S84, and F9Q, and 800 or 804
13BI - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
In all cases, this engine idling speed correction is deac-tivated 10 minutes after engine start and adopts a va-lue of 800 rpm .
X: Engine idling speed (rpm)
Y: Engine coolant temperature (˚C)
II - IDLE SPEED CORRECTION IN THE EVENT OF AN ACCELERATOR PEDAL POTENTIOMETER FAULT
If the two accelerator pedal potentiometer tracks aredefective, the injection computer sets the idling speedat 1400 rpm . By pressing on the brake pedal, theidling speed falls back to 1000 rpm .
If there is inconsistency between the accelerator pedalpotentiometer signals and the brake switch, the idlingspeed increases to 1400 rpm .
III - ENGINE IDLE SPEED CORRECTION WHEN THE VEHICLE IS BEING DRIVEN
The engine idling speed when the vehicle is being dri-ven is:
- 870 rpm when the 1stor the 2ndgear is engaged,
- 900 rpm when a higher gear than 2ndis engaged.
103129
13B-69
DIESEL INJECTIONCentralised coolant temperature management
K9K, and 722 or 728 or 729 or 732
13B
The coolant temperature sensor (injection and coolanttemperature indicator on the instrument panel) is a 3-track sensor:
- 2 tracks for the coolant temperature signal to the com-puter (tracks B H2 and B H3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be con-trolled by the injection computer. It consists of a singletemperature sensor serving injection, the engine coo-ling fan, the temperature indicator and the instrumentpanel engine coolant temperature warning light.
The request to operate the engine cooling fan is madeby the injection computer through the multiplexnetwork.
I - FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING
The fan assembly is controlled:
- at low speed if the engine coolant temperature ex-ceeds 99 ˚C or in the event of a coolant temperaturesensor fault and stops when the temperature falls be-low 96 ˚C ,
- at high speed if the engine coolant temperature ex-ceeds 102 ˚C or if the low speed is faulty and stopswhen the temperature falls below 99 ˚C .
The fan assembly low and high speeds are controlledwhen the air conditioning function is selected on theinstrument panel.
The fan will operate at high speed under the low speedoperating conditions if low speed is faulty.
II - OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT
The warning light is actuated by the injection computervia the multiplex network.
The warning light is continuously lit if the coolant tem-perature exceeds 118˚C . It goes out when the tempe-rature drops below 115 ˚C .
Note:
For vehicles fitted with K9K 732 engines (see MR370 Mechanics, Scénic II ).
13B-70
DIESEL INJECTIONCentralised coolant temperature management
F9Q, and 800 or 804 or 808
13BThe coolant temperature sensor (injection and coolanttemperature indicator on the instrument panel) is a 3-track sensor:
- 2 tracks for the coolant temperature signal to the com-puter (tracks B E1 and B K3),
- 1 track for instrument panel indicators.
This system allows the engine cooling fan to be con-trolled by the injection computer. It consists of a singletemperature sensor serving injection, the engine coo-ling fan, the temperature indicator and the instrumentpanel engine coolant temperature warning light.
The request to operate the engine cooling fan is madeby the injection computer through the multiplexnetwork.
I - FAN ASSEMBLY OPERATION WITH THE ENGINE RUNNING
The fan assembly is controlled:
- at low speed if the engine coolant temperature ex-ceeds 99˚C and stops when the temperature dropsbelow 96˚C ,
- at high speed if the engine coolant temperature ex-ceeds 102˚C and stops when the temperature dropsbelow 99˚C ,
- The fan assembly low and high speeds are controlledwhen the air conditioning function is selected on theinstrument panel.
II - ENGINE COOLANT TEMPERATURE WARNING LIGHT
The warning light is actuated by the injection computervia the multiplex network.
The warning light is lit continuously if the coolant tem-perature exceeds 120˚C . It goes out if the temperaturefalls below 115˚C .
13B-71
DIESEL INJECTIONComputer configuration
K9K, and 722 or 728 or 729 or 732
13B
The system can be programmed and reprogrammedvia the diagnostic socket using the diagnostic tool .
PROGRAMMING, REPROGRAMMING OR REPLACING THE COMPUTER
Before programming, reprogramming or replacing the computer, save to the diagnostic tool the fol-lowing data:
- the C2I parameters (individual injector correction),
- the engine adaptives using command SC003« Save computer data » .
After programming, reprogramming or replacing the computer:
- switch off the ignition,
- start and then stop the engine (to initialise the com-puter) and wait for 30 seconds ,
- switch on the ignition again.
- Use the diagnostic tool :
• use command SC001 « Write saved data » torestore the C2I and engine adaptives,
• enter the VIN using command VP010 « WriteVIN » ,
• rectify any faults in computers indicated by thediagnostic tool ,
• clear the computer memory,
• carry out a road test,
• carry out a new check using the diagnostic tool .
Equipment required
diagnostic tool
WARNING- Connect (to the mains or the cigarette lighter) the
diagnostic tool .
- Check the condition of the battery.
- Connect a battery charger (throughout the dura-tion of computer (re)programming, the engine coo-ling fan is automatically engaged).
- Comply with the engine coolant temperaturevalues given in the diagnostic tool beforecarrying out any (re)programming.
WARNING
- The injection computer retains the immobilisercode for life.
- The system has no security code.
- Running tests with computers borrowed fromthe Parts Department or from another vehiclewhich must then be returned is prohibited.
- The computers are permanently coded.
Note:
If commands SC001 and SC003 are not run orcannot be run following programming, repro-gramming or replacement of the computer, theC2I of each injector must be written manually,reading the C2Is on the injectors (see 13B, Die-sel Injection, Injectors: Configuration ).
13B-72
DIESEL INJECTIONComputer configuration
F9Q, and 800 or 808
13B
The system can be programmed and reprogrammedvia the diagnostic socket using the diagnostic tool (re-fer to Technical Note 3585A ).
PROGRAMMING, REPROGRAMMING OR REPLACING THE COMPUTER
When a computer is reprogrammed or replaced, it isnecessary to reprogram it with the IMA (InjectorFlow Correction) codes of the four injectors.
There are two possibilities:
- If it is possible to enter into dialogue with the computer:
• download the data from the old computer into thediagnostic tool ,
• replace the computer,
• transfer the data from the diagnostic tool to thenew computer,
• using the diagnostic tool , ensure that the com-puter has not detected any faults relating to the in-jector codes and that the instrument panelwarning light is off.
- If it is not possible to enter into dialogue with the computer:
• replace the computer,
• read the data from the injectors,
• enter it into the computer using the diagnostictool ,
• reconfigure the computer for the equipment (airconditioning),
• using the diagnostic tool , ensure that the com-puter has not detected any faults relating to the in-jector codes and that the instrument panelwarning light is off.
Equipment required
diagnostic tool
WARNING
- Connect the diagnostic tool (to the mains or thecigarette lighter).
- Check the condition of the battery.
- Connect a battery charger (the engine coolingfans are automatically activated for the entireduration of the computer (re)programming ).
- Keep to the engine coolant temperature guidelinessupplied in the diagnostic tool before carryingout any (re)programming.
13B-73
DIESEL INJECTIONHigh pressure pipe: Checking
K9K, and 722 or 728 or 729
13B
Reprime the diesel circuit using the manual primingpump.
Remove the engine covers.
Run command AC029 « high pressure circuit sea-ling test » , in the « LPG/fuel circuit » tab.
Check that there are no leaks in the high pressurecircuit.
Deal with the causes of any leaks.
Refit the engine covers.
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no die-sel fuel leakage.
Note:
The diagnostic tool can be used for testing thehigh pressure circuit with the engine running.
This command can be used for finding a leak dueto an incorrectly fitted or tightened union. Thiscommand only works if the engine coolant tem-perature is above 60˚C . The fault finding proce-dure will not reveal small leaks due to incorrecttightening.
WARNING
Do not leave anything in the engine bay duringthe test phase (significant vibration).
Note:
The engine automatically runs a cycle of fouraccelerations and decelerations to lower the railpressure.
13B-74
DIESEL INJECTIONHigh pressure pipe: Checking
K9K, and 732
13B
Reprime the diesel circuit using the manual primingpump.
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip and (2) move the air inlet duct aside(3) .
Pull out the clip.
Remove the stainless steel pipe mounting bolt (4) .
Move the air inlet duct to one side (5) .
Equipment required
diagnostic tool
WARNING
After any operation, check that there are is no die-sel fuel leakage.
112815
112811
112991
13B-75
DIESEL INJECTIONHigh pressure pipe: Checking
K9K, and 732
13B
Unclip the injection rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injection railprotector cover,
- the injection rail protector cover,
Refit the clip onto the stainless steel pipe if necessa-ry.
Clip the stainless steel pipe to turbocharger.
Refit the air inlet duct on the damper valve.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Run command AC029 « high pressure circuit sea-ling test » , in the « LPG/fuel circuit » tab.
Check that there are no leaks in the high pressurecircuit.
Deal with the causes of any leaks.
Disconnect:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the air inlet pressure sensor connector.
Loosen the clip and move the air inlet duct aside.
Pull out the stainless steel pipe clip.
Remove the air inlet duct.
Refit:
- the injection rail protector cover,
- the injection rail protector cover mounting nut andbolt,
Clip the injection rail protector cover.
Refit the clip onto the stainless steel pipe if necessa-ry.
Clip the stainless steel pipe to the turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine covers.
112992
Note:
The diagnostic tool can be used for testing thehigh pressure circuit with the engine running.
This command can be used for finding a leak dueto an incorrectly fitted or tightened union. Thiscommand only works if the engine coolant tem-perature is above 60˚C . The fault finding proce-dure will not reveal small leaks due to incorrecttightening.
WARNING
Do not leave anything in the engine bay duringthe test phase (significant vibration).
Note:
The engine automatically runs a cycle of fouraccelerations and decelerations to lower the railpressure.
13B-76
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13B
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove the engine covers.
Disconnect air inlet duct (1) .
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Equipment required
diagnostic tool
pipe socket for tightening the pump-rail high-pres-sure pipe (19-17 mm Crowfoot spanner)
high-pressure pipe wrench (DM19)
pipe socket for tightening injector-rail high pressurepipes ("Crowfoot 18-17" wrench)
low torque wrench
Tightening torquesm
rail mounting nuts 28 Nm
« pump-rail » high-pressure pipe nuts
38 Nm
« rail-injectors » high-pressure pipe nuts
38 Nm
filler neck nut on the rail 21 Nm
battery cover mountingbolts
4 Nm
Note:
For vehicles fitted with K9K 732 engines (see MR370 Mechanics, Scénic II ).
IMPORTANT
Before carrying out any work on the injection circuit, check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Ensure that you have a special high-pressureinjection circuit blanking plugs kit.
- Ensure that any high-pressure pipe or high-pres-sure pipe clips that have been removed are repla-ced.
K9K, and 722
102120
1
13B-77
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13B
Pull out clip (2) .
Loosen bolt (3) .
Move aside the air duct (4) .
Remove diesel fuel splash plate (5) .
Remove dipstick guide tube (6) .
Fit blanking plugs into the openings.
Carefully disconnect:
- the heater plugs (7) ,
- the injectors,
- the high-pressure pump electrical connectors (8) ,
- the diesel supply and return pipes (9) .
K9K, and 728 or 729
110325
110323
2
3
4
102362
102361
5
7777
8996
13B-78
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13B
Carefully disconnect:
- the diesel return pipe (10) connecting the injectorsto the high-pressure injection pump,
- the spherical injector rail pressure sensor (11) ,
- the accelerometer (12) ,
- the oil level sensor (13) ,
- the timing cover cylinder marking sensor (14) .
Shift the electrical harness to one side.
Remove filler neck (15) located on the spherical in-jector rail.
102360
WARNING- Be sure to hold the intermediate injector union(18) in place with a spanner when loosening thehigh-pressure pipes.
- Do not damage injector leak return nozzle (19) .
12 11
10
15
14
13
13B-79
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13B
Loosen mounting nuts (16) on the spherical injectorrail by several turns.
Remove clips (17) connecting the high-pressure pi-pes.
Loosen:
- the high-pressure pipe nut at the injector end usingtool (Mot. 1566) ,
- the high-pressure pipe nut at the injector rail endusing tool (Mot. 1566) .
Move the nuts along the tube, keeping the olive incontact with the taper.
Remove high-pressure pipes (20) one by one.
Fit blanking plugs into the openings.
20803
19724
1717
1616
19
18
Note:
Loosen the nuts pipe by pipe.
20803
20
13B-80
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13BREFITTING
I - REFITTING THE « PUMP - RAIL » HIGH PRESSURE PIPE
Remove the plugs.
Insert the high-pressure pipe olive in the high-pres-sure pump high-pressure outlet taper.
Insert the high-pressure pipe olive in the sphericalinjector rail inlet taper.
Finger tighten the high-pressure pipe nuts, startingwith the one at the rail end.
Slightly pretighten the high-pressure pipe nuts.
II - REFITTING THE « RAIL - INJECTORS » HIGH-PRESSURE PIPES
Remove the plugs.
Insert the high-pressure pipe olive in the injectorhigh-pressure inlet taper.
Insert the high-pressure pipe olive in the rail high-pressure outlet taper.
Tighten the high-pressure pipe nuts by hand, star-ting with the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts.
Fit a new clip provided with the new high-pressure pipe:
- insert the first half-shell using adjustable pliers,
- insert the second half-shell using adjustable pliers.
20960
WARNING
- Before fitting a new high-pressure pipe, lightlylubricate the nut threads with the oil from theapplicator provided in the new parts kit.
- Be careful not to allow oil into the high-pressurepipe.
- Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.
WARNING
Do not remove the caps from each componentuntil the last moment.
WARNING
When tightening the high-pressure pipes, it isessential to support the injector central union(18) .
Note:
The order of fitting the injector rail pipes is notimportant.
19723
Note:
Follow the direction of fitting (the lugs onlyengage in one position).
13B-81
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13BIII - REFITTING THE « PUMP - RAIL » HIGH PRESSURE PIPE AND THE « RAIL - INJECTOR » HIGH PRESSURE PIPES
Tighten to torque the rail mounting nuts ( 28 Nm ) .
WARNING
- Do not touch the high-pressure pipes with thespanner when tightening.
- Be sure to hold the injector central union inplace with a spanner when tightening.
13B-82
DIESEL INJECTIONHigh pressure pipe: Replacement
K9K, and 722 or 728 or 729 or 732
13B
Tighten to torque and in order the « pump-rail » high-pressure pipe nuts ( 38 Nm ) :
- pump end,
- rail end.
Use the pipe socket for tightening the pump-railhigh-pressure pipe (19-17 mm Crowfoot span-ner) or the high-pressure pipe wrench (DM19) .
Tighten to torque and in order the « rail-injectors » high-pressure pipe nuts ( 38 Nm ) :
- injectors end,
- rail end.
Use the pipe socket for tightening injector-railhigh pressure pipes ("Crowfoot 18-17" wrench)or the high-pressure pipe wrench (DM19) .
Proceed in the reverse order to removal.
Prime the diesel circuit using the priming pump.
Tighten to torque the filler neck nut on the rail ( 21Nm ) using a low torque wrench .
Connect the battery, starting with the negative termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
110404
Note:
Tighten each pipe fully before moving on to thenext pipe.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- check the sealing after repair (see 13B, Dieselinjection, High-pressure pipe: Sealing check,
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-83
DIESEL INJECTIONDiesel injector: check
K9K, and 722 or 728 or 729
13BCommand AC029 « High pressure circuit sealingtest » in the « Fuel/LPG » tab also enables the lea-kage rate of each injector to be checked in order todetermine an internal leak in one or several injec-tors. This test only works when the engine tempera-ture is greater than 60˚C .
Switch off the ignition.
Disconnect the return pipes of the four injectors.
Connect the four transparent hoses with an internaldiameter of 4 mm and a length of 50 cm in the placeof the return pipes.
Immerse these hoses into four graduated measuringcylinders (or use the measuring tool found in the« capped rail » kit).
Start the engine.
Allow the engine to run for 2 minutes at idle speed.
Run command AC029 « High pressure circuit sea-ling test » in the « Fuel/LPG » tab. The engine willautomatically carry out a cycle of four accelerations /decelerations to increase the pressure in the rail andcheck whether there are internal leaks on the injec-tors' return circuit.
When the cycle is complete, the test must be runagain, to obtain a correct reading of the flow of eachinjector.
After two cycles the flow of each injector should be35 ml .
Replace the faulty injector.
IMPORTANT
Never leave a tool or other object on the side ofthe engine housing during the four cycles (signifi-cant vibration).
13B-84
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Special tooling required
Mot. 1367-02 Engine support
Mot. 1367 Engine support tool forreplacing cyl inderhead
Mot. 1606 High pressure pump-pulley retaining tool
Mot. 1525 Extractor for timinggear with tapered hub
Mot. 1525-02 Adaptor claws for Mot.1525
Equipment required
diagnostic tool
Tightening torquesm
high pressure injectionpump mounting bolts
21 Nm
high pressure injectionpump pulley mountingnut
55 Nm
rail mounting nuts 28 ±±±± 3 Nm
union at the rail end 24 Nm
union at the pump end 24 Nm
battery cover mountingbolts
4 Nm
WARNING
Before starting work on the vehicle, obtain:
- a new set of blanking plugs (part no.: 77 01 206804 ),
- cleaning cloths (part no.: 77 11 211 707 ),
- cleaning product (part no.: 77 11 224 188 ).
WARNING
Tighten to torque 38 Nm the « pump-rail » and « injection rail » high pressure pipes with the fol-lowing part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
for high pressure pipes with other part numbers,tighten to a torque of 24 Nm .
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
• that the injection rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high pressure injection cir-cuit plugs.
- Always replace any high pressure pipe or highpressure pipe clip removed with a new one.
WARNING
Never turn the engine against its operating direc-tion.
13B-85
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13BREMOVAL
I - PROCEDURE FOR HIGH PRESSURE PUMPS WITH A PULLEY BEARING NUMBER 070 575
Replace the « pump-pulley » assembly, followingthe removal procedure for the high pressure pumpnot fitted with a pulley 070 575 .
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- the timing belt (see 11A, Top and front of engine,Timing belt ),
- the « pump-pulley » assembly.
II - PROCEDURE FOR HIGH PRESSURE PUMPS WITH A PULLEY BEARING A NUMBER OTHER THAN 070 575
Remove the engine covers.
Disconnect:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the air inlet duct (1) .
21265
WARNING
Removing any high pressure pump pulley bea-ring the number 070 575 is strictly prohibited.
21265
K9K, and 722
102120
13B-86
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Pull out the clip.
Undo the bolt (2) .
Remove the air duct (3) .
Remove dipstick guide tube (4) .
Plug the opening on the engine block.
Carefully disconnect:
- the heater plug connectors (5) ,
- the injectors,
- the fuel flow actuator electrical connectors (6) ,
- the diesel temperature sensor connector (7) ,
- the supply and return pipes (8) .
Remove the diesel fuel splash plate (9) .
K9K, and 728 or 729
110325
110323
102361
102362
4
55
55
6
7
88
13B-87
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Disconnect:
- the fuel return pipe connecting the injectors to thepump (10) ,
- the rail pressure sensor (11) ,
- the accelerator (12) ,
- the oil level sensor (13) ,
- the cylinder reference sensor (14) on the timing co-ver.
Unclamp the electrical harness and move it to oneside.
Remove the channel located on the spherical injec-tion rail.
Remove the (16) « pump-rail » high pressure pipe(see 13B, Diesel injection, High pressure pipe:Replacing ).
Slacken the rail mounting nuts (15) by a few turns.
Loosen the nut at the pump end, then the nut at therail end.
Slide the nut down the tube, keeping the olive in con-tact with the taper.
Plug the openings on the injection circuit.
Fit the (Mot. 1367-02) (1) and (Mot. 1367) (2) .
102360 102083
19626
13B-88
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Remove:
- the right-hand suspended mounting support andcover,
- the tie-bar and make a mark.
Remove the upper timing cover by unclipping both tabs (17) .
102114
19654
13B-89
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Remove the engine tie-bar mounting bolts (18) onthe gearbox and sub-frame.
Raise the engine a few centimetres for access to thesuspended mounting attachments on the cylinderhead and the high pressure pump pulley.
Remove the mounting bolts securing (19) the enginetie-bar on the gearbox and on the engine sub-frame.
Raise the engine a few centimetres for access to thesuspended mounting attachments on the cylinderhead and the high pressure pump pulley.
102115
WARNING
Do not dislodge the right-hand driveshaft whenlifting the engine.
K9K, and 729, and DP0
103749
WARNING
Do not dislodge the right-hand driveshaft whenlifting the engine.
13B-90
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Remove:
- the cylinder reference sensor (20) ,
- the plastic bolt (21) ,
Unclip the three tabs (22) .
Remove the lower timing cover.
19654-1
13B-91
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Remove the suspended mounting (23) from the cy-linder head.
Position the engine at Top Dead Centre. The cams-haft pulley hole (24) should be opposite the cylinderhead hole (25) .
19654-2
23167
13B-92
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Position the (Mot. 1606) (3) .
If necessary, turn the engine slowly to adjust the po-sition of the locking tool on the pump pulley teeth.
Remove the high pressure pump pulley nut (26) ,holding the pulley with an open-jawed spanner.
Fit the (Mot. 1525) (4) fitted with the (Mot. 1525-02).
23168 23169
WARNING
Ensure that the tool pushrod is correctly orientedand is pressing against the high pressure pumpshaft.
13B-93
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Remove the high pressure pump mounting bolts(27) .
Screw down the pushrod of the (Mot. 1525) .
Detach the « pulley - pump » assembly.
Remove:
- the high pressure pump,
- the high pressure pump extractor tool.
REFITTING
Ensure that the pulley clamping pin is still in place.
Fit the high pressure injection pump.
Tighten to torque the high pressure injectionpump mounting bolts ( 21 Nm ) .
Fit the high pressure injection pump pulley nut.
Tighten to torque the high pressure injectionpump pulley mounting nut ( 55 Nm ) , holding thepulley with an open-jawed spanner.
Remove the (Mot. 1606) .
Before fitting the new high pressure pipe, lightly lu-bricate the union threads with the oil from the appli-cator provided in the new parts kit.
102085
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
WARNING
Always replace all high pressure pipes removed.
WARNING
Some pipes are supplied with applicator andsome without.
The pipes supplied without applicator are self-lubricating pipes.
13B-94
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Refit the high pressure pipe - to do this:
- remove the protective plugs,
- insert the high pressure pipe olive in the pump out-let taper,
- insert the high pressure pipe olive in the rail inlet ta-per.
Finger tighten the high pressure pipe unions, star-ting with the one located at the rail end.
Tighten to torque the rail mounting nuts ( 28 ±±±± 3Nm ) .
Tighten to torque and in order:
- the union at the rail end ( 24 Nm ) ,
- the union at the pump end ( 24 Nm ) .
Proceed in the reverse order to removal.
Prime the diesel fuel supply circuit with the primingpump (automatic degassing).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
If replacing the high pressure pump, reprime the die-sel circuit using the diagnostic tool .
Connect the diagnostic tool to the vehicle.
Establish dialogue with the diesel injection compu-ter.
Run command AC212 « FILLING NEW PUMPCHAMBER » .
Follow the instructions on the diagnostic tool untilthe command is completed.
Start the engine.
If the engine does not start or if the start-up sequen-ce is interrupted:
- switch off the ignition,
- wait for 30 seconds ,
- restart the engine.
Using the diagnostic tool clear any faults stored bythe injection computer.
Check the high pressure circuit sealing after the re-pair operation (see 13B, Diesel injection, Highpressure pipe: Test ).
110404
Note:
For VDiag numbers earlier than VDiag 48 , it is essentialthat the injection computer is reprogrammed.
If the reprogramming is not carried out, do not apply theprocedure detailed below but prime the fuel circuit usingthe priming bulb.
WARNINGNever start the engine until the pump has been reprimed.
Also comply with the operation instructions provided toprevent the high pressure pump from being damagedinternally, due to running with no load and no diesel lubri-cation.
Note:
The star ting phase can last up to 20 seconds .
WARNING
Confirm that there is no diesel fuel leak:
- let the engine run at idle speed until the engine coolingfan starts to operate,
- accelerate several times at no load,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-95
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 800 or 808
13B
It is essential to read the repair precautions (see 13A,Diesel injection, Repair precautions ).
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ),
- the timing belt (see 11A, Top and front of engine,Timing belt ).
- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting), if fitted to the vehicle.
Special tooling required
Mot. 1668 Locking high pressurepump sprocket
Mot. 1525 Extractor for timinggear with tapered hub
Mot. 1525-03 Adapter claws for Mot.1525 (for 33-tooth pul-ley)
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Mot. 1566 Wrench for removinghigh-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
high-pressure pumpmounting bolts on thepump supports
30 Nm
high-pressure pumppulley nut
50 Nm
high-pressure pumpsupport mounting boltson the cylinder head
20 Nm + 80˚
high-pressure pumprear support mountingbolts on the cylinderblock
44 Nm
injector rail mountingbolts
22 Nm
pump-rail high-pressurepipe nut on the pumpside
29 Nm
pump-rail high-pressurepipe nut on the rail side
25 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
Ensure that any high-pressure pipe removed isreplaced.
WARNING
Dismantling the interior of the high-pressure pumpand the injectors is prohibited.
13B-96
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 800 or 808
13B
Disconnect:
- the diesel fuel heater from the diesel filter,
- the heater plugs,
- the pressure regulator (1) ,
- the pressure sensor (2) (version without injector railprotector).
Disconnect the diesel supply and return pipes.
Plug the openings.
Remove the diesel pipes retaining clip.
Remove the pump-rail high-pressure pipe.
Plug the openings.
Remove the two mounting bolts (3) from the high-pressure pump on the high-pressure pump rear sup-port.
102352
102351
102353
102348
13B-97
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 800 or 808
13B
Remove:
- the three mounting bolts (4) from the high-pressurepump front support,
- the high-pressure pump, with the high-pressurepump support.
Position the (Mot. 1668) (1) .
Remove the nut (5) from the high-pressure pumppulley.
Fit the pulley extractor (Mot. 1525) (2) with claws(Mot. 1525-03) for pulleys with thirty-three teeth.
Remove the pulley by tightening the pulley extractorthrust bolt (6) .
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.1668) .
Remove:
- the three mounting bolts (7) from the high-pressurepump,
- the high-pressure pump.
102350
102893
102894
102345
13B-98
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 800 or 808
13BREFITTING
Refit the high-pressure pump on the pump support.
Tighten to torque:
- the high-pressure pump mounting bolts on thepump supports ( 30 Nm ) ,
- the high-pressure pump pulley nut ( 50 Nm ) byimmobilising the pulley with (Mot. 1668) .
Push the ring (8) back as shown in the diagram.
Undo the two mounting bolts (9) on the high-pressu-re pump rear support on the cylinder block.
Refit the high-pressure pump assembly and thepump support.
Tighten to torque the high-pressure pump supportmounting bolts on the cylinder head ( 20 Nm +80˚ ) .
I - REFITTING THE HIGH-PRESSURE INJECTION PUMP REAR SUPPORT
Finger tighten the mounting bolts to press the sup-port against the high-pressure pump and the cylin-der block.
Tighten to torque the high-pressure pump rearsupport mounting bolts on the cylinder block (44 Nm ) .
II - REFITTING THE PUMP - RAIL HIGH-PRESSURE PIPE
Undo the injector rail mounting bolts (the injector railshould be « loose » ).
Insert the high-pressure pipe olive in the pump outlettaper
Insert the high-pressure pipe olive into the injectorrail inlet taper.
Finger tighten the high-pressure pipe nuts, startingwith the one at the rail end.
Slightly pretighten the high-pressure pipe nuts.
Tighten to torque the injector rail mounting bolts (22 Nm ) .
Tighten to torque using (Mot. 1746) or (Mot. 1566) :
- the pump-rail high-pressure pipe nut on thepump side ( 29 Nm ) ,
- the pump-rail high-pressure pipe nut on the railside ( 25 Nm ) .
Proceed in the reverse order to removal.
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
102349
WARNING
- Be careful not to allow oil into the high-pressurepipe.
- Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.
WARNINGDo not remove the plugs from each componentuntil the last moment.
13B-99
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 800 or 808
13BRefit:
- the timing belt (see 11A, Top and front of engine,Timing belt ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belts ).
For versions with injector rail protector covers:
- Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
Prime the diesel circuit using the manual primingpump.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
For versions with injector rail protector covers:
- Remove the air inlet duct,
- Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).
- Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
Note:
Refit the inlet duct without refitting the injector railprotector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,Battery, Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- Run the engine at idle speed,
- accelerate several times under no load,
- Switch off the ignition,
- Check that there is no diesel fuel escaping.
13B-100
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 804
13B
It is essential to read the repair precautions (see 13A,Diesel injection, Repair precautions ).
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belts ),
- the timing belt (see 11A, Top and front of engine,Timing belt ).
Special tooling required
Mot. 1668 Locking high pressurepump sprocket
Mot. 1525 Extractor for timinggear with tapered hub
Mot. 1525-03 Adapter claws for Mot.1525 (for 33-tooth pul-ley)
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Mot. 1566 Wrench for removinghigh-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
high-pressure pumpmounting bolts on thepump supports
30 Nm
high-pressure pumppulley nut
50 Nm
high-pressure pumpsupport mounting boltson the cylinder head
20 Nm + 80˚
high-pressure pumprear support mountingbolts on the cylinderblock
44 Nm
high-pressure pumpmounting bolts on therear pump support
30 Nm
injector rail mountingbolts
25 Nm
pump-rail high-pressurepipe nut on the pumpside
29 Nm
pump-rail high-pressurepipe nut on the rail side
25 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
Ensure that any high-pressure pipe removed isreplaced.
WARNING
Dismantling the interior of the high-pressure pumpand the injectors is prohibited.
13B-101
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 804
13B
Remove the injector rail protector (see 13B, Dieselinjection, Injector rail protector: Removal - Refit-ting ).
Disconnect:
- the diesel fuel heater from the diesel filter,
- the heater plugs,
- the pressure regulator (1) ,
Disconnect the diesel supply and return pipes (2) .
Plug the openings.
Remove the diesel pipes retaining clip.
Remove the pump - rail high-pressure pipe (3) .
Plug the openings.
Remove the bolts mounting the high-pressure pumpto the high-pressure pump rear support.
111888
102351
102353
102348
13B-102
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 804
13B
Remove:
- the bolts (5) mounting the high-pressure pumpfront support,
- the high-pressure pump, with the high-pressurepump support.
Position the (Mot. 1668) (6) .
Remove the nut (7) from the high-pressure pumppulley.
Set the pulley extractor (Mot. 1525) in place; fittedwith claws (Mot. 1525-03) (8) for pulleys with thirty-three teeth.
Remove the pulley by tightening the pulley extractorthrust bolt (9) .
Remove (Mot. 1525) , (Mot. 1525-03) and (Mot.1668) .
Remove:
- the high-pressure pump mounting bolts (10) ,
- the high-pressure pump.
102350
102893
102894
102345
13B-103
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 804
13BREFITTING
Refit the high-pressure pump on the pump support.
Tighten to torque:
- the high-pressure pump mounting bolts on thepump supports ( 30 Nm ) ,
- the high-pressure pump pulley nut ( 50 Nm ) byimmobilising the pulley with (Mot. 1668) .
Push the ring (11) back as shown in the diagram.
Undo the two mounting bolts on the high-pressurepump rear support on the cylinder block.
Refit the « high-pressure pump - pump support » as-sembly.
Tighten to torque the high-pressure pump supportmounting bolts on the cylinder head ( 20 Nm +80˚ ) .
I - REFITTING THE HIGH-PRESSURE PUMP REAR SUPPORT
Finger tighten the mounting bolts to press the sup-port against the high-pressure pump and the cylin-der block.
Tighten to torque:
- the high-pressure pump rear support mountingbolts on the cylinder block ( 44 Nm ) ,
- the high-pressure pump mounting bolts on therear pump support ( 30 Nm ) .
II - REFITTING THE PUMP-RAIL HIGH-PRESSURE PUMP
Undo the injector rail mounting bolts (the injector railshould be « loose » ).
Refit a new pump-rail high-pressure pipe.
Finger tighten the high-pressure pipe nuts, startingwith the one at the rail end.
Tighten to torque the injector rail mounting bolts (25 Nm ) .
Tighten to torque using (Mot. 1746) or (Mot. 1566) :
- the pump-rail high-pressure pipe nut on thepump side ( 29 Nm ) ,
- the pump-rail high-pressure pipe nut on the railside ( 25 Nm ) .
Proceed in the reverse order to removal.
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
102349
WARNING- Be careful not to allow oil into the high-pressure
pipe.
- Do not put high-pressure pipes under stress.
WARNING
Do not remove the plugs from each componentuntil the last moment.
13B-104
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
F9Q, and 804
13BRefit:
- the timing belt (see 11A, Top and front of engine,Timing belt ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belts ),
- the air inlet duct (see 12A, Fuel mixture, Air inletduct: Removal - Refitting ).
Prime the diesel circuit using the manual primingpump.
Connect the battery, starting with the positive termi-nal.
Remove the air inlet duct.
Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).
Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Note:
Refit the inlet duct without refitting the injector railprotector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,Battery, Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- Run the engine at idle speed,
- accelerate several times under no load,
- Switch off the ignition,
- Check that there is no diesel fuel escaping.
13B-105
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 732
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Switch off the ignition and wait 30 seconds beforestarting work on the injection system.
Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal- Refitting .
Pull the clip
Remove the air inlet duct mounting bolt.
Move the air inlet duct to one side.
Remove:
- the rigid air duct between the intercooler hose andthe turbocharger,
Special tooling required
Mot. 855 Timing gear lockingstrap.
Mot. 1768 SIEMENS injectionpump pulley extractorclaws
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Mot. 1566 Wrench for removinghigh-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
high-pressure pumppulley mounting bolt
55 Nm
high-pressure pumpmounting bolts
21 Nm
high-pressure pipe nuts 24 Nm
WARNING
Before starting work on the vehicle, have to hand:
- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,
- cleaning product (part no. 77 11 224 188) .
WARNING
Parts always to be replaced:
- the high-pressure pipe between the high-pressurepump and the injector rail.
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, cleanliness guidelines ).
112811
13B-106
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 732
13B- the injector rail protector cover
Disconnect:
- the heater plug connectors,
- the injector connectors,
- the rail pressure sensor connector,
- the fuel flow actuator connector,
- the fuel temperature sensor connector.
Clean (see 13B, Diesel injection, Repair precau-tions ):
- the fuel return pipe connecting the injectors,
- the fuel inlet pipe.
Disconnect:
- the fuel return pipe connecting the injectors to thehigh-pressure pump,
- the fuel inlet pipe.
Fit blanking plugs into the openings (see 13B, Die-sel injection, Cleanliness guidelines ).
Remove:
- the accessories belt (see section 10A, Accesso-ries belt: Removal - Refitting ).
- the timing belt (see section 10A, Timing belt: Re-moval - Refitting ).
Remove:
- the mounting bolts (3) from the dipstick guide onthe mounting of the diesel anti-splash device.
- the bolt (4) and mounting nuts (5) from the injectorrail protector cover support.
Move the wiring harness to one side.
Unpick the drain pipe on the injector rail protectorcover support.
Clean the high-pressure pipe between the high-pressure pump and injector rail (see 13B, Diesel in-jection, Repair precautions ).
Remove:
- the injector rail protector cover support,
- the high-pressure pipe between the high-pressurepump and rail.
Fit the correct blanking plugs on:
- the high-pressure pump,
- the injector rail.
Note:
Make preparations for the fuel outflow,
Clean with new wipes.
WARNING
- Strictly observe the cleanliness guidelines.
- Beware of diesel fuel splashing when discon-necting the supply unions.
111748
Note:
Make preparations for fuel outflow,
Clean with new wipes.
WARNING
When loosening the union of the high-pressurepipe on the high-pressure pump, the interme-diate nut must be secured on the high-pressurepump using a lock wrench.
13B-107
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 732
13BII - OPERATION FOR REMOVAL OF PART CONCERNED
REMOVAL OF THE HIGH-PRESSURE PUMP
Remove:
- the high-pressure pump mounting bolts,
- the high-pressure pump.
REMOVAL OF THE HIGH-PRESSURE PUMP PULLEY
Hold the high-pressure pump in a vice, using thelower securing point on the pulley side.
Hold the high-pressure pump pulley with a 32 mmoffset wrench then remove the mounting nut fromthe pulley.
Fit (Mot. 1768) on the high-pressure pump pulleythen extract the pulley.
REFITTING
WARNING
If the high-pressure pump is to be reused, keep itin a sealed plastic bag all the time it is discon-nected.
WARNING
When replacing a high-pressure pump, retain thehigh-pressure pump pulley and refit on the newpump.
111743
111744
Note:
The high-pressure pump pulley can also beimmobilised using the (Mot. 855) .
WARNING
Ensure that you do not mark the high-pressurepulley when extracting it using the tool.
You must replace any damaged high-pressurepump pulleys.
WARNING
- Remove the blanking plugs only before recon-necting the fuel circuit pipes
- The plugs are single-use. Do not reuse themand throw away the complete kit after opening.
13B-108
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 732
13BI - REFITTING OPERATION FOR PART CONCERNED
1 - REFITTING THE HIGH-PRESSURE PULLEY
Take the high-pressure pump out of its plastic bag.
Finger tighten the mounting nut of the high-pressurepump pulley.
Lock the high-pressure pump pulley with the toolsused previously.
Tighten to torque the high-pressure pump pulleymounting bolt ( 55 Nm ) .
2 - REFITTING THE HIGH-PRESSURE PUMP
Position the high-pressure pump on the cylinderhead.
Tighten to torque the high-pressure pump moun-ting bolts ( 21 Nm )
Remove: the blanking plugs from the injector rail andhigh-pressure pump.
Fit a new high-pressure pipe between the injectorrail and the high-pressure pump.
Hand-tighten the nut on the high-pressure pipe onthe pump end, then the one on the rail end.
Tighten to torque the high-pressure pipe nuts ( 24Nm ) using (Mot. 1746) or (Mot. 1566) and startingwith the high-pressure pump side.
WARNING
When replacing an injector rail, only remove itfrom its packaging just before it is refitted.
Note:
If the new parts kit does not contain an applica-tor, lubrication of the pipe threads will be unne-cessary (as they are self-lubricating pipes).
13B-109
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
K9K, and 732
13BII - FINAL OPERATION
Refit:
- the injector rail protector cover support,
- the injector rail protector cover support mountingnuts and bolt,
- the dipstick guide,
- the dipstick guide mounting bolts.
Connect:
- the drain pipe to the injector rail protector coversupport
- the heater plug connectors,
- the injector connectors,
- the rail pressure sensor connector,
- the fuel flow actuator connector,
- the fuel return pipe connecting the injectors to thehigh-pressure pump,
- the fuel supply pipe,
- the fuel temperature sensor connector.
Reposition the wiring harness.
Refit:
- the mounting nut to the wiring harness retainingclip,
- the timing belt (see section 10A, Timing belt: Re-moval - Refitting ),
- the accessories belt (see section 10A, Accesso-ries belt: Removal - Refitting ).
- the injector rail protector cover,
Clip the air inlet duct onto the turbocharger.
Refit the inlet duct mounting bolt.
Refit the battery (see 80A, Battery: Removal - Re-fitting ).
Reprime the fuel circuit using the priming pump.
Using the diagnostic tool , clear any faults storedby the injection computer, before restarting the engi-ne.
Using diagnostic tool , check that there are no sto-red faults. Clear them if necessary.
Note:
Ensure that the injector rail protector supportmounting bolt does not fall under the high-pres-sure pump.
WARNING
Confirm that there are no diesel fuel leaks:
- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: test ),
- run the engine at idle speed,
- accelerate several times at no load,
- Check that there are no diesel fuel leaks
13B-110
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
M9R, and 700
13BREMOVAL
I - REMOVAL PREPARATION OPERATION
It is essential to respect the safety and cleanlinessadvice whenever work is carried out on this system(see 13B, Diesel injection, Repair precautions).
Position the vehicle on the two-post lift (see 02A,Lifting equipment, Underbody lift ).
Remove:
- the engine protector,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Remove the high-pressure pipe between the high-pressure pump and the injector rail (see 13B, Dieselinjection, High-pressure pipe: Replacing ).
Disconnect the fuel inlet quick-release union on thehigh-pressure pump.
Plug the openings.
Disconnect the fuel return union.
Plug the openings.
Disconnect the pressure regulator connector on thehigh-pressure pump.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the high-pressure pump mounting bolts,
- the high-pressure pump.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
high-pressure pumpmounting bolts
25 Nm
high-pressure pipeunion on the high-pres-sure pump
32 Nm
high-pressure pipeunion on the injector rail
32 Nm
high-pressure piperetaining bracket moun-ting bolts on the bea-ring cap casing
10 Nm
clips on the air filterduct at the turbochar-ger inlet
5.5 Nm
bolts securing the tur-bocharger outlet air ducton the inlet manifold
8 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
Obtain a set of special high-pressure injectioncircuit plugs.
Ensure that any high-pressure pipe removed isreplaced.
13B-111
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
M9R, and 700
13BREFITTING
I - REFITTING PREPARATION OPERATION
Always replace:
- the high-pressure pump O-ring seal,
- the high-pressure pump mounting bolt.
Lubricate the new high-pressure pump seal with en-gine oil.
II - REFITTING OPERATION FOR PART CONCERNED
Fit the high-pressure pump.
Finger tighten the high-pressure pump mountingbolts as far as possible.
Tighten to torque and in order the high-pressurepump mounting bolts ( 25 Nm ) (1-2-3-4).
WARNINGDo not remove the blanking plugs from eachcomponent until the last moment.
WARNING
Do not apply pressure to the high-pressure pumpgear teeth.
WARNING
Check that the high-pressure pump is in contactwith the cylinder head before positioning thebolts.
13B-112
DIESEL INJECTIONHigh pressure pump: Removal - Refitting
M9R, and 700
13BIII - FINAL OPERATION
Proceed in the reverse order to removal.
Remove the « wiring harness and fuel pipe » as-sembly.
Check that the seal is correctly positioned on thehigh-pressure pipe.
Finger tighten as far as possible and in order:
- the high-pressure pipe union on the high-pressurepump,
- the high-pressure pipe union on the injector rail,
- the bolt mounting the high-pressure pipe retainingbracket on the bearing cap casing.
Tighten to torque and in order:
- the high-pressure pipe union on the high-pres-sure pump ( 32 Nm ) , using (Mot. 1566) ,
- the high-pressure pipe union on the injector rail( 32 Nm ) , using (Mot. 1746) ,
- the high-pressure pipe retaining bracket moun-ting bolts on the bearing cap casing ( 10 Nm ) .
Tighten to torque:
- the clips on the air filter duct at the turbochar-ger inlet ( 5.5 Nm ) ,
- the bolts securing the turbocharger outlet airduct on the inlet manifold ( 8 Nm ) .
Proceed in the reverse order to removal.
Prime the diesel circuit using the manual primingpump.
Connect the battery, starting with the positive termi-nal.
WARNING
Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.
Do not allow oil into the high-pressure pipe.
WARNING
Carry out the necessary programming (see 80A,Battery, Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- run the engine at idle speed,
- accelerate several times at no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-113
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 722 or 728 or 729
13B
It is essential to read the repair precautions wheneverwork is carried out (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect:
- the heater plugs,
- the connectors to injectors no. 3 and no. 4.
- injector connectors no. 1 and no. 2.
Remove the diesel fuel splash plate (1) .
Equipment required
diagnostic tool
Tightening torquesm
injector mounting brac-ket
28 Nm
rail mounting nuts 28 Nm
high-pressure pipe nutsof the « pump-rail »
24 Nm
high-pressure pipe nutsof the « injector rail »
24 Nm
of the neck on the rail 21 Nm
IMPORTANT
Before any operation on the injection circuit, use thediagnostic tool to check that the injector rail is nolonger under pressure, and that the fuel tempera-ture is not too high.
It is essential to respect the safety and cleanlinessadvice specified in this document whenever work iscarried out on this system.
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
Tighten to torque 38 Nm the « pump-rail » and « injector-rail » high-pressure pipes with one of the following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
For high-pressure pipes with different part numbers,tighten to torque 24 Nm .
WARNING
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206804 ),
- cleaning cloths (part no.: 77 11 211 707 ),
- cleaning product (part no.: 77 11 224 188 ).
102362
13B-114
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Disconnect the injector diesel return pipe (2) .
Fit plugs into the openings.
Disconnect the high-pressure pump electrical con-nectors (3) .
Remove the mounting bolts from the neck (4) fixedto the spherical injector rail.
Pull the electric wiring harness to one side with theneck on the side.
Loosen the injector rail mounting nuts by severalturns.
Remove the clips connecting the high-pressure pi-pes.
Clean the high-pressure pipe (see 13B, Diesel in-jection, Diesel injection: Precautions during re-pair ).
Remove the « injector-rail » high-pressure pipe con-cerned.
109463 109467
13B-115
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 722 or 728 or 729
13BII - OPERATION FOR REMOVAL OF PART CONCERNED
Undo the injector bracket (5) .
Remove the injector (6) .
If an injector is reused, always mark a removed in-jector in relation to its cylinder.
Pull off the compression washer.
REFITTING
I - CLEANING THE INJECTORS
Soak the injectors in degreaser.
Wipe with new cloths (part no.: 77 11 211 707 ).
II - REFITTING OPERATION FOR PART CONCERNED
If removing the four injectors, loosen the mountingnuts of the injector rail by a few turns (the rail shouldbe loose).
Using cloths (part no.: 77 11 211 707 ) soaked in fresh solvent, clean:
- the injector wells,
- the injector bodies,
- the injector brackets.
Use a new cloth to dry components that have beencleaned.
Replace the compression washer with a new one.
Position the injector.
Tighten to torque the injector mounting bracket (28 Nm ) .
109462
Note:
an injector corresponds to a cylinder.
WARNING
It is strictly forbidden to clean the injectors with:
- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
WARNING
Do not remove the plugs from each componentuntil the last moment.
19724
Note:
If one or more injectors are replaced, note thealphanumeric code (C2I) (7) and the cylinder onwhich it is fitted.
13B-116
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 722 or 728 or 729
13BIII - FINAL OPERATION
Insert the high-pressure pipe olive in the injectorhigh-pressure inlet taper.
Insert the high-pressure pipe olive into the rail high-pressure conical outlet.
Finger tighten the high-pressure pipe nuts, startingwith the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts.
Fit the new clip provided with the new high-pressurepipe.
If removing the four injectors, torque tighten the railmounting nuts ( 28 Nm ) .
Tighten to torque and in order the high-pressure pipe nuts of the « pump-rail » ( 24 Nm ) :
- high-pressure pump end,
- rail end.
Tighten to torque and in order the high-pressure pipe nuts of the « injector rail » ( 24 Nm ) :
- injectors end,
- rail end.
Refit the neck on the injector rail.
Torque tighten the nuts of the neck on the rail ( 21Nm )
Connect:
- the injector diesel fuel return pipe,
- the connectors to injectors no. 1 and no. 2,
- the connectors to injectors no. 3 and no. 4.
- the heater plugs.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Refit the engine undertray.
Program the alphanumeric code (C2I) for the repla-ced injector(s) using diagnostic tool (see 13B, Die-sel injection, Injectors: configuration ).
20960
WARNING
Before fitting a new high-pressure pipe, lightlylubricate the nut threads with oil from the applica-tor provided with the new part.
Be careful not to allow oil into the high-pressurepipe.
Do not lubricate high-pressure pipes suppliedwithout an applicator; these pipes are self-lubri-cating.
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
Note:
The assembly order of the « injector-rail » high-pressure pipes is not important.
Note:
Tighten a pipe fully before moving on to the nextpipe.
WARNING
Confirm that there is no diesel fuel leak:
- Run the engine until the fan starts up.
- Accelerate several times at no load.
- Switch off the ignition.
- Check that there is no diesel fuel escaping.
13B-117
DIESEL INJECTIONDiesel injector: Removal - Refitting
F9Q, and 800 or 804 or 808
13B
It is essential to read the repair precautions wheneverwork is carried out (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).
Injectors may be replaced individually. Only removethe high-pressure pipe concerned.
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the injector rail protector (see 13B, Dieselinjection, Injector rail protector: Removal - Refit-ting ), if fitted to the vehicle.
For versions without injector rail protectors:
- remove the inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ), if necessary.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector bracket bolt 25 Nm
nut on the injector side 25 Nm
nut on the rail side 29 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNINGOpening the injectors is prohibited.
13B-118
DIESEL INJECTIONDiesel injector: Removal - Refitting
F9Q, and 800 or 804 or 808
13B
Disconnect the injector connector.
Do not remove the injector clip.
Press the injector clip.
Pull the return rail end piece vertically.
Remove the return rail.
Fit blanking plugs into the openings.
18297-1
13B-119
DIESEL INJECTIONDiesel injector: Removal - Refitting
F9Q, and 800 or 804 or 808
13B
Remove the « injector-rail » high-pressure pipeusing (Mot. 1566) or (Mot. 1746) .
Fit blanking plugs into the openings.
If an injector is reused, always mark a removed in-jector in relation to its cylinder.
Remove:
- the injector bracket mounting bolt,
- the injector and its bracket,
- the compressor washer.
REFITTING
I - CLEANING INJECTORS (IF THEY ARE TO BE REUSED)
Clean, using new cloths soaked in cleaning product (see 13B, Diesel injection, Diesel injection: Re-pair precautions ) clean:
- the injector wells,
- the injector bodies,
- the injector brackets.
Use a new cloth to dry components that have beencleaned.
II - REFITTING THE INJECTOR
1327
WARNING
The injector filter rod must not be removed.
WARNING
When loosening the injector pipe unions (2) onthe injectors, be sure to hold the filter rod retai-ning nuts (3) with a lock wrench.
Note:
an injector corresponds to a cylinder.
WARNING
It is strictly forbidden to clean the injectors with:
- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
WARNING
Do not remove the protective caps from eachcomponent until the last moment.
13B-120
DIESEL INJECTIONDiesel injector: Removal - Refitting
F9Q, and 800 or 804 or 808
13B
Replace the heat shield washer (4) with a new one.
Refit the injector with its bracket.
Tighten to torque the injector bracket bolt ( 25 Nm) .
Screw, by hand, the high-pressure pipe nuts on therail and injector.
Tighten to torque using (Mot. 1566) or (Mot. 1746) :
- the nut on the injector side ( 25 Nm ) ,
- the nut on the rail side ( 29 Nm ) ,
1326
Note:
If one or more injectors have been replaced, notedown the alphanumeric code (IMA) that is writtenon the new injector and the cylinder it is fitted on.
WARNING
Do not fit high-pressure pipes without mountings.
WARNING
Always replace any high-pressure pipe removedwith a new one.
WARNING
Always hold the filter rod mounting nuts on theinjector holder with a lock wrench when tighte-ning.
13B-121
DIESEL INJECTIONDiesel injector: Removal - Refitting
F9Q, and 800 or 804 or 808
13B
Refit the return rail (5) .
Do not remove the injector clip.
Press the injector clip.
Push the return rail end piece vertically.
Throw away the plug set upon completion of theoperation.
To refit, proceed in the reverse order to removal.
Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ), if removed.
Connect the battery, starting with the positive termi-nal.
Program the alphanumeric code (IMA) for the injec-tor(s) replaced using the diagnostic tool (see MR366 Fault finding, 13B, Diesel injection, Fault fin-ding - Replacement of components ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
For versions with injector rail protector covers:
- Remove the air inlet duct,
- Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).
- Refit the inlet duct (see 12A, Fuel mixture, Air in-let duct: Removal - Refitting ).
18297-1
Note:
For versions with injector rail protector covers:
- Refit the inlet duct without refitting the injectorrail protector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- Run the engine at idle speed.
- Accelerate several times at no load.
- Switch off the ignition.
- Check that there is no diesel fuel escaping.
13B-122
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Switch off the ignition and wait 30 seconds beforestarting work on the injection system.
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip and (2) move the air inlet duct aside(3) .
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector bracket moun-ting bolt
30 Nm
injector rail mountingnuts
28 Nm
high-pressure pipe nuts 24 Nm
air inlet duct clip 5.5 Nm
WARNING
Before starting work on the vehicle, have to hand:
- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,
- cleaning product (part no. 77 11 224 188) .
WARNING
Parts always to be replaced:
- all the high-pressure pipes which have been remo-ved.
- any injector that has been opened, contrary to ins-tructions,
- Any damaged mounting clips for the fuel returnpipe on the injector must be replaced.
- the compressor washer.
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, cleanliness guidelines ).
112815
13B-123
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13B
Pull out the clip.
Remove the stainless steel pipe mounting bolt (4) .
Move the air inlet duct to one side (5) .
Unclip injector rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injector railprotector cover,
- the dipstick,
- the dipstick tube mounting bolts (8) .
Move the dipstick tube to one side.
Protect the alternator from fuel outflow.
Clean (see 13B, Repair precautions ). :
- the high-pressure pipes between the injector railand the injectors,
- the fuel return connectors of the injectors.
112811
112991
112992
13B-124
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13B
Disconnect the injector connector (9) .
Remove:
- the nut of the high-pressure pipe between the injec-tor rail and the injector on the rail end,
- the nut of the high-pressure pipe between the injec-tor rail and the injector on the injector end,
Remove the high-pressure pipe in question and dis-card it.
Fit blanking plugs,
Using a fine, flat-blade screwdriver, push the lowersection of the clip (12) holding the fuel return con-nector on the injector towards the rocker cover.
Extract the fuel return connector from the injectorwhile pushing the lower bracket of the retaining clipdownwards.
114075
1327
WARNING
When the high-pressure pipe unions (10) on theinjector holder are loosened, it is imperative tohold the filter rod retaining nut (11) with a lockwrench.
Note:
Make preparations for the fuel outflow. Clean withnew wipes.
111749
WARNING
Ensure that the clip is not fully removed from itshousing to prevent it from being twisted whentouching the rocker cover.
111751
13B-125
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13BFit the correct blanking plug.
Remove the fuel return pipe from the injector.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the injector bracket mounting bolt (13) ,
- the injector bracket,
- the spacer between the cylinder head and the in-jector bracket,
- the injector,
- the compression washer located at the bottom ofthe injector well in the cylinder head.
Fit the appropriate blanking plug on the injector's no-se.
Remove four injectors
111746
114010
Note:
If the injector is jammed in its well and does notcome out, turn the injector at the flat support sur-faces of the injector bracket using a 13 mm openend wrench.
WARNING
If it is to be reused, keep the injector(s) in a sea-led plastic bag until required.
WARNING
Ensure that no impurities enter into the cylindervia the injector well in the cylinder head: plug theorifice using a clean cloth.
Note:
This procedure only applies if removing all theinjectors and, after having removed them all, inpreparation for refitting them.
13B-126
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13B
Disconnect:
- the injector connector (14) ,
- the heater plugs connector (15) .
Disconnect:
- the connector (16) from the damper valve,
- the cylinder marking sensor connector (17) ,
- the pressure regulation solenoid valve connector(18) ,
- the flow regulation solenoid valve connector (19) ,
- the diesel temperature sensor connector (20) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (21) .
Remove the wiring harness clip mounting nut (22) .
Move the electric wiring harness to one side.
112993 112994
13B-127
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13B
Clean the fuel supply and return pipe unions (see13B, Repair Precautions ).
Disconnect:
- the fuel supply pipe (23) ,
- the fuel return pipe (24) .
Fit blanking plugs,
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support bolt and mountingnuts (25) ,
- the injector rail protector support.
Undo the injector rail mounting nuts by a few turns(the injector rail should be loose).
REFITTING
I - REFITTING PREPARATION OPERATION
Cleaning the injectors
Leave the injectors to soak in cleaner fluid.
Clean using new wipes.
Remove the injector from its plastic bag.
Remove the blanking plugs on the nose of the injec-tor.
II - REFITTING OPERATION FOR PART CONCERNED
Refit:
- a new compression washer at the bottom of the in-jector well in the cylinder head,
- the injector,
- the spacer between the cylinder head and the in-jector bracket,
- the injector bracket,
- the injector bracket mounting bolt.
112656
Note:
Make preparations for the fuel outflow. Clean withnew wipes.
111748
WARNING
It is strictly forbidden to clean the injectors with:
- a wire brush,
- an emery cloth,
- an ultrasonic cleaner.
WARNING
Only remove the blanking plugs immediatelybefore connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;dispose of the whole set after use.
WARNING
If replacing the injector, do not remove it (them)from its (their) packaging until just before you refitit (them).
13B-128
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13BTighten to torque the injector bracket mountingbolt ( 30 Nm ) .
Remove the blanking plugs.
Fit the new high-pressure pipe(s) between the injec-tor rail and the injector.
Finger tighten the high-pressure pipe nuts, startingwith the one at the injector rail side.
1 - Refit the four high-pressure pipes
Tighten to torque the injector rail mounting nuts (28 Nm ) .
Refit:
- the injector rail protector support,
- the mounting nuts and bolt of the injector rail pro-tector support.
Clip the diesel evacuation pipe.
Remove the blanking plugs.
Connect:
- the fuel supply pipe,
- fuel return pipe.
Fit the wiring harness.
Refit the mounting nut of the wiring harness clip.
Clip on the retaining clip of the wiring harness.
Connect:
- the rail pressure sensor connector,
- the diesel fuel temperature sensor connector,
- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoidvalve,
- the cylinder marking sensor connector,
- the connector on the damper valve,
- the heater plugs connector,
- the injectors' connector.
2 - All types
Tighten to torque the high-pressure pipe nuts ( 24Nm ) using (Mot. 1566) or (Mot. 1746) and startingat the injector rail end.
Remove the blanking plugs.
Push the retaining clip of the fuel return connectoron the injector to the front of the vehicle in order toplace it in its initial position.
Clip on the fuel return connector of the injector.
III - FINAL OPERATION
Refit:
- the dipstick tube mounting bolts.
- the dipstick,
- the injector rail protector cover mounting nut andbolt,
Clip injector rail protector cover.
Refit:
- the clip on the stainless steel pipe if necessary,
- the stainless steel pipe on the hose, aligning themarkings,
- the air inlet duct clip between the turbocharger andthe intercooler.
Tighten the air inlet duct clip ( 5.5 Nm ) .
Clip the stainless steel pipe to turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Reprime the fuel circuit with the manual primingpump.
Refit the engine covers.
Note:
If the new pipes kit does not contain an applica-tor, lubrication of the pipe threads will be unne-cessary (as they are self-lubricating pipes).
WARNING
Check the condition of the seal on the fuel returnconnector of the injector.
Change the diesel return rail if one of its compo-nents is damaged.
13B-129
DIESEL INJECTIONDiesel injector: Removal - Refitting
K9K, and 732
13BUsing the diagnostic tool , clear any faults storedby the injection computer, before restarting the engi-ne.
Using diagnostic tool , check that there are no sto-red faults; clear if necessary.
WARNING
Confirm that there is no diesel fuel leak:
- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: Check ),
- run the engine at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check for leaks and for diesel fuel outflow.
13B-130
DIESEL INJECTIONInjectors: Configuration
K9K, and 722 or 728 or 729 or 732
13BREPLACING THE INJECTORS
The correction values are written on a label affixed toeach injector then entered in the computer which canthen control each injector by taking account of their dif-ferences in manufacture.
The system can be configured at the diagnostic socketusing the RENAULT CLIP diagnostic tools.
The C2I parameters must be renewed after an injector is replaced. To do this, the C2I parameters must be re-entered into the computer using the following com-mands:
- To enter the four C2Is when replacing the computer,run the SC002 « Enter injector codes » .
- To enter an individual C2I parameter, when replacing one or more injectors, enter the following commands:
• cylinder 1 injector: control VP001 (flywheel end cy-linder),
• cylinder 2 injector, command: control VP002 ,
• cylinder injector 3: control VP003 ,
• cylinder injector 4: control VP004 .
By using the relevant command, the technician can re-enter the new C2I parameters for the injector replacedand delete the old C2I parameters.
Note:
The C2I (individual injector correction) parametersare a factory calibration carried out on each injectorto adjust the flow of each injector precisely, takinginto account differences in manufacture.
Note:
Only after replacing all four injectors at once, resetthe injector programming adaptives using theRZ004 « Pressure regulation adaptives » .
13B-131
DIESEL INJECTIONInjectors: Configuration
F9Q, and 800 or 808
13B
INJECTORS
A 6-character « alphanumeric » code known as theIMA (Injector Flow Correction) is marked on the injec-tors. This code is specific to each injector, and takesinto account manufacturing dispersion and specifiesthe flow of the injector.
When one or more injectors is replaced, the code of thenew injector(s) must be programmed into the compu-ter. If this operation is not carried out then the enginespeed will be limited to 1800 rpm .
Follow the procedure described below:
- Replace the faulty injector(s) and establish dialogue with the computer:
• read the data on the replaced injector(s),
• enter them into the computer using the diagnostictool CLIP,
• make sure, using the diagnostic tool CLIP, that thecomputer has not detected any faults relating to theinjector codes and that the instrument panel warninglight is off.
- When a computer is reprogrammed or replaced, it isnecessary to program the codes of the four injectorsinto the new computer.
There are two possibilities:
- if it is possible to enter into dialogue with the computer again:
• download the data from the old computer into thediagnostic tool CLIP,
• replace the computer,
• transfer the data from the diagnostic tool CLIP tothe new computer,
• make sure, using the diagnostic tool CLIP, that thecomputer has not detected any faults relating to theinjector codes and that the instrument panel warninglight is off.
- if it is not possible to establish dialogue with the computer:
• replace the computer,
• read the data from the injectors,
• enter them into the computer using the diagnostictool CLIP,
• reconfigure the computer for the equipment (air con-ditioning),
• make sure, using the diagnostic tool CLIP, that thecomputer has not detected any faults relating to theinjector codes and that the instrument panel warninglight is off.
Equipment required
diagnostic tool
13B-132
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732
13BREMOVAL
I - REMOVAL PREPARATION OPERATION
Switch off the ignition and wait 30 seconds beforestarting work on the injection system.
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip (2) and move the air inlet duct aside(3) .
Pull out the clip.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector rail mountingnuts
28 Nm
high-pressure pipe nuts 24 Nm
WARNING
Before starting work on the vehicle, have to hand:
- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,
- cleaning product (part no. 77 11 224 188) .
WARNING
Parts always to be replaced:
- all the high-pressure pipes which have been remo-ved.
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, cleanliness guidelines ).
112815
112811
13B-133
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732
13B
Remove:
- the stainless steel pipe mounting bolt (4) ,
- the stainless steel pipe (5) .
Unclip the injector rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injector railprotector cover,
- the injector rail protector cover,
- the dipstick,
- the dipstick pipe mounting bolts (8) .
Move the dipstick pipe to one side.
Protect the alternator from fuel outflow.
Clean the high-pressure pipe unions between the in-jector rail and injectors (see 13B, Repair precau-tions ).
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the nut of the high-pressure pipe between the injec-tor rail and the injector on the rail end,
- the nut of the high-pressure pipe between the injec-tor rail and the injector on the injector end,
Remove the high-pressure pipe in question and dis-card it.
Fit blanking plugs,
112991
112992
1327
WARNING
When the high-pressure pipe unions (9) on theinjector holder are loosened, it is imperative tohold the filter rod retaining nut (10) with a lockwrench.
Note:
Make preparations for the fuel outflow. Clean withnew wipes.
13B-134
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732
13BRemoving the four high-pressure pipes
Disconnect:
- the injector connector (11) ,
- the heater plugs connector (12) .
Disconnect:
- the connector (13) from the damper valve,
- the cylinder marking sensor connector (14) ,
- the pressure regulation solenoid valve connector(15) ,
- the flow regulation solenoid valve connector (16) ,
- the diesel temperature sensor connector (17) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (18) .
Remove the wiring harness clip mounting nut (19) .
Move the electric wiring harness to one side.
Note:
This procedure only applies if removing all thehigh-pressure pipes and, after having removedthem all, in preparation for refitting them.
112993
112994
13B-135
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732
13B
Protect the alternator from fuel outflow.
Clean the fuel supply and return pipes unions (see13B, Repair Precautions ).
Disconnect:
- the fuel inlet pipe (20) ,
- the fuel return pipe (21) .
Fit blanking plugs,
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support bolt and mountingnuts (22) ,
- the injector rail protector support,
- the fuel supply and return pipes.
Clean the unions (see 13B, Repair precautions ):
- of the fuel return pipe on the high-pressure pumpand injector rail,
- on the high-pressure pipe between the high-pres-sure pump and the injector rail,
REFITTING
I - REFITTING PREPARATION OPERATION
Take the new high-pressure pipe out of its plasticbag.
Remove the blanking plugs.
112656
Note:
Make preparations for the fuel outflow. Clean withnew wipes.
111748
WARNING
Only remove the blanking plugs immediatelybefore connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;dispose of the whole set after use.
13B-136
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 732
13BII - REFITTING OPERATION FOR PART CONCERNED
Fit the new high-pressure pipe between the injectorrail and the injector.
Finger tighten the high-pressure pipe nuts, startingwith the one at the injector rail side.
1 - Refit the four high-pressure pipes
Tighten to torque the injector rail mounting nuts (28 Nm ) .
Refit:
- the injector rail protector support,
- the mounting nuts and bolt of the injector rail pro-tector support.
Clip the diesel evacuation pipe.
Remove the blanking plugs.
Connect:
- the fuel supply pipe,
- fuel return pipe.
Fit the wiring harness.
Refit the mounting nut of the wiring harness clip.
Clip the retaining clip of the wiring harness into pla-ce.
Connect:
- the rail pressure sensor connector,
- the diesel fuel temperature sensor connector,
- the connector of the flow regulation solenoid valve,
- the connector of the pressure regulation solenoidvalve,
- the cylinder marking sensor connector,
- the connector on the damper valve,
- the heater plugs connector,
- the injectors' connector.
2 - All types
Tighten to torque the high-pressure pipe nuts ( 24Nm ) using (Mot. 1566) or (Mot. 1746) and startingwith the injector rail side.
III - FINAL OPERATION
Refit:
- the dipstick tube mounting bolts.
- the dipstick,
- the injector rail protector cover,
- the injector rail protector cover mounting nut andbolt,
Clip injector rail protector cover.
Refit the clip onto the stainless steel pipe if necessa-ry.
Clip the stainless steel pipe to turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clamp.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Reprime the fuel circuit with the manual primingpump.
Refit the engine covers.
Using the diagnostic tool , clear any faults storedby the injection computer, before restarting the engi-ne.
Use diagnostic tool to check for stored faults. Clearthem if necessary.
Note:
If the new pipes kit does not contain an applica-tor, lubrication of the pipe threads will be unne-cessary (as they are self-lubricating pipes).
WARNING
Confirm that there is no diesel fuel leak:
- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: Check ),
- run the engine at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check for leaks and for diesel fuel outflow.
13B-137
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the turbocharging duct retaining pin (1)from the turbocharger.
Remove the duct mounting bolt on the cylinderhead.
Move the duct to one side.
Disconnect the inlet air pressure sensor (2)
Loosen the clip (3) and remove the inlet duct (4) .
Equipment required
diagnostic tool
Tightening torquesm
injector rail mountingnuts
28 Nm
« pump-rail » high-pressure pipe nuts
24 Nm
high-pressure pipe nutsof the « injector rail »
24 Nm
nuts of the neck on therail
21 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice whenever work is carr ied out on this system.
Loosening a high-pressure pipe union when theengine is running is prohibited.
WARNING
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206804 ),
- cleaning cloths (part no.: 77 11 211 707 ),
- cleaning product (part no.: 77 11 224 188 ).
WARNING
Tighten to torque 38 Nm the « pump-rail » and « injector-rail » high-pressure pipes with one of the following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
For high-pressure pipes with different part numbers,tighten to torque 24 Nm .
112331
13B-138
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729
13B
Remove the dipstick mounting bolts (5) .
Place the dipstick to one side.
Remove the injector rail protector cover (6) .
Remove the diesel fuel splash plate (7) .
Remove the connectors (8) :
- the heater plugs,
- the injectors.
K9K, and 724
109473
109470
K9K, and 722 or 728 or 729
102362
109466
13B-139
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729
13B
Disconnect the high-pressure pump electrical con-nectors (9) .
Remove the mounting bolts from the neck (10) fixedto the spherical injector rail.
Move the electric wiring harness and neck to theside as shown by the arrow.
Loosen the injector rail mounting nuts by severalturns.
Remove the clips connecting the high-pressure pi-pes.
II - REMOVAL OF PART CONCERNED
Clean the pipe(s) to be removed (see 13B, Dieselinjection, Diesel injection: Repair precautions .
Loosen:
- the high-pressure nut at the injector end,
- the high-pressure pipe nut at the injector rail end.
Fit blanking plugs into the openings.
Throw away the pipe.
REFITTING
I - REFITTING PREPARATION OPERATION
If replacing the four high-pressure pipes:
- remove the anti-splash cover mounting,
- Undo the injector rail mounting nuts by a few turns(the injector rail should be loose).
II - REFITTING OPERATION FOR PART CONCERNED
Remove the blanking plugs.
Insert the high-pressure pipe olive in the injectorhigh-pressure inlet taper.
109467
20960
WARNING
Before fitting a new high-pressure pipe, lightlylubricate the nut threads with oil from the applica-tor provided in the new part.
Be careful not to allow oil into the high-pressurepipe.
Do not lubricate high-pressure pipes suppliedwithout an applicator, as these high-pressurepipes are self-lubricating.
WARNING
Leave removal of the blanking plugs from anycomponent until last.
13B-140
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
K9K, and 722 or 724 or 728 or 729
13BInsert the high-pressure pipe olive in the rail high-pressure outlet taper.
Finger tighten the high-pressure pipe nuts, startingwith the nut at the injector end.
Slightly pretighten the high-pressure pipe nuts.
Fit the new clip provided with the new high-pressurepipe.
If replacing the four high-pressure pipes, torque tigh-ten the injector rail mounting nuts ( 28 Nm ) .
Tighten to torque and in order the « pump-rail » high-pressure pipe nuts ( 24 Nm ) :
- pump end,
- rail end.
Tighten to torque and in order the high-pressure pipe nuts of the « injector rail » ( 24 Nm ) .
- injectors end,
- rail end.
III - FINAL OPERATION
Refit the neck to the injector rail and torque tightenthe nuts of the neck on the rail ( 21 Nm ) .
Connect the connectors:
- on the accelerometer
- of the injectors,
- of the heater plugs.
Refit the injector rail protector cover.
Insert the dipstick.
Refit the dipstick mounting bolts.
Refit the inlet duct and tighten its clip.
Connect the inlet air pressure sensor
Fit the turbocharger air duct.
Lock the air duct between the turbocharger and theintercooler air inlet pipe.
Tighten the bolt of the air duct on the rocker cover.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Prime the diesel circuit using the priming pump.Note:
The assembly order of the « injector-rail » high-pressure pipes is not important.
Note:
Tighten a pipe fully before moving on to the nextpipe.
K9K, and 724
WARNING
Confirm that there is no diesel fuel leak:
- check the seal after repair,
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- switch off the ignition,
- confirm that there is no diesel fuel leak.
13B-141
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
M9R, and 700
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine protector,
- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting).
- the oil separator (see 13B, Diesel injection, Oilseparator: Removal - Refitting ).
Remove the bolt mounting the diesel return pipe onthe rocker cover.
Disconnect the quick-release union from the dieselreturn pipe.
Lift the mobile section of the diesel return pipe on theinjectors.
Remove the diesel return pipe.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
« rail-injector » high-pressure pipe mountingnuts
32 Nm
diesel return pipemounting bolt on therocker cover
10 Nm
WARNING
Before carrying out any work on the injection sys-tem, use the diagnostic tool to check that:
- the rail is not under pressure,
- that the fuel temperature is not too high.
The cleanliness and safety advice specified in thisdocument must be followed during each operation.
Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
Obtain the special high-pressure injection circuitplug kit.
Always replace any high-pressure pipe or high-pressure pipe clip removed with a new one.
113142
13B-142
DIESEL INJECTIONHigh-pressure pipe between the rail and injector: Removal - Refitting
M9R, and 700
13BII - OPERATION FOR REMOVAL OF PART CONCERNED
Using (Mot. 1566) , loosen:
- the high-pressure nut at the injector end,
- the high-pressure pipe nut at the injector rail end.
Move the nuts along the tube, keeping the olive incontact with the taper.
Remove the high-pressure pipes one by one.
Plug the openings.
REFITTING
I - REFITTING PREPARATION OPERATION
Remove the blanking plugs.
II - REFITTING OPERATION FOR PART CONCERNED
Fit:
- the high-pressure pipe olive in the injector taper,
- the high-pressure pipe olive into the injector railoutlet taper.
Finger tighten until contact the high-pressure pipenuts, starting with the nut at the injector rail side.
Tighten to torque and in order, using (Mot. 1566) , the « rail-injector » high-pressure pipe mounting nuts ( 32 Nm ) :
- on the injectors,
- on the injector rail.
III - FINAL OPERATION
Refit:
- the diesel return pipe,
- the bolt mounting the diesel return pipe on the roc-ker cover
Drive the mobile section of the diesel return pipe intothe injectors.
Tighten to torque the diesel return pipe mountingbolt on the rocker cover ( 10 Nm ) .
Connect the quick-release union to the diesel returnpipe.
Refit:
- the oil separator (see 13B, Diesel injection, Oilseparator: Removal - Refitting ).
- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting).
- the engine protector.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
113134
Note:
Loosen the nuts pipe by pipe.
WARNING
Do not lubricate the high-pressure pipes suppliedwithout an applicator, these high-pressure pipesare self-lubricated.
Do not allow oil into the high-pressure pipe.
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
13B-143
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 722 or 728 or 729
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a lift (see 02A, Lifting equi-pment, Underbody lift ).
It is essential to read the repair precautions whene-ver work is carried out (see 13B, Diesel injection,Diesel injection: Precautions during repair ).
Switch off the ignition and wait 30 seconds beforestarting work on the injection system.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine undertray.
Special tooling required
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Mot. 1566 Wrench for removinghigh-pressure pipes
Equipment required
diagnostic tool
Tightening torquesm
injector rail mountingnuts
28 Nm
high-pressure pipe nutsbetween the injector railand the injectors
24 Nm
high-pressure pipe nutsbetween the injector railand the high-pressurepump
24 Nm
WARNING
Before starting work on the vehicle, make sure you have:
- a new blanking plug kit ( PART NO. 77 01 206 804),
- some wipes ( PART NO. 77 11 211 707 ),
- cleaning product ( PART NO. 77 11 224 188 ).
WARNING
Parts always to be replaced:
- all the high-pressure pipes which have been remo-ved.
WARNING
Tighten to torque 38 Nm the « pump-rail » and « injector-rail » high-pressure pipes with one of the following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
For high-pressure pipes with different part numbers,tighten to torque 24 Nm .
WARNING
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the rail is not under pressure,
- that the fuel temperature is not too high.
13B-144
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Disconnect the injector connectors (1) and the hea-ter plugs (2) .
Remove the diesel fuel splash plate (3) .
Disconnect:
- the connectors (4) for the flow actuator and the die-sel fuel temperature sensor,
- the spherical rail pressure sensor (5) .
Move the electric wiring harness and channel to theside as shown by the arrow.
Remove the mountings from the channel (6) fixed onthe spherical rail.
Protect the alternator from fuel outflow.
Clean the high-pressure pipes (see 13B, Diesel in-jection, Diesel injection: Precautions during re-pair ).
109466
102362
109467
WARNING
Do not blast with compressed air once the fuelcircuit is open, otherwise impurities may enterthe system. Use wipes if necessary.
13B-145
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 722 or 728 or 729
13B
Remove the clips between the high-pressure pipes.
Loosen the nuts securing the high-pressure pipesbetween the injector rail and the injector.
Remove the four high-pressure pipes and discard.
Insert the blanking plugs.
Remove the high-pressure pipe between the high-pressure pump and the injector rail (7) .
Insert the blanking plugs.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the injector rail mounting nuts (8) ,
- the injector rail.
REFITTING
I - REFITTING PREPARATION OPERATION
Take the injector rail out of its plastic bag.
20803
Note:
Make preparations for fuel outflow. Clean withnew wipes.
Note:
Make preparations for the fuel outflow. Clean withnew wipes.
20803
WARNING
If the injector rail is to be reused, keep it in a sea-led plastic bag all the time it is disconnected.
WARNING
Only remove the blanking plugs immediatelybefore connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them andthrow away the complete kit after opening.
WARNINGIf an injector rail is being replaced, only removethe new one from its original packaging when it isabout to be fitted.
13B-146
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 722 or 728 or 729
13BII - REFITTING OPERATION FOR PART CONCERNED
Fit the injector rail.
Tighten the injector rail mounting bolts (the injectorrail should be loose).
III - FINAL OPERATION
Remove the blanking plugs from:
- the high-pressure pump,
- the injector rail fuel inlet opening.
Fit a new high-pressure pipe between the injectorrail and the high-pressure pump.
Finger tighten the high-pressure pipe nuts until theymake contact.
Remove the blanking plugs from:
- the rail injector fuel return openings,
- the injector fuel inlet.
Fit the new high-pressure pipes between the rail andthe injectors.
Finger tighten the high-pressure pipe nuts until theymake contact.
Tighten to torque:
- the injector rail mounting nuts ( 28 Nm ) ,
- the high-pressure pipe nuts between the injec-tor rail and the injectors ( 24 Nm ) using (Mot.1746) or (Mot. 1566) starting at the injector end,
- the high-pressure pipe nuts between the injec-tor rail and the high-pressure pump ( 24 Nm )using (Mot. 1746) or (Mot. 1566) starting at thehigh-pressure pump end.
Refit:
- the wiring harness with the neck,
- the neck mountings.
Connect the electrical connectors.
Reprime the fuel circuit.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Confirm that there is no diesel fuel leak:
- check the seal after repair (see 13B, Diesel injec-tion, Diesel injection: Repair precautions ),
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- check for leaks and for diesel fuel outflow.
Use diagnostic tool to check for stored faults. Clearthem if necessary.
Note:
If the new pipe kit does not contain an applicator,lubrication of the pipe threads will be unneces-sary (as they are self-lubricating pipes).
Note:
If the new pipe kit does not contain an applicator,lubrication of the pipe threads will be unneces-sary (as they are self-lubricating pipes).
13B-147
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 800 or 808
13B
It is essential to read the repair precautions (see 13B,Diesel injection, Repair precautions ).
REMOVAL
Disconnect the battery, starting with the positive ter-minal.
Remove:
- the engine covers,
- the air inlet duct (see 12A, Fuel mixture, Air inletduct: Removal - Refitting ).
- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting), if fitted to the vehicle.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector rail mountingbolts
25 Nm
nuts on the injector endand the nut on the injec-tion pump end
25 Nm
nuts on the rail end 29 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
13B-148
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 800 or 808
13B
Disconnect:
- the pressure sensor connector (1) ,
- the injector connectors (2) ,
- the fuel temperature sensor connector,
- the cylinder marking sensor connector,
- the fuel return pipe on the injection pump side,
- the fuel return pipe on the diesel temperature sen-sor side.
Fit blanking plugs into the openings.
Move the diesel temperature sensor (3) to one side.
Do not remove the injector clip.
Press the injector clip.
Pull the return rail end piece vertically.
Remove the diesel return pipe (4) .
Plug the openings.
18297-1
Note:
The diesel temperature sensor is an integral partof the fuel return pipe; these two components areconnected and cannot be removed separately.
13B-149
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 800 or 808
13B
Remove the high-pressure diesel pipes using (Mot.1566) or (Mot. 1746) .
Plug the openings.
Remove:
- the injector rail bolts,
- the injector rail (5) .
REFITTING
Position the injector rail.
Position the injector rail.
Pretighten the injector rail bolts, leaving clearancebetween the bolt heads and the rail.
Refit the injector rail pipes and the rail pump pipe:
- screw, by hand, the high-pressure pipe nuts ontothe pump and injector side,
- screw, by hand, the high-pressure pipe nuts ontothe rail side.
Tighten to torque using (Mot. 1566) or (Mot. 1746) :
- the injector rail mounting bolts ( 25 Nm ) ,
- the nuts on the injector end and the nut on theinjection pump end ( 25 Nm ) ,
- the nuts on the rail end ( 29 Nm )
1327
WARNING
When loosening the injector pipe unions (6) onthe injectors, be sure to hold the filter rod retai-ning nuts (7) with a lock wrench.
76
WARNING
Do not remove the protective caps from eachcomponent until the last moment.
Always replace any high-pressure pipe removedwith a new one.
WARNING
Do not put high-pressure pipes under stress.
Always hold the filter rod retaining nuts on theinjector holder when tightening.
13B-150
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 800 or 808
13B
Refit the return rail (4) :
- do not remove the clip from the injector,
- press the injector clip,
- push the return rail end piece vertically.
Throw away the plug set upon completion of theoperation.
Proceed in the reverse order to removal.
For versions with injector rail protector covers:
- Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
For versions with injector rail protector covers:
- Remove the air inlet duct,
- Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ), if fitted to the vehicle,
- Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
18297-1
Note:
Refit the inlet duct without refitting the injector railprotector or refitting the duct seal.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- run the engine at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-151
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 804
13B
It is essential to read the repair precautions (see 13B,Diesel injection, Repair precautions ).
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the injector rail protector (see 13B, Diesel injec-tion, Injector rail protector: Removal - Refitting).
Disconnect:
- the injector connectors (1) ,
- the cylinder marking sensor connector (2) ,
- the fuel return pipe.
Plug the openings.
Do not remove the injector clip.
Press the injector clip.
Pull the return rail end piece vertically.
Remove the diesel return pipe (3) .
Plug the openings.
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector rail mountingbolts
25 Nm
nuts on the injector sideand the nut on the injec-tor pump side
25 Nm
nuts on the rail side 29 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
111965
3
2 1111
13B-152
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 804
13B
Remove the high-pressure diesel pipes using (Mot.1566) or (Mot. 1746) .
Plug the openings.
Remove the oil separator.
Remove:
- the injector rail bolts (6) ,
- the injector rail (7) .
REFITTING
Position the injector rail.
Tighten the injector rail bolts, leaving clearancebetween the bolt heads and the rail.
Refit the injector rail pipes and the rail pump pipe:
- screw, by hand, the high-pressure pipe nuts ontothe pump and injector side,
- screw, by hand, the high-pressure pipe nuts ontothe rail side.
Tighten to torque using (Mot. 1566) or (Mot. 1746) :
- the injector rail mounting bolts ( 25 Nm )
- the nuts on the injector side and the nut on theinjector pump side ( 25 Nm )
- the nuts on the rail side ( 29 Nm )
1327
WARNING
When loosening the injector pipe unions (4) onthe injectors, be sure to hold the filter rod retai-ning nuts (5) with a lock wrench.
111859
5
4
7
66
WARNING
Do not remove the protective caps from eachcomponent until the last moment.
Always replace any high-pressure pipe removedwith a new one.
WARNING
Do not put high-pressure pipes under stress.
Do not touch the high-pressure pipes with thespanner when tightening them.
Always hold the filter rod retaining nuts on theinjector holder when tightening.
13B-153
DIESEL INJECTIONInjector rail: Removal - Refitting
F9Q, and 804
13B
Refit the return rail (8) :
- do not remove the clip from the injector,
- press the injector clip,
- push the return rail end piece vertically.
Throw away the plug set upon completion of theoperation.
To refit, proceed in the reverse order to removal.
Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Remove the air inlet duct.
Refit the injector rail protector (see 13B, Diesel in-jection, Injector rail protector: Removal - Refit-ting ).
Refit the air inlet duct (see 12A, Fuel mixture, Airinlet duct: Removal - Refitting ).
111965
Note:
Refit the inlet duct without refitting the injector railprotector or replacing the duct seal.
WARNING
Carry out the necessary programming (see 80A,Battery, Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- run the engine at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check that there is no diesel fuel escaping.
8
13B-154
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 732
13B
REMOVAL
I - REMOVAL PREPARATION OPERATION
Switch off the ignition and wait 30 seconds beforestarting work on the injection system.
Remove the engine covers
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip and (2) move the air inlet duct aside(3) .
Special tooling required
Mot. 1566 Wrench for removinghigh-pressure pipes
Mot. 1746 Offset spanner fortightening high pres-sure pump pipe
Equipment required
diagnostic tool
Tightening torquesm
injector rail mountingnuts
28 Nm
high-pressure pipe nutsbetween the injector railand the injectors
24 Nm
high-pressure pipe nutsbetween the injector railand the high-pressurepump
24 Nm
air inlet duct clip 5.5 Nm
WARNING
Before starting work on the vehicle, have to hand:
- a new plug kit (part no. 77 01 476 857) ,
- some cleaning cloths (part no. 77 11 211 707) ,
- cleaning product (part no. 77 11 224 188) .
WARNING
Parts always to be replaced:
- all the high-pressure pipes which have been remo-ved.
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the diagnostic tool :
- that the injector rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system (see 13B, Diesel injec-tion, cleanliness guidelines ).
112815
13B-155
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 732
13B
Pull out the clip.
Remove the stainless steel pipe mounting bolt (4)
Move the air inlet duct to one side.
Unclip injector rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injector railprotector cover,
- the injector rail protector cover,
- the dipstick,
- the dipstick tube mounting bolts (8) .
Move the dipstick tube to one side.
Disconnect:
- the injector connector (9) ,
112811
112991
112992
112993
13B-156
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 732
13B- the heater plugs connector (10) .
Disconnect:
- the connector (11) from the damper valve,
- the cylinder marking sensor connector (12) ,
- the pressure regulation solenoid valve connector(13) ,
- the flow regulation solenoid valve connector (14) ,
- the diesel temperature sensor connector (15) ,
- the rail pressure sensor connector.
Unclip the wiring harness retaining clip (16) .
Remove the wiring harness clip mounting nut (17) .
Move the electric wiring harness to one side.
Protect the alternator from fuel outflow.
Clean (see 13B, Repair precautions ):
- the fuel supply pipe (18) ,
- the fuel return pipe (19) .
Disconnect:
- the fuel supply pipe (18) ,
- the fuel return pipe (19) .
Fit blanking plugs,
112994
112656
Make preparations for the fuel outflow. Clean withnew wipes.
13B-157
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 732
13B
Unclip the diesel evacuation pipe.
Remove:
- the injector rail protector support mounting bolt andmounting nuts,
- the injector rail protector support.
Clean (see 13B, Repair precautions ):
- the high-pressure pipes between the injector railand the injectors,
- the high-pressure pipes (19) between the high-pressure pump and the injector rail.
Remove:
- the nuts from the four high-pressure pipes betweenthe injector rail and the injector on the rail end,
- the nuts from the four high-pressure pipes betweenthe injector rail and the injector on the injector end,
Remove the four high-pressure pipes and dispose ofthem in a bin.
Fit blanking plugs,
111748
1327
WARNING
When loosening the high-pressure pipe unions(21) on the injector holder, it is essential to holdthe filter rod mounting nut (22) with a lockwrench.
Note:
Make preparations for the fuel outflow. Clean withnew wipes.
13B-158
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 732
13BRemove the high-pressure pipe between the high-pressure pump and the injector rail and dispose of itin a bin.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the injector rail mounting nuts (23) ,
- the injector rail.
REFITTING
I - REFITTING PREPARATION OPERATION
Take the injector rail out of its plastic bag.
II - REFITTING OPERATION FOR PART CONCERNED
Fit the injector rail.
Finger tighten the injector rail mounting bolts.
Remove the blanking plugs.
Fit the new high-pressure pipe between the injectorrail and the high-pressure pump.
Finger tighten the high-pressure pipe nuts, startingwith the one at the injector rail side.
Remove the blanking plugs.
Fit the new high-pressure pipes between the injectorrail and the injectors.
Finger tighten the high-pressure pipe nuts, startingwith the one at the injector rail side.
Tighten to torque the injector rail mounting nuts (28 Nm ) .
WARNING
When loosening the connector of the high-pres-sure pipe, the intermediate nut must be securedon the pump using a lock wrench.
Note:
Make preparations for fuel outflow. Clean withnew wipes.
111745
WARNING
If the injector rail is to be reused, keep it in a sea-led plastic bag all the time it is disconnected.
WARNING
Only remove the blanking plugs immediatelybefore connecting the fuel circuit pipes.
The plugs are single-use. Do not reuse them;dispose of the whole set after use.
WARNING
If an injector rail is being replaced, only removethe new one from its original packaging when it isabout to be fitted.
Note:
If the new pipes kit does not contain an applica-tor, lubrication of the pipe threads will be unne-cessary (as they are self-lubricating pipes).
Note:
If the new pipes kit does not contain an applica-tor, lubrication of the nut threads will be unneces-sary (as they are self-lubricating pipes).
13B-159
DIESEL INJECTIONInjector rail: Removal - Refitting
K9K, and 732
13BTighten to torque:
- the high-pressure pipe nuts between the injec-tor rail and the injectors ( 24 Nm ) using (Mot.1566) or (Mot. 1746) starting with the rail end.
- the high-pressure pipe nuts between the injec-tor rail and the high-pressure pump ( 24 Nm )using (Mot. 1566) or (Mot. 1746) starting with thehigh-pressure pump end.
III - FINAL OPERATION
Refit:
- the injector rail protector support,
- the mounting nuts and bolt of the injector rail pro-tector support.
Clip the diesel evacuation pipe.
Remove the blanking plugs.
Connect:
- the fuel supply pipe,
- fuel return pipe.
Fit the wiring harness.
Refit the mounting nut of the wiring harness clip.
Clip the retaining clip of the wiring harness.
Connect:
- the rail pressure sensor connector,
- the diesel fuel temperature sensor connector,
- the connector of the flow control solenoid valve,
- the connector of the pressure control solenoid val-ve,
- the cylinder marking sensor connector,
- the connector on the damper valve,
- the heater plugs connector,
- the injectors' connector.
Refit:
- the dipstick tube mounting bolts.
- the dipstick,
- the injector rail protector cover,
- the injector rail protector cover mounting nut andbolt,
Clip injector rail protector cover.
Refit:
- the clip on the stainless steel pipe if necessary,
- the stainless steel pipe on the hose, aligning themarkings,
- the clamp of the air inlet duct between the turbo-charger and the intercooler.
Tighten the air inlet duct clip ( 5.5 Nm ) .
Clip the stainless steel pipe to turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clamp.
Connect:
- the connector to the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Reprime the fuel circuit with the manual primingpump.
Refit the engine covers.
Using the diagnostic tool , clear any faults storedby the injection computer, before restarting the engi-ne.
Using diagnostic tool , check that there are no sto-red faults; clear if necessary.
Note:
Ensure that the injector rail protector supportmounting bolt does not fall under the high-pres-sure pump.
WARNING
Confirm that there is no diesel fuel leak:
- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: Check ),
- run the engine at idle speed,
- accelerate several times at no load,
- switch off the ignition,
- check for leaks and for diesel fuel outflow.
13B-160
DIESEL INJECTIONRail pressure sensor
K9K, and 722 or 724 or 728 or 729 or 732
13B
Pressure sensor (1) cannot be removed from the sphe-rical injector rail.
In the event of a pressure sensor fault, the « rail pres-sure sensor and high-pressure pipe » assembly mustbe replaced (see 13B, Diesel injection, Injector rail ).
102086
1
13B-161
DIESEL INJECTIONRail pressure sensor: Removal - Refitting
F9Q, and 800
13B
Equipment required
diagnostic tool
Tightening torquesm
pressure sensor to tor-que
3.5 daNm +/-0.5
battery cover mountingbolts to torque
0.4 daNm
IMPORTANT
Before starting any work on the injection circuit, use the diagnostic tool to check that:
• the injection rail is no longer pressurised,
• the fuel temperature is not too high.
- Whenever work is carried out, it is essential to res-pect the safety and cleanliness advice given in thisdocument.
- It is strictly forbidden to undo a high-pressure pipeunion when the engine is running.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- All high-pressure pipes must be replaced and anyremoved high-pressure pipe clips.
13B-162
DIESEL INJECTIONRail pressure sensor: Removal - Refitting
F9Q, and 800
13BREMOVAL
Disconnect:
- the battery, starting with the negative terminal.
- the pressure sensor.
Unscrew the pressure sensor.
18297-5
13B-163
DIESEL INJECTIONRail pressure sensor: Removal - Refitting
F9Q, and 800
13BREFITTING
Replace the seal.
Screw in the sensor.
Tighten the pressure sensor to torque ( 3.5 daNm+/- 0.5 ) .
Connect the connector.
Tighten the battery cover mounting bolts to tor-que ( 0.4 daNm ) .
WARNINGConnect the battery; carry out the necessary pro-gramming (see (see 8, Electrical equipment) ).
WARNING
Check that there are no diesel leaks:
- run the engine at idle speed until the fan startsup,
- accelerate several times under no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel leak:
13B-164
DIESEL INJECTIONFuel flow actuator: Removal - Refitting
K9K, and 722
13B
REMOVALRemove the engine covers.
Disconnect:
- the battery, starting with the negative terminal,
- the air intake duct (1) .
Remove diesel splash plate (2) .
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
fuel flow actuatormounting bolts
5.5 ±±±± 0.6 Nm
battery cover securingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection circuit, check using the diagnostic tool CLIP:
• that the injection rail is no longer under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Always replace any high pressure pipe and highpressure pipe clips removed with new ones.
102120
102362
1
2
13B-165
DIESEL INJECTIONFuel flow actuator: Removal - Refitting
K9K, and 722
13B
Disconnect:
- the heater plugs,
- the injector connectors (3) from cylinders no. 3 andno. 4,
- the pump electrical connectors (4) ,
- the supply and return pipes (5) .
Remove the high-pressure pipe (6) on injector no. 4(see 13B, Diesel injection, High pressure pipes:Replacement ).
Cap the openings.
Undo bracket bolts (7) .
Withdraw the fuel flow actuator (by hand using smallsuccessive turns).
102514
3
45
102315
WARNING
Do not use the electrical connector as a leverarm.
6
7
13B-166
DIESEL INJECTIONFuel flow actuator: Removal - Refitting
K9K, and 722
13BREFITTING
Only unpack the new component when you are rea-dy to fit it.
Fit the actuator.
Finger-tighten the two mounting bolts.
Tighten to torque the two fuel flow actuator moun-ting bolts ( 5.5 ±±±± 0.6 Nm ) using tool low torquewrench .
Refit a new high-pressure pipe to injector no. 4 (see13B, High pressure pipes: Replacement ) and anew clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover securing bolts( 4 Nm ) .
WARNINGDo not remove the blanking plugs from any com-ponent until the last moment.
WARNING
Do not damage the seal when refitting.
Note:
Do not lubricate the seals with grease or useddiesel fuel. Use the applicator provided in the kitfor the new part.
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
WARNING
Confirm that there is no diesel fuel leakage:
- check the sealing after repair (see 13B, Highpressure pipe: Fuel-tightness check ).
- Let the engine run at idle speed until the enginecooling fan starts up.
- Accelerate several times under no load.
- Carry out a road test.
- Switch off the ignition.
- Check that there is no diesel fuel escaping.
13B-167
DIESEL INJECTIONFuel flow actuator: Removal - Refitting
K9K, and 728 or 729
13B
REMOVAL
Remove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Pull the clip.
Undo bolt (1) .
Remove air duct (2) .
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
flow actuator mountingbolts
5.5 ±±±± 0.6 Nm
battery cover mountingbolts
4 Nm
Note:
For vehicles with a K9K 732 engine (see MR 370Mechanical, Scénic II ).
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the CLIP diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Always replace any high-pressure pipe or high-pressure pipe clip removed with a new one.
110325
110323
1
2
13B-168
DIESEL INJECTIONFuel flow actuator: Removal - Refitting
K9K, and 728 or 729
13B
Remove the diesel splash plate (3) .
Disconnect:
- the heater plugs,
- the injector connectors (6) from cylinders n˚3 andn˚4,
- the pump electrical connectors (4) ,
- the supply and return pipes (5) .
Remove the high-pressure pipe (7) from injector no.4 (see 13B, Diesel injection, High-pressure pi-pes: Replacing ).
Fit plugs into the openings.
Undo bracket bolts (8) .
Withdraw the fuel flow actuator (by hand using smallsuccessive turns).
102362
102514
3
4
6
5
6
102315
WARNING
Do not use the electrical connector as a leverarm.
7
88
13B-169
DIESEL INJECTIONFuel flow actuator: Removal - Refitting
K9K, and 728 or 729
13BREFITTING
Only unpack the new component when you are rea-dy to fit it.
Fit the actuator.
Finger tighten the mounting bolts.
Tighten to torque the two flow actuator mountingbolts ( 5.5 ±±±± 0.6 Nm ) using low torque wrench .
Refit a new high-pressure pipe on injector no. 4 (see13B, High-pressure pipes: Replacement ) and anew clip.
Reconnect:
- the diesel fuel supply and return pipes,
- the electrical connectors.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNINGDo not remove the blanking plugs from eachcomponent until the last moment.
WARNING
Do not damage the seal when refitting.
Note:
Do not lubricate the seals with grease or useddiesel fuel. Use the applicator provided in the kitfor the new part.
WARNING
carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- Check the tightness after repair (see 13B,High-pressure pipe: Sealing check ).
- Let the engine run at idle speed until the enginecooling fan starts to operate.
- Accelerate several times at no load.
- Carry out a road test.
- Switch off the ignition.
- Check that there is no diesel fuel escaping.
13B-170
DIESEL INJECTIONLeak flow from injectors: Check
K9K, and 722 or 728 or 729
13B
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Connect the four transparent hoses of (Mot. 1711)to the injectors instead of the injector fuel return pi-pes.
Fit the correct blanking plugs, in particular onto theventuri pipe to prevent depriming the circuit.
Insert these hoses in the four graduated measuringcylinders of the (Mot. 1711) .
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Follow the procedures described in the Fault findingMR (see MR 372 Fault finding, 13B, Diesel injec-tion, Fault finding - Tests ).
Disconnect:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the four transparent hoses of (Mot. 1711) .
Remove the blanking plugs.
Refit the injector fuel return pipes.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Refit the engine covers.
Special tooling required
Mot. 1711 Kit for measuringinjector leak rate
IMPORTANT
Do not leave any object (tools or other) on theside of the engine housing during the entire ope-ration.
Position the tools so that they do not fall duringthe « engine running » phase of the test.
13B-171
DIESEL INJECTIONLeak flow from injectors: Check
K9K, and 732
13B
Switch off the ignition and wait 30 seconds beforestarting work on the injection system.
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip and (2) move the air inlet duct aside(3) .
Pull out the clip.
Remove the stainless steel pipe mounting bolt (4) .
Move the air inlet duct to one side (5) .
Special tooling required
Mot. 1771 Kit for measuring SIE-MENS injector leakrate
Mot. 1711 Kit for measuringinjector leak rate
112815
112811
112991
13B-172
DIESEL INJECTIONLeak flow from injectors: Check
K9K, and 732
13B
Unclip injector rail protector cover (6) .
Remove:
- the mounting nut and bolt (7) from the injector railprotector cover,
- the injector rail protector cover,
- the dipstick,
- the dipstick tube mounting bolts (8) .
Move the dipstick tube to one side.
Disconnect the four fuel return pipes of the four in-jectors (see 13B, Diesel injector fuel return rail:Removal - Refitting ).
Connect the transparent hoses of (Mot. 1771) to theinjectors instead of the injector fuel return pipes.
Fit the correct blanking plug to the injector fuel returnconnectors.
Insert these hoses in the four graduated measuringcylinders of the (Mot. 1711) .
Refit:
- the dipstick tube mounting bolts.
- the dipstick.
Refit the clip onto the stainless steel pipe if necessa-ry.
Clip the stainless steel pipe to turbocharger.
Refit the air inlet duct on the damper valve.
Tighten the clamp.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Follow the procedures described in the Fault findingMR (see MR 372 Fault finding, 13B, Diesel injec-tion, Fault finding - Tests ).
Disconnect:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the air inlet pressure sensor connector.
Loosen the clip and move the air inlet duct aside.
Pull out the clip from the stainless steel pipe.
Move the air inlet duct to one side.
Remove:
- the dipstick,
- the dipstick tube mounting bolts.
Move the dipstick tube to one side.
Disconnect the four transparent pipes from (Mot.1771) .
Refit:
- the dipstick tube mounting bolts.
- the dipstick,
- the injector rail protector cover,
- the injector rail protector cover mounting nut andbolt,
Clip injector rail protector cover.
Refit the clip onto the stainless steel pipe if necessa-ry.
Clip the stainless steel pipe to turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clamp.
112992
IMPORTANT
Do not leave any object (tools or other) on theside of the engine housing during the entire ope-ration.
Position the tools so that they do not fall duringthe « engine running » phase of the test.
13B-173
DIESEL INJECTIONLeak flow from injectors: Check
K9K, and 732
13BConnect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Reprime the fuel circuit with the manual primingpump.
Refit the engine covers.
13B-174
DIESEL INJECTIONFuel pressure regulator: Removal - Refitting
F9Q, and 800 or 808
13B
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
regulator bolts 6 Nm
battery cover mountingbolt
4 Nm
IMPORTANT
Before carrying out any work on the injection circuit, check using the diagnostic tool CLIP:
• that the injection rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Be sure to replace any high pressure pipe andhigh pressure pipe clips that have been removed.
13B-175
DIESEL INJECTIONFuel pressure regulator: Removal - Refitting
F9Q, and 800 or 808
13BREMOVAL
Disconnect the battery, starting with the negativeterminal.
Blow the area with compressed air to clean impuri-ties away from the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
- fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not useany tool for leverage).
18297-1
1
13B-176
DIESEL INJECTIONFuel pressure regulator: Removal - Refitting
F9Q, and 800 or 808
13BREFITTING
Clean the fuel pressure regulator bearing face onthe high pressure pump, taking care not to introduceany impurities.
Wipe the fuel pressure regulator bearing face on thehigh pressure pump, taking care not to introduce anyimpurities.
Connect the battery.
Rinse the fuel pressure regulator housing in the highpressure pump, with the ignition on for a few se-conds.
Disconnect the battery.
Prepare the new regulator:
- remove the protective cap,
- check the seal positions,
- lubricate the O-rings with clean diesel fuel.
Offer up the regulator, rotating it slightly.
Push the regulator gently in until it engages fully.
Pretighten the new regulator bolts to 3 Nm .
Tighten to torque the three regulator bolts ( 6 Nm )using a low torque wrench .
Clean the area with cleaning cloths.
Fit the fuel pressure regulator connector.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolt ( 4Nm ) .
Switch on the ignition.
Clear the fault shown in the diagnostic tool CLIP ifnecessary.
Note:
Lubrication is very important to avoid externalleakage.
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
WARNING
Confirm that there is no diesel fuel leakage:
- let the engine run at idle speed until the enginecooling fan starts up,
- accelerate several times at no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-177
DIESEL INJECTIONFuel pressure regulator: Removal - Refitting
F9Q, and 804
13BREMOVAL
Disconnect the battery, starting with the negativeterminal.
Blow compressed air into the area to clean dirt fromaround the fuel pressure regulator.
Disconnect the fuel pressure regulator connector.
Clean the area with brake degreaser.
Remove:
- fuel pressure regulator bolts (1) ,
- the fuel pressure regulator manually (do not useany tool for leverage).
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
regulator bolts 6 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection circuit, check using the diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain the special high-pressure injection cap kit.
- Be sure to replace any high-pressure pipe remo-ved.
111887
1
13B-178
DIESEL INJECTIONFuel pressure regulator: Removal - Refitting
F9Q, and 804
13BREFITTING
Clean the fuel pressure regulator bearing face onthe high-pressure pump, taking care not to introduceany impurities.
Wipe the fuel pressure regulator bearing face on thehigh-pressure pump, taking care not to introduceany impurities.
Connect the battery, starting with the positive termi-nal.
Flush the fuel pressure regulator housing in thehigh-pressure pump, with the ignition on for a fewseconds.
Disconnect the battery, starting with the negativeterminal.
Prepare the new regulator:
- remove the protective cap,
- check the seal positions,
- lubricate the O-rings with clean diesel fuel.
Offer up the regulator, rotating it slightly.
Push the regulator gently in until it engages fully.
Pretighten the new regulator bolts (3 Nm) .
Tighten to torque the regulator bolts ( 6 Nm ) usinglow torque wrench .
Clean the area with cleaning cloths.
Fit the fuel pressure regulator connector.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Switch on the ignition.
Clear the fault indicated on the diagnostic tool ifnecessary.
Note:
Lubrication is very important to avoid externalleaks.
WARNING
Carry out the necessary programming (see 80A,Battery, Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-179
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 722
13B
REMOVAL
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine covers.
Disconnect air aspiration hose (1) .
Equipment required
diagnostic tool
Tightening torquesm
diesel temperature sen-sor
15 Nm
batter cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the CLIP diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.
WARNING
Tighten to torque 38 Nm the « pump-rail » and « injector rail » high-pressure pipes with one of the following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
For high-pressure pipes with different part numbers,tighten to torque 24 Nm .
WARNING
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206804 ),
- cleaning cloths (part no.: 77 11 211 707 ),
- cleaning product (part no.: 77 11 224 188 ).
102120
1
13B-180
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 722
13B
Disconnect:
- the heater plugs from cylinders n˚ 3 and 4,
- the injectors (2) on cylinders 3 and 4,
- the diesel fuel temperature sensor connector (3) .
Clean the sensor (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).
Remove the fuel temperature sensor (4) .
Fit plugs into the openings.
REFITTING
Lubricate the O-ring with the lubricant from the appli-cator supplied with the new part.
Fit the diesel fuel temperature sensor.
Tighten to torque the diesel temperature sensor (15 Nm ) .
Reconnect the electrical connector.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque the batter cover mounting bolts( 4 Nm ) .
Check the sealing after repair (see 13B, Diesel in-jection, High-pressure pipe: Check sealing ).
102514
102317
3
2
4
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
WARNING
Do not damage the O-ring when refitting.
WARNING
Confirm that there is no diesel fuel leak:
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-181
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 728 or 729
13B
REMOVAL
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine covers.
Pull the clip.
Equipment required
diagnostic tool
Tightening torquesm
diesel temperature sen-sor
15 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the CLIP diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice given in this document whenever work iscarried out on this system.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Always replace any high-pressure pipe and high-pressure pipe clips that have been removed.
WARNING
Tighten to torque 38 Nm the « pump-rail » and « injector rail » high-pressure pipes with one of the following part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 .
For high-pressure pipes with different part numbers,tighten to torque 24 Nm .
WARNING
Before starting work on the vehicle, have to hand:
- a new set of blanking plugs (part no.: 77 01 206804 ),
- cleaning cloths (part no.: 77 11 211 707 ),
- cleaning product (part no.: 77 11 224 188 ).
110325
13B-182
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 728 or 729
13B
Unscrew bolt (1)
Remove the air duct (2) .
Disconnect:
- the heater plugs from cylinders n˚ 3 and 4,
- the injectors (3) on cylinders 3 and 4,
- the fuel temperature sensor connector (4) .
Clean the sensor (see 13B, Diesel injection, Dieselinjection: Precautions during repair ).
Remove the diesel fuel temperature sensor (5) .
Fit plugs into the openings.
REFITTING
Lubricate the O-ring with the lubricant from the appli-cator supplied with the new part.
Fit the diesel fuel temperature sensor.
Tighten to torque the diesel temperature sensor (15 Nm ) .
Reconnect the electrical connector.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
110323
102514
1
2
4
33
102317
WARNING
Do not remove the blanking plugs from eachcomponent until the last moment.
WARNING
Do not damage the O-ring when refitting.
5
13B-183
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 728 or 729
13BCheck the sealing after repair (see 13B, Diesel in-jection, High-pressure pipe: Check sealing ).
WARNING
Confirm that there is no diesel fuel leak:
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-184
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 732
13B
The diesel temperature sensor (1) is attached to thediesel injector fuel return rail.
Replace the diesel injector fuel return rail and dieseltemperature sensor assembly if there is a diesel tem-perature sensor fault (see 13B, Diesel injection, Die-sel injector fuel return rail: Removal - Refitting ).
111747
13B-185
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 724
13B
During each operation, always read the precautions forrepair (see 13B, Diesel injection, Diesel injection:Precautions for repair ).
REMOVAL
I - REMOVAL PREPARATION OPERATION
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove the engine undertray.
Remove the pin securing the turbocharger pipe onthe turbocharger (1) .
Remove the bolt mounting the pipe on the cylinderhead.
Move the pipe to one side.
Disconnect the inlet air pressure sensor (2)
Loosen the clip (3) .
Move the inlet air duct to one side (4) .
Equipment required
diagnostic tool
Tightening torquesm
diesel temperature sen-sor
15 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the CLIP diagnostic tool :
- that the injection rail is not under pressure,
- that the fuel temperature is not too high.
It is essential to respect the safety and cleanlinessadvice whenever work is carr ied out on this system.
Loosening a high pressure pipe union when theengine is running is strictly prohibited.
WARNING
Tighten to a torque of 38 Nm the « pump-rail » and « rail-injectors » high pressure pipes with the fol-lowing part numbers:
- 77 01 207 025 ,
- 77 01 207 026 ,
- 77 01 207 027 ,
- 77 01 207 028 ,
- 77 01 207 029 ,
For high pressure pipes with different part numbers,tighten to a torque of 24 Nm .
WARNING
Before starting work on the vehicle, obtain:
- a new blanking plug kit ( PART NUMBER 77 01206 804 ),
- cleaning cloths ( PART NUMBER 77 11 211 707 ).
112331
13B-186
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 724
13B
Remove:
- the dipstick,
- the dipstick pipe mounting bolts.
Move the dipstick pipe to one side.
Unclip the clips (5) from the injection rail protector.
Remove:
- the mounting bolts (6) from the injection rail protec-tor,
- the injection rail protector (7) .
Remove the high pressure pump protectors (8) and(9)
Clean the pipes (see 13B, Diesel injection, Dieselinjection: Precautions for repair ).
Disconnect the diesel supply and return pipes (10) .
Fit the correct blanking plugs.
109470 109465
102514
Note:
Make preparations for fuel outflow. Clean withnew cloths.
13B-187
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 724
13B
Disconnect the diesel temperature sensor connector(11) .
II - REMOVAL OF PART CONCERNED
Clean the diesel temperature sensor (see 13B, Die-sel injection, Diesel injection: Precautions for re-pair ).
Remove the diesel temperature sensor (12) .
REFITTING
I - REFITTING PREPARATION OPERATION
Lubricate the O-ring with lubricant from the applica-tor supplied with the new part.
II - REFITTING PART CONCERNED
Refit the diesel temperature sensor.
Tighten to torque the diesel temperature sensor (15 Nm ) .
III - FINAL OPERATION
Connect:
- the diesel fuel temperature sensor connector,
- the diesel supply and return pipes.
Refit:
- the high pressure pump protectors,
- the injection rail protector.
Refit the air inlet duct and tighten the clip.
Connect the inlet air pressure sensor
Fit the turbocharger air duct.
Lock the air duct onto the turbocharger and the inter-cooler inlet air pipe.
Tighten the bolt of the air duct on the rocker cover.
Refit the engine undertray.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
102514
102317
Note:
Do not lubricate the diesel temperature sensorseals with grease or used diesel. Use the appli-cator supplied with the kit.
WARNING
Do not damage the O-ring when refitting.
Do not remove the blanking plugs from eachcomponent until the last moment.
13B-188
DIESEL INJECTIONDiesel temperature sensor: Removal - Refitting
K9K, and 724
13BCheck the sealing after repair (see 13B, Diesel in-jection, High pressure pipe: check ).
WARNING
Confirm that there is no diesel fuel leak:
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- switch off the ignition,
- check that there is no diesel fuel leaking.
13B-189
DIESEL INJECTIONAccelerometer: Removal - Refitting
K9K, and 722 or 728 or 729
13B
REMOVAL
Disconnect the accelerometer connector (1) .
Remove the accelerometer using tool (Emb. 1596) .
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the accelerometer ( 20 Nm )using tool low torque wrench .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover securing bolts( 4 Nm ) .
Special tooling required
Emb. 1596 24 mm socket forremoving/refittingclutch master cylinder
Equipment required
low torque wrench
Tightening torquesm
accelerometer 20 Nm
battery cover securingbolts
4 Nm
102086
1
WARNINGcarry out the necessary programming (see 80A,Battery: Removal - refitting ).
13B-190
DIESEL INJECTIONVenturi: Removal - Refitting
K9K, and 722
13B
REMOVAL
Remove the engine covers.
Disconnect:
- the battery, starting with the negative terminal,
- the intake duct (1) .
Disconnect the fuel supply and return pipes (2) .
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
Venturi mounting bolt 5.5 Nm ±±±± 0.6
battery cover securingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection circuit, check using the diagnostic tool CLIP:
• that the injection rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice whenever work is carried out on this sys-tem.
- Loosening a high pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Always replace any high pressure pipe and highpressure pipe clips removed with new ones.
102120
102514
1
2
13B-191
DIESEL INJECTIONVenturi: Removal - Refitting
K9K, and 722
13B
Disconnect the return pipe (3) connecting the injec-tor to the pump.
Remove:
- the Venturi mounting bolt (4) ,
- the Venturi.
REFITTING
Lubricate the O-ring with the lubricant from the appli-cator provided with the new part.
Do not damage the O-ring when fitting the Venturi.
Fit the Venturi.
Tighten to torque the Venturi mounting bolt ( 5.5Nm ±±±± 0.6 ) using tool low torque wrench .
Reconnect the various pipes.
Tighten to torque the battery cover securing bolts( 4 Nm )
102316
3
4
WARNINGDo not remove the blanking plugs from any com-ponent until the last moment.
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
WARNING
Confirm that there is no diesel fuel leakage:
- check the sealing after repair (see 13B, Dieselinjection, High pressure pipe: Fuel tightnesscheck ),
- let the engine run at idle speed until the enginecooling fan starts up,
- accelerate several times under no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-192
DIESEL INJECTIONVenturi: Removal - Refitting
K9K, and 728 or 729
13B
REMOVAL
Remove the engine covers.
Pull the clip.
Undo bolt (1) .
Remove the air duct (2) .
Equipment required
diagnostic tool
low torque wrench
Tightening torquesm
Venturi mounting bolt 5.5 Nm ±±±± 0.6
battery cover mountingbolts
4 Nm
IMPORTANT
Before carrying out any work on the injection sys-tem, check using the CLIP diagnostic tool :
• that the injector rail is not under pressure,
• that the fuel temperature is not too high.
- It is essential to respect the safety and cleanlinessadvice whenever work is carried out on this sys-tem.
- Loosening a high-pressure pipe union when theengine is running is strictly prohibited.
WARNING
- Obtain a set of special high-pressure injection cir-cuit plugs.
- Be sure to replace any high-pressure pipe andhigh-pressure pipe clips that have been removed.
110325
110323
1
2
13B-193
DIESEL INJECTIONVenturi: Removal - Refitting
K9K, and 728 or 729
13B
Disconnect the fuel supply and return pipes (3) .
Disconnect the return pipe (4) connecting the injec-tor to the pump.
Remove:
- the Venturi mounting bolt (5) ,
- the Venturi.
REFITTING
Lubricate the O-ring with the lubricant from the appli-cator provided with the new part.
Do not damage the O-ring when fitting the Venturi.
Fit the Venturi.
Tighten to torque the Venturi mounting bolt ( 5.5Nm ±±±± 0.6 ) using tool low torque wrench .
Reconnect the various pipes.
Connect the battery, starting with the positive termi-nal
Tighten to torque the battery cover mounting bolts( 4 Nm )
102514
102316
33
5
4
WARNINGDo not remove the blanking plugs from eachcomponent until the last moment.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
WARNING
Confirm that there is no diesel fuel leak:
- Check the tightness after repair (see 13B, Die-sel injection, High-pressure pipe: Sealingcheck ),
- let the engine run at idle speed until the enginecooling fan starts to operate,
- accelerate several times at no load,
- carry out a road test,
- switch off the ignition,
- check that there is no diesel fuel escaping.
13B-194
DIESEL INJECTIONAccelerator pedal potentiometer: General information
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
13BThe accelerator pedal potentiometer is incorporated inthe accelerator pedal. If it is replaced, the acceleratorpedal must also be replaced.
There are two types of pedal: with or without a kic-kdown point.
Vehicles fitted with cruise control / speed limiter havean accelerator pedal with a kickdown point at the endof their travel ( « kick-down » ).
This kickdown point makes it possible to exit the speedlimiter function if the driver has to increase speed.
WARNING
A pedal fitted with a kickdown point may be fitted inplace of a pedal without a kickdown point. However,fitting a pedal without a kickdown point in place of apedal with a kickdown point is prohibited.
13B-195
DIESEL INJECTIONAccelerator pedal potentiometer: Removal - Refitting
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
13B
REMOVAL
Disconnect:
- the battery, starting with the negative terminal,
- the accelerator pedal connector.
Remove:
- pedal mounting bolts (1) ,
- the pedal.
REFITTING
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolt ( 4Nm ) .
Tightening torquesm
battery cover mountingbolt
4 Nm
102204
11
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
Note:
A fault on the accelerator pedal position potentio-meter results in changes in the idle speed orengine operation (see 13B, Diesel injection,Idle speed ).
13B-196
DIESEL INJECTIONDiesel injection computer: Removal - Refitting
K9K, and 722 or 728 or 729 – F9Q, and 800 or 808
13B
There are two procedures for doing this (see 13B, Die-sel Injection, Injectors: Configuration and pro-gramming ):
- an automatic procedure which can be used if it is pos-sible to read the information contained in the old com-puter,
- a manual procedure for when it is not possible to readthe information contained in the old computer.
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove the battery.
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
- the wiring harness bracket (3) .
Detach the wiring harnesses from the battery tray.
Remove the battery tray.
Remove the injection computer and its support (4) .
Equipment required
diagnostic tool
Tightening torquesm
battery tray mountingbolts
21 Nm
battery cover mountingbolts
4 Nm
Note:
When programming, reprogramming or replacing acomputer, it is necessary to program the C2I para-meters (individual injector correction) and theengine parameters into the new computer using thediagnostic tool RENAULT CLIP tool. 101822
101811
3
221
4
13B-197
DIESEL INJECTIONDiesel injection computer: Removal - Refitting
K9K, and 722 or 728 or 729 – F9Q, and 800 or 808
13B
Remove:
- the computer mounting bolts (5) ,
- the computer.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Make sure you refit the battery tray correctly on thecomputer support.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Respect the programming instructions for the C2Iparameters (individual injector correction) and engi-ne adaptives (see 13B, Diesel injection, Computerconfiguration ).
Switch on the ignition and read the fault codes usingthe diagnostic tool .
If necessary, repair the faults indicated.
Clear the faults.
Check that the vehicle is operating correctly.
101890
55
101887
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
13B-198
DIESEL INJECTIONDiesel injection computer: Removal - Refitting
K9K, and 724 or 728 or 729 – F9Q, and 804 – M9R, and 700
13B
When replacing the computer (see MR 372 Fault fin-ding, Diesel injection, Fault finding - Replacementof components ).
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the engine covers.
Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Disconnect the computer connectors (1) .
Unclip:
- the wiring harness (2) from the battery negative ter-minal,
- the wiring harness.
Remove:
- the upper mounting bolt (3) from the computer sup-port,
- the mounting bolt (4) from the computer support
- the mounting nut (6) from the wiring harness,
- the computer (5) and its support.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the computer mounting nuts,
- the computer from its support.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the computer on its support,
- the computer mounting nuts.
Tightening torquesm
mounting bolt on thecomputer support
21 Nm
WARNING
- The injection computer retains the immobilisercode for life.
- The system has no security code.
- It is forbidden to perform tests with computers bor-rowed from the Parts Department or from anothervehicle, that must then be returned. These compu-ters are permanently coded.
115720
13B-199
DIESEL INJECTIONDiesel injection computer: Removal - Refitting
K9K, and 724 or 728 or 729 – F9Q, and 804 – M9R, and 700
13BII - FINAL OPERATION
Refit the mounting bolt to the computer support.
Tighten to torque the mounting bolt on the compu-ter support ( 21 Nm ) .
Refit the upper mounting bolt to the computer sup-port.
Clip on:
- the wiring harness to the battery negative terminal,
- the wiring harness.
Connect the computer connectors.
Refit:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine covers.
13C-1
PREHEATINGPre/postheating unit: Removal - Refitting
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732 – M9R, and 700
13C
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove:
- the front left-hand wheel,
- the front left-hand wheel arch liner.
Disconnect the pre-postheating unit connector.
Remove:
- the pre-postheating unit mounting bolt,
- the pre-postheating unit.
REFITTING
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
.
Tightening torquesm
battery cover mountingbolts
4 Nm
wheel bolts 110 Nm
Note:
It is located behind the front left-hand wheel archliner.
101823
102125
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
13C-2
PREHEATINGHeater plugs Removal - Refitting
K9K, and 722
13C
The resistance of a heater plug is 0.6 Ω (connector dis-connected).
The heater plugs are removed without opening thehigh pressure diesel circuit.
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Disconnect the air duct.
Disconnect the electrical connector from the heaterplugs.
Clean around the outside of the heater plugs with acompressed air gun to prevent contamination of thecylinders.
Undo then remove the plugs using a 10 mm diame-ter long radio socket connected to a universal joint.
Use a hose to unscrew the plugs completely.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the heater plugs ( 15 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
heater plugs 15 Nm
battery cover mountingbolts
4 Nm
102120
15762
WARNING
Ensure that no foreign bodies enter the cylinderduring this operation.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
13C-3
PREHEATINGHeater plugs Removal - Refitting
K9K, and 728 or 729
13C
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Pull the clip.
Undo the bolt (1) .
Move the air duct aside (2) .
Disconnect the electrical connector from the heaterplugs.
Clean around the outside of the heater plugs with acompressed air gun to prevent contamination of thecylinders.
Undo then remove the plugs using a 10 mm diame-ter long radio socket connected to a universal joint.
Use a hose to unscrew the plugs completely.
Tightening torquesm
heater plugs 15 Nm
battery cover mountingbolts
4 Nm
110325
110323
15762
WARNING
Ensure that no foreign bodies enter the cylinderduring this operation.
1
2
13C-4
PREHEATINGHeater plugs Removal - Refitting
K9K, and 728 or 729
13CREFITTING
Proceed in the reverse order to removal.
Tighten to torque the heater plugs ( 15 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
13C-5
PREHEATINGHeater plugs Removal - Refitting
F9Q, and 800 or 804 or 808
13C
The resistance of a heater plug is 0.6 Ω (connector dis-connected).
The heater plugs are removed without opening thehigh pressure diesel circuit.
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the inlet duct (see 12A, Fuel mixture, Inlet duct:Removal - Refitting ).
- the injection rail protector (see 13B, Diesel injec-tion, Injection rail protector: Removal - Refitting)
Disconnect the electrical connector from the heaterplugs.
Clean around the outside of the heater plugs with acompressed air gun to prevent contamination of thecylinders.
Undo then remove the plugs using a 10 mm diame-ter long radio socket connected to a universal joint.
Use a hose to unscrew the plugs completely.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the heater plugs ( 15 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
Tightening torquesm
heater plugs 15 Nm
battery cover mountingbolts
4 Nm
F9Q, and 804
15762
WARNING
Ensure that no foreign bodies enter the cylinderduring this operation.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
13C-6
PREHEATINGHeater plugs Removal - Refitting
F9Q, and 804
13CUD replaced with 11,05,08,02-01,37-001,016 on 08/06/2005
13C-7
PREHEATINGHeater plugs Removal - Refitting
K9K, and 732
13C
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the engine covers.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the air inlet pressure sensor connector(1) .
Loosen the clip (2) and move the air inlet duct aside(3) .
Pull out the clip.
Special tooling required
Car. 1363 Trim removal lever
Tightening torquesm
heater plugs 15 Nm
WARNING
Procedure for removing the air inlet duct (risk of leaking and slipping if this procedure is not obser-ved):
- detach the hose using the (Car. 1363) ,
- do not use a degreaser, brake cleaning product, orany other product,
- clean the bearing face on the intercooler and onthe hose with a dry, lint-free cloth,
- always replace the clip with a new one,
- place the clip in the same position if the hose isnot replaced,
- always replace the hose and/or the intercooler ifdamaged.
112815
112811
13C-8
PREHEATINGHeater plugs Removal - Refitting
K9K, and 732
13C
Make a marking (4) on the air inlet duct between thestainless steel pipe and the hose.
Detach the hose from the stainless steel pipe.
Remove:
- the mounting bolt (5) from the stainless steel pipe,
- the stainless steel pipe (6) .
Unclip the injection rail protector cover (7) .
Remove:
- the mounting nut and bolt (8) from the injection railprotector cover,
- the injection rail protector cover,
- the dipstick,
- the dipstick pipe mounting bolts (9) .
Move the dipstick pipe to one side.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the connector from the heater plug.
Clean around the outside of the heater plugs with acompressed air gun to prevent contamination of thecylinders.
Undo then remove the plugs using a 10 mm diame-ter long radio socket connected to a universal joint.
Use a hose to unscrew the plugs completely.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the heater plugs using the hose.
112991
112992
112993
Note:
Do not pull on the plug cable.
WARNING
Ensure that no foreign bodies enter the cylinderduring this operation.
13C-9
PREHEATINGHeater plugs Removal - Refitting
K9K, and 732
13CTighten to torque the heater plugs ( 15 Nm ) .
Connect the connector to the heater plugs.
II - FINAL OPERATION
Refit:
- the mounting bolts to the dipstick pipe,
- the dipstick,
- the injection rail protector cover,
- the injection rail protector mounting bolt and moun-ting nut.
Clip on the injection rail protector cover.
Refit:
- the clip on the stainless steel pipe if necessary,
- the stainless steel pipe on the hose, aligning themarking,
Clip the stainless steel pipes onto the turbocharger.
Refit:
- the stainless steel pipe mounting bolt,
- the air inlet duct on the damper valve.
Tighten the clip.
Connect:
- the connector of the air inlet pressure sensor,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Refit the engine covers.
13C-10
PREHEATINGHeater plugs Removal - Refitting
M9R, and 700
13C
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the front engine cover.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Disconnect the heater plug connectors.
Clean and blast the outside of the plugs to preventany contamination of the cylinders.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Unscrew then remove the plugs using a socketwrench for removing/refitting preheating plugsor a 1/4-inch square drive long 10 mm socket with auniversal joint.
If necessary, use a hose to unscrew the plugs com-pletely.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the heater plugs.
Bring the heater plugs just into contact.
Tighten to torque the heater plugs ( 16.5 Nm ) usinga socket wrench for removing/refitting prehea-ting plugs or a 1/4-inch square drive long socket 10mm in diameter connected to a universal joint.
II - FINAL OPERATION
Connect
- the heater plug connectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Refit the engine cover.
Equipment required
socket wrench for removing/refitting preheatingplugs
Tightening torquesm
heater plugs 16.5 Nm
WARNING
Ensure that no foreign bodies enter the cylinderduring this operation.
WARNING
The heater plugs are damaged by being tighte-ned to any torque greater than 19 Nm .
13C-11
PREHEATINGPre-postheating control
F9Q, and 800 or 808
13CThe pre/post heating function is controlled by the injec-tion computer.
PRE/POST HEATING OPERATING PRINCIPLE
1 - Switching on the ignition « preheating »
a - Variable preheating
The duration the indicator light is lit and of the supply tothe heater plugs depends on the coolant temperatureand the battery voltage.
X: Time in seconds
Y: Coolant temperature in ˚C
In all cases the preheating warning light should light upfor more than 12 seconds .
b - Fixed preheating
After the warning light goes out the plugs remain sup-plied for a fixed period of 10 seconds .
2 - Starting
The plugs continue to be supplied while the starter isbeing activated.
3 - Engine running « postheating »
During this phase the plugs are supplied continuouslyaccording to coolant temperature.
At idling speed with no depression of the acceleratorpedal.
X: Time in seconds
Y: Coolant temperature in ˚C
101189
101188
13C-12
PREHEATINGPre-postheating control
K9K, and 722 or 728 or 729 or 732
13CThe pre-postheating function is controlled by the injec-tion computer.
PRE-POSTHEATING OPERATING PRINCIPLE
1 - Ignition on « preheating »
a - Variable preheating
The time taken for the warning light to come on and forsupply to the heater plugs depends on the coolant tem-perature and the battery voltage.
X: Time in seconds
Y: Coolant temperature in ˚C
Whatever the situation, the heater plug warning lightcannot remain lit for more than 12 seconds (except inthe event of a coolant temperature sensor fault).
b - Fixed preheating
After the warning light goes out, the heater plugs conti-nue to be supplied for a fixed period of 5 seconds .
2 - Starting
The plugs remain supplied while the starter motor isbeing activated.
3 - Engine running « postheating »
During this phase the plugs are supplied continuouslyaccording to the coolant temperature.
At idling speed with no depression of the acceleratorpedal.
X: Time in seconds
Y: Coolant temperature in ˚C
103123
103124
14A-1
ANTIPOLLUTIONPetrol vapour rebreathing: Operation
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
14AI - OPERATING DIAGRAM OF THE CIRCUIT
106679
(1) Inlet manifold
(2) Fuel vapour absorber bleedsolenoid valve
(3) Fuel vapour absorber
(4) Tank
(5) Breather
(6) Anti-return valve (F4R 776 only)
102724
(7) Fuel vapour absorber bleedsolenoid valve
12
34
5
6
6
7
F4R, and 776
106278
(8) Fuel vapour absorber bleedsolenoid valve
102734
(9) Fuel vapour absorber
(10) Fuel vapour recirculation comingfrom the tank
8
9
10
1112
14A-2
ANTIPOLLUTIONPetrol vapour rebreathing: Operation
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
14A
II - OPERATING PRINCIPLE
The tank is vented by means of the fuel vapour absor-ber.
Fuel vapour is trapped by the active charcoal contai-ned in the absorber as it passes through.
Fuel vapour trapped in the absorber is eliminated andburnt by the engine.
To do this, connect the fuel vapour absorber and the in-let manifold via the solenoid valve. This solenoid valveis located on the shock absorber cup.
The principle behind the solenoid valve is to open apassage of variable size (according to the opening cy-clic ratio signal sent by the injection computer).
The variation in the passage opened for fuel vapour inthe solenoid valve results from the balance betweenthe magnetic field created by the supply to the windingand the return spring force attempting to close the so-lenoid valve.
(11) Recirculation of fuel vapoursgoing to the engine
(12) Tank breather
WARNING
The breather should not be blocked during normalengine operation.
14A-3
ANTIPOLLUTIONFuel vapour recirculation circuit: check
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
14AI - CHECKING THE OPERATION OF THE FUEL VAPOUR ABSORBER BLEED
Check the conformity of the circuit (see 14A, Anti-pollution, Fuel vapour rebreathing Operation ).
Check the condition of the pipes to the tank.
II - FUEL VAPOUR ABSORBER BLEEDING CONDITIONS
The fuel vapour absorber bleed solenoid valve is controlled by track C-E1 of the computer if:
- the coolant temperature is above 55˚C ,
- the air temperature is above 10˚C ,
- the engine is not at idle speed,
- a given load threshold is reached,
- the throttle potentiometer is not in the « no load »position.
During « on board diagnostic » fault finding, fuel va-pour absorber bleeding is not authorised.
The opening cyclic ratio of the fuel vapour absorberbleed solenoid valve can be displayed using the dia-gnostic tools by referring to parameter PR102: Fuelvapour absorber bleed solenoid valve OCR .
The solenoid valve is closed for values below 1.2 % .
Note:
A fault with this system may result in rough idlingor the engine stalling.
106679
(1) Inlet manifold
(2) Fuel vapour absorber bleedsolenoid valve
(3) Fuel vapour absorber
(4) Tank
(5) Breather
(6) Anti-return valve (F4R 776 only)
12
34
5
6
6
14A-4
ANTIPOLLUTIONFuel vapour canister: Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
14AThe absorber is located on the fuel tank under the ve-hicle.
REMOVAL
Release absorber (1) from the fuel tank retainingnotch by pushing it in the direction of the arrow.
Disconnect:
- pipe (2) bringing the fuel vapour from the tank,
- pipe (3) taking the fuel vapours to the solenoid val-ve,
- breather pipe (4) .
Remove the absorber.
REFITTING
Proceed in the reverse order to removal.
102483
1
102734
2
3 4
14A-5
ANTIPOLLUTIONFuel vapour canister:Checking
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
14A
CHECKING THE FUEL VAPOUR ABSORBER
On the fuel vapour absorber, cap the circuit comingfrom the tank.
Connect a pressure gauge on tool (Mot. 1311-01) tothe absorber breather outlet.
With the engine at idle speed, check that there is novacuum at the absorber breather outlet (under thesame conditions, the command value read by thediagnostic tool in parameter: Fuel vapour absorberbleed solenoid valve OCR remains minimal ( Xlower than or equal to 1.5 % ).
Is there a vacuum?
- Yes: with the ignition off, use a vacuum pump to apply a vacuum of 500 mbar to the solenoid valve outlet . The vacuum pressure should not vary by more than 10 mbar over 30 seconds .
Does the pressure vary?
• Yes: the solenoid valve is faulty, replace it.
• No: there is an electrical fault, check the circuit.
- No: under bleeding conditions (see « bleedingconditions » ), the vacuum should increase (at thesame time the parameter value on the diagnostictool should also increase).
CHECKING THE FUEL VAPOUR ABSORBER TANK CONNECTION
Check this connection by connecting a vacuumpump to the pipe going to the absorber.
Special tooling required
Mot. 1311-01 Fuel pressure test kit
14A-6
ANTIPOLLUTIONOil vapour rebreathing
B84 or C84 or S84, and K4J, and 730 or 732
14AI - LOCATION OF COMPONENTS
101495
1
(1) Oil vapour breather port
101499
3
2
(2) Oil vapour recovery plate loca-ted on the cylinder head cover
(3) Sized port
101869
2
14A-7
ANTIPOLLUTIONOil vapour rebreathing
B84 or C84 or S84, and K4J, and 730 or 732
14AFor information on removing oil vapour recovery plate(2) , (see 11A, Top and front of engine, Tighteningthe cylinder head ).
II - OPERATING DIAGRAM
A: At low loads, small quantities of oil vapour are sucked back in via sized opening (7).
B: At medium and high loads, large quantities of oil vapour are sucked in by the gas throttle.
III - CHECKING
To ensure the antipollution system works properly, theoil vapour rebreathing circuit must be kept clean and ingood condition.
101956
101957
(1) Engine
(2) Oil vapour recovery plate
7
65
4 3
2
1
7
65
43
2
1
(3) Air unit
(4) Motorised throttle valve
(5) Inlet manifold
(6) Air inlet
(7) Sized port
14A-8
ANTIPOLLUTIONOil vapour rebreathing
K4M, and 760 or 761
14AI - LOCATION OF COMPONENTS
For information on removing oil vapour recovery plate(3) , (see 11A, Top and front of engine, Cylinderhead gasket ).
102305
2
1
(1) Oil vapour breather pipe
(2) Sized opening
101820
(3) Oil vapour recovery plate on thecylinder head cover
(4) Oil vapour breather pipe
43
102073
3
14A-9
ANTIPOLLUTIONOil vapour rebreathing
K4M, and 760 or 761
14AII - OPERATING DIAGRAM
A: At low loads, the oil vapours are rebreathed in small quantities through the sized opening (6)
B: Under average and heavy loads, the oil vapours are rebreathed in large quantities through the gas throttle valve.
III - CHECKING
To ensure the antipollution system works properly, theoil vapour rebreathing circuit must be kept clean and ingood condition.
102308
102309
(1) Engine
(2) Oil vapour recovery plate
(3) Motorised throttle
(4) Inlet manifold
3
2
1
6
5
4
3
2
1
6
5
4
(5) Air inlet
(6) Sized opening
14A-10
ANTIPOLLUTIONOil vapour rebreathing
K9K, and 722 or 728 or 729 or 732
14AI - PRESENTATION OF THE CIRCUIT
A : Under low load, the vacuum in the air inlet duct isbelow the spring calibration. The oil vapours are re-breathed in large volumes by the vacuum in the air inletduct.
B : Under medium or high load, the pressure in the airinlet duct pulls the valve diaphragm, the oil vapours arerebreathed in small quantities via a sized opening.
II - CHECK
To ensure the correct operation of the anti-pollutionsystem, the oil vapour rebreathing circuit must be keptclean and in good condition.
20965
20965-1
(1) Cylinder head cover
(2) Oil vapour breather pipe
(3) Oil vapour rebreathing valve
(4) Air inlet duct
(5) Turbocharger
(6) Atmospheric pressure
3
2
1
6 54
3
2
1
654
14A-11
ANTIPOLLUTIONOil vapour rebreathing
F9Q, and 800 or 808
14AI - CIRCUIT PRESENTATION
II - CHECK
To ensure the correct operation of the anti-pollutionsystem, the oil vapour rebreathing circuit must be keptclean and in good condition.
100053
(1) Engine
(2) Oil separator
(3) Air filter unit
(4) Air duct
(5) Turbocharger
(6) Inlet manifold
4
3
2
1
6
5
100054
(1) Oil vapour rebreathing pipe con-nected to the intake pipes
(2) Cylinder block outlet oil vapourrebreathing pipe
(3) Separator filter oil return pipe
(4) Oil separator
4
3
2
1
14A-12
ANTIPOLLUTIONOil vapour rebreathing
F4R, and 770 or 771 or 776
14AI - PRESENTATION OF COMPONENTS
102723
1
2
(1) Oil vapour breather pipe
(2) Oil vapour recirculation valve
102729
3
(3) Oil vapour recovery plate on thecylinder head cover
14A-13
ANTIPOLLUTIONOil vapour rebreathing
F4R, and 770 or 771 or 776
14A
Oil vapour recovery plate located on the rocker cover
F4R, and 776
106629
B A
(A) Circuit upstream of turbochar-ger, used for medium and highloads. The vapour is suckedback in by the prevailing vacuumpressure in the inlet manifold
(B) Circuit downstream of throttlevalve, used for low loads. Thevapour is sucked back in by theprevailing vacuum pressurebetween the throttle and engine
106588
14A-14
ANTIPOLLUTIONOil vapour rebreathing
F4R, and 770 or 771 or 776
14AFor removal, (see 11A, Top and front of engine, Cy-linder head gasket ).
II - OIL VAPOUR RECIRCULATION CIRCUIT
102738
(4) Throttle upstream oil vapourrecirculation aperture
4
3
102745
10
9
8
5
7
6
14A-15
ANTIPOLLUTIONOil vapour rebreathing
F4R, and 770 or 771 or 776
14A
III - CHECKING
To ensure the antipollution system works properly, theoil vapour rebreathing circuit must be kept clean and ingood condition.
(5) Air duct
(6) Throttle valve
(7) Inlet manifold
(8) Throttle valve upstream oilvapour rebreathing port
(9) Oil vapour recovery plate
(10) Oil vapour rebreathing valve
14A-16
ANTIPOLLUTIONOil vapour rebreathing
F9Q, and 804
14AI - THE CIRCUIT
II - CHECK
To ensure the antipollution system works properly, theoil vapour rebreathing circuit must be kept clean and ingood condition.
100053
(1) Engine
(2) Oil separator
(3) Air filter unit
(4) Air duct
(5) Turbocharger
(6) Inlet manifold
100054
(1) Oil vapour rebreathing pipe con-nected to the inlet pipes
(2) Cylinder block outlet oil vapourrebreathing pipe
(3) Oil separator filter return pipe
(4) Oil separator
14A-17
ANTIPOLLUTIONExhaust gas recirculation: Description
K9K, and 722 or 728 or 729
14AI - THE CIRCUIT
II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the nitro-gen oxide (NOx) content of the exhaust gases.
The computer regulates the passage of gases by ac-tuating a solenoid valve.
III - OPERATING PRINCIPLE
The solenoid valve is controlled by an opening cyclicratio signal issued by the injection computer. The ope-ning cyclic ratio signal modulates the opening of thesolenoid valve, and consequently the quantity of ex-haust gas directed back to the inlet manifold.
The computer runs a constant test to keep track of theposition of the exhaust gas recirculation solenoid val-ve.
IV - OPERATING CONDITIONS
The following parameters determine actuation of the exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
- atmospheric pressure,
- accelerator pedal position,
- diesel injected,
- engine speed.
Operating point for checking the exhaust gas recirculation solenoid valve
The exhaust gas recirculation solenoid valve is actua-ted if:
- the air temperature is between -30˚C and 67 ˚C , in-clusive,
- or the coolant temperature is between 0˚C and 127˚Cinclusive,
- the engine speed is above 500 rpm ,
- the diesel fuel injection flow is between 10 and 31mg/stroke inclusive,
- the atmospheric pressure is above 421 mbar .
If so, the diagnostic tool indicates an exhaust gas recir-culation solenoid valve position opening cylinder ratiovalue equal to 4 and 60% .
Exhaust gas recirculation is cut off if:
- the battery voltage is below 9 V ,
- the engine speed is below 500 rpm ,
- the mapping (engine speed - load) exceeds a thres-hold,
- the air conditioning compressor is actuated.
The exhaust gas recirculation solenoid valve is notsupplied after starting for 2 seconds .
The exhaust gas recirculation solenoid valve is no lon-ger supplied if there is a fault on:
- the exhaust gas recirculation solenoid valve,
- the turbocharging pressure sensor,
102364
(1) Engine
(2) Air filter unit
(3) Plenum chamber
(4) Exhaust manifold
(5) Exhaust gas recirculation unitwith solenoid valve
(6) Turbocharger
(7) Injection computer
(8) Intercooler
(A) Air inlet
(B) Exhaust gas outlet
A
8
1
7 6
5
4
3Note:
The position of the exhaust gas recirculation sole-noid valve is a determining factor in the calculationof the quantity of air admitted by the engine.
14A-18
ANTIPOLLUTIONExhaust gas recirculation: Description
K9K, and 722 or 728 or 729
14A
15761
Track Description
1 Solenoid supply
2 Position potentiometer supply
3 Not used
4 Position potentiometer earth
5 Solenoid earth control
6 Position potentiometer signal
14A-19
ANTIPOLLUTIONExhaust gas recirculation: Description
F9Q, and 800 or 808
14AI - THE CIRCUIT
II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the nitro-gen oxide (NOx) content of the exhaust gases.
The injection computer allows gas to pass by actuatinga solenoid valve.
III - OPERATING PRINCIPLE
The solenoid valve is controlled by an opening cyclicratio signal issued by the injection computer. The ope-ning cyclic ratio signal modulates the opening of thesolenoid valve, and consequently the quantity of ex-haust gas directed back to the inlet manifold.
The computer runs a constant test to keep track of theposition of the exhaust gas recirculation solenoid val-ve.
IV - OPERATING CONDITIONS
The following parameters determine activation of the exhaust gas recirculation solenoid valve:
- coolant temperature,
- the air temperature,
- atmospheric pressure,
- the injection flow,
- the engine speed.
Exhaust gas recirculation is cut off if:
- the battery voltage is below 9 V ,
23244
11
2
10
1
9
84
7
3
6
5
(1) Engine
(2) Injection computer
(3) Inlet manifold
(4) Exhaust manifold
(5) Turbocharger
(6) Exhaust gas recirculation sole-noid valve
(7) Air flowmeter
(8) Air inlet
(9) Exhaust gas outlet
(10) Intercooler inlet
(11) Intercooler outlet
14A-20
ANTIPOLLUTIONExhaust gas recirculation: Description
F9Q, and 800 or 808
14A- If the engine speed is above 2,950 rpm when the pe-
dal is released (low pedal value),
- if the mapping (engine speed/load) exceeds a giventhreshold,
- after 40 seconds if
• the vehicle speed is below 7 mph (12 km/h) ,
• the engine speed is below 1,000 rpm .
• the coolant temperature is above 60 ˚C .
The exhaust gas recirculation solenoid valve is notcontrolled after engine start-up depending on coolanttemperature mapping.
The exhaust gas recirculation solenoid valve is no lon-ger supplied if there is a fault on:
- the coolant temperature sensor,
- the air temperature sensor,
- the turbocharging pressure sensor,
- the atmospheric pressure sensor.
Note:
There is no exhaust gas recirculation at altitude (>1,200m).
103127
X Time in seconds
Y Coolant temperature in ˚C
15761
Track Description
1 Solenoid supply
2 Sensor feed
4 Sensor earth
5 Solenoid earth
6 Sensor output
14A-21
ANTIPOLLUTIONExhaust gas recirculation: Description
F9Q, and 804
14AI - DIAGRAM
II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the nitro-gen oxide (NOX) content of the exhaust gases.
The injection computer authorises gas passage by run-ning an electric motor which actuates a valve linkingthe exhaust manifold and the inlet manifold.
III - OPERATING PRINCIPLE
The principle of the exhaust gas recirculation consistsof reintroducing some of the exhaust fumes into the en-gine air breathing cycle.
The EGR valve is controlled by a direct current motor.
114451
(1) Engine
(2) Exhaust gas cooler
(3) Exhaust gas recirculation unit
(4) Inlet manifold
(5) Exhaust manifold
(6) Turbocharger
14A-22
ANTIPOLLUTIONExhaust gas recirculation: Description
K9K, and 732
14AI - THE CIRCUIT
II - PURPOSE OF THE EXHAUST GAS RECIRCULATION SYSTEM
Exhaust gas recirculation is used to reduce the con-centration of nitrogen oxides (NOx) in exhaust fumes.
The computer regulates the passage of gases by ac-tuating a solenoid valve.
III - OPERATING PRINCIPLE
The solenoid valve is controlled by an opening cyclicratio signal issued by the injection computer. The ope-ning cyclic ratio signal modulates the opening of thesolenoid valve, and consequently the quantity of ex-haust gas directed back to the inlet manifold.
The computer runs a constant test to keep track of theposition of the exhaust gas recirculation solenoid val-ve.
IV - OPERATING CONDITIONS
The following parameters determine actuation of the exhaust gas recirculation solenoid valve:
- coolant temperature,
- air temperature,
- atmospheric pressure,
- accelerator pedal position,
- diesel injected,
- engine speed.
102364
(1) Engine
(2) Air filter unit
(3) Plenum chamber
(4) Exhaust manifold
(5) Exhaust gas recirculation unitwith solenoid valve
(6) Turbocharger
(7) Injection computer
(8) Intercooler
(A) Air inlet
(B) Exhaust gas outlet
Note:
The position of the exhaust gas recirculation sole-noid valve is a determining factor in the calculationof the quantity of air admitted by the engine.
14A-23
ANTIPOLLUTIONExhaust gas recirculation unit
K9K, and 722
14A
REMOVALDisconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the air duct (1) .
Disconnect the wiring harness (2) .
Move the wiring harness to one side.
Disconnect:
- turbocharging pressure regulation valve pipe (3)from the air duct,
- air inlet pipe (4) on the exhaust gas recirculationunit.
Remove:
- bracket (5) ,
- engine lifting eye (6) ,
- air intake metal pipe (7) .
Special tooling required
Mot. 1567 Remote operationpliers for EGR clips
Tightening torquesm
exhaust gas recircula-tion unit mounting bolt
21 Nm
metal air inlet tubemounting bolt
21 Nm
lifting eye (timing end) 21 Nm
mounting bolts for theheat shield on theexhaust gas recircula-tion solenoid valve
12 Nm
engine cover mountingbolts
4 Nm
102120
1
102126
102119
2
3
4
56
7
14A-24
ANTIPOLLUTIONExhaust gas recirculation unit
K9K, and 722
14A
Remove:
- exhaust gas recirculation solenoid valve heatshield (8) ,
- exhaust gas recirculation pipe (9) ,
- the two exhaust gas recirculation unit mountingbolts (10) ,
- the exhaust gas recirculation unit.
REFITTING
Replace the exhaust gas recirculation tube completewith new clips.
Tighten the new clips using tool (Mot. 1567) .
Replace the O-rings on the air inlet metal tube.
Tighten to torque:
- the exhaust gas recirculation unit mountingbolt ( 21 Nm ) ,
- the metal air inlet tube mounting bolt ( 21 Nm ) ,
- the lifting eye (timing end) ( 21 Nm ) ,
- the mounting bolts for the heat shield on the ex-haust gas recirculation solenoid valve ( 12 Nm ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the engine cover mounting bolts( 4 Nm ) .
102074
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
8
9
10
14A-25
ANTIPOLLUTIONExhaust gas recirculation unit
K9K, and 728 or 729 or 732
14A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Pull the clip.
Undo bolt (1) .
Remove the air duct (2) .
Disconnect the wiring harness (3) .
Move the wiring harness to one side.
Special tooling required
Mot. 1567 Remote operationpliers for EGR clips
Tightening torquesm
exhaust gas recircula-tion unit mounting bolts
21 Nm
metal inlet air tubemounting bolts
21 Nm
lifting eye (timing end) 21 Nm
exhaust gas recircula-tion solenoid valve heatshield mounting bolts
12 Nm
front engine covermounting bolts
4 Nm
Note:
For vehicles fitted with the K9K 732 engine (seeWorkshop Repair Manual 370 Mechanics, Scé-nic II ).
110325
110323
102126
1
2
3
14A-26
ANTIPOLLUTIONExhaust gas recirculation unit
K9K, and 728 or 729 or 732
14A
Disconnect:
- the turbocharging pressure regulation valve pipe(4) from the air duct,
- the air inlet pipe (5) on the exhaust gas recircula-tion unit.
Remove:
- the bracket (6) ,
- the engine lifting eye (7) ,
- the air inlet metal tube (8) .
Remove:
- the exhaust gas recirculation solenoid valve heatshield (9) ,
- the exhaust gas recirculation pipe (10) ,
- the two exhaust gas recirculation unit mountingbolts (11) ,
- the exhaust gas recirculation unit.
REFITTING
Replace the exhaust gas recirculation tube completewith new clips.
Tighten the new clips using (Mot. 1567) .
Replace the O-rings on the metal air inlet tube.
Tighten to torque:
- the exhaust gas recirculation unit mountingbolts ( 21 Nm ) ,
- the metal inlet air tube mounting bolts ( 21 Nm ),
- the lifting eye (timing end) ( 21 Nm ) ,
- the exhaust gas recirculation solenoid valveheat shield mounting bolts ( 12 Nm ) .
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the front engine cover mountingbolts ( 4 Nm ) .
102119
102074
6
5
4
8
7
11
10
911
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
14A-27
ANTIPOLLUTIONExhaust gas recirculation unit
F9Q, and 804
14A
REMOVAL
Disconnect the battery, starting with the negativeterminal.
Remove the battery.
Remove the air duct (see 12A, Fuel mixture, Inletduct: Removal - Refitting ).
Remove the mounting bolts (1) from the exhaust gasrecirculation pipe.
Remove the mounting bolts (2) from the exhaust gasrecirculation unit.
REFITTING
Proceed in the reverse order to removal.
Tightening torquesm
exhaust gas recircula-tion unit mounting bolts
25 Nm
exhaust gas recircula-tion pipe mounting bolts
18 Nm
battery cover mountingbolts
4 Nm
111861
111964
113177
WARNING
Never remove the exhaust gas recirculation sole-noid valve from the unit.
14A-28
ANTIPOLLUTIONExhaust gas recirculation unit
F9Q, and 804
14ATighten to torque:
- the exhaust gas recirculation unit mountingbolts ( 25 Nm ) ,
- the exhaust gas recirculation pipe mountingbolts ( 18 Nm ) .
Connect the battery, starting with the positive termi-nal.
Reconnect the connectors.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
14A-29
ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
14A
The exhaust gas recirculation solenoid valve is fittedinto the exhaust gas recirculation unit.
REMOVALRemove:
- the heat shield,
- the exhaust gas recirculation solenoid valve moun-ting bolts,
- the exhaust gas rebreathing solenoid valve by uns-crewing it gradually,
- the exhaust gas recirculation solenoid valve by gra-dually turning it using tool (Mot. 1729) .
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the exhaust gas recirculationsolenoid valve mounting bolts ( 9 Nm ) .
Special tooling required
Mot. 1729 Pin spanner for remo-ving the EGR valve
Tightening torquesm
exhaust gas recircula-tion solenoid valvemounting bolts
9 Nm
Note:
For vehicles fitted with the K9K 732 engine (seeWorkshop Repair Manual 370 Mechanics, Scé-nic II ).
WARNING
Always replace the exhaust gas recirculationsolenoid valve seal with a new one
14A-30
ANTIPOLLUTIONExhaust gas recirculation solenoid valve: Removal - Refitting
F9Q, and 800 or 808
14A
The exhaust gas recirculation solenoid valve is fittedinto the exhaust gas recirculation unit.
REMOVALRemove:
- the inlet and exhaust manifolds (see 12A, Fuelmixture, Manifold ),
- the bolts securing the exhaust gas recirculation so-lenoid valve,
- the exhaust gas recirculation solenoid valve by gra-dually turning it using tool (Mot. 1729) .
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the mounting bolts on the ex-haust gas recirculation solenoid valve ( 9 Nm ) .
Special tooling required
Mot. 1729 Pin spanner for remo-ving the EGR valve
Tightening torquesm
mounting bolts on theexhaust gas recircula-tion solenoid valve
9 Nm
WARNING
Always replace the exhaust gas recirculationsolenoid valve gasket with a new one
14A-31
ANTIPOLLUTIONIntercooler: Removal - Refitting
K9K, and 732
14A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine covers,
- the engine undertray.
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove the oil vapour rebreather pipe (1) .
Disconnect the connector (2) from the oil vapour re-circulation solenoid valve.
Pull out the clip.
Special tooling required
Ms. 583 Hose clamps
Mot. 1567 Remote operationpliers for EGR clips
Equipment required
diagnostic tool
Tightening torquesm
bolts mounting theexhaust gas cooler onits two supports
12 Nm
bolt mounting theexhaust gas cooler sup-ports on the cylinderhead
25 Nm
mounting bolts of therigid exhaust gas recir-culation pipe
35 Nm
coolant circulationcover mounting bolts
10 Nm
bolts mounting the lif-ting bracket on thetiming end
10 Nm
112816
112811
14A-32
ANTIPOLLUTIONIntercooler: Removal - Refitting
K9K, and 732
14A
Remove the mounting bolt (3) from the stainlesssteel pipe.
Move the air inlet duct (4) to one side.
Disconnect the connector (5) from the air inlet pres-sure sensor.
Loosen the clip (6) and move the air inlet duct aside.
Remove the damper valve (see 12A, Fuel mixture,Damper valve: Removal - Refitting ).
Remove the mounting bolts (7) from the injection railprotector cover mounting bracket.
112991
112815
113475
14A-33
ANTIPOLLUTIONIntercooler: Removal - Refitting
K9K, and 732
14A
Position the (Ms. 583) on the exhaust gas cooler in-let and outlet hoses.
Remove the mounting bolts (8) from the exhaust gascoolant recirculation cover.
Move the exhaust gas coolant recirculation cover toone side.
Remove the seals from the cover.
Remove:
- the lifting bracket mounting bolts (9) from the timingend,
- the lifting bracket on the timing end (10) ,
- the air inlet metal tube (11) ,
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the mounting bolts from the exhaust gas inlet pipe(12) ,
- the mounting bolts from the exhaust gas recircula-tion unit assembly (13) ,
- the exhaust gas recirculation unit assembly.
II - OPERATION FOR REMOVAL OF PART CONCERNED
At the workbench, remove:
- the bolt mounting the exhaust gas cooler on its twosupports,
- the exhaust gas cooler,
- the exhaust gas inlet pipe snap-fit clamp,
- the exhaust gas inlet pipe.
114341
Note:
Make preparations for coolant outflow.
112329
112326
14A-34
ANTIPOLLUTIONIntercooler: Removal - Refitting
K9K, and 732
14AREFITTING
I - REFITTING PREPARATION OPERATION
All the bearing faces on each removed part must becarefully cleaned.
II - REFITTING OPERATION FOR PART CONCERNED
Refit the exhaust gas cooler on its two supports fit-ted with new seals.
Refit:
- the mounting bolts to the cooler, without makingcontact so that the cooler can move,
- the exhaust gas recirculation unit assembly, with itscooler, onto the cylinder head.
- the mounting bolts for the two exhaust gas coolersupports.
Tighten the bolts mounting the two exhaust gas coo-ler supports on the cylinder head until they makecontact.
Adjust the exhaust gas cooler on its two supports sothat it is immobilised.
Tighten the mounting bolts of the exhaust gas cooleron its two supports until they make contact, in orderto immobilise it.
Remove the exhaust gas recirculation unit assemblywith its cooler.
At the workbench, tighten to torque the bolts moun-ting the exhaust gas cooler on its two supports (12 Nm ) .
Refit the exhaust gas recirculation unit assembly onthe cylinder head with its cooler.
Refit the bolts mounting the exhaust gas cooler sup-ports on the cylinder head.
Tighten to torque the bolt mounting the exhaustgas cooler supports on the cylinder head ( 25Nm ) .
WARNING
Take care not to damage the bearing faces toprevent any risk of coolant leaks.
WARNING
Always replace:
- the metal air inlet tube and its O-rings,
- the exhaust gas inlet pipe, its mounting bolts, itsseal and its snap-fit clamp,
- the cooler seals and its supports,
- the seals of the coolant circulation cover withinthe exhaust gas cooler,
- the seal between the downstream duct of thecut-off valve and the exhaust gas cooler sup-port,
- the seal between the catalytic converter and theturbocharger.
WARNING
Ensure that the seals between the cooler and itstwo supports are correctly positioned to avoidany coolant leaks.
112326
WARNING
Ensure that the seals between the cooler and itstwo supports are correctly positioned to avoidany coolant leaks.
14A-35
ANTIPOLLUTIONIntercooler: Removal - Refitting
K9K, and 732
14ARefit:
- the new rigid exhaust gas recirculation pipe with anew seal,
- the new exhaust gas recirculation pipe mountingbolts,
Fit the new snap-fit clamp.
Tighten the rigid exhaust gas recirculation pipemounting bolts until they make contact.
Adjust the rigid exhaust gas recirculation pipe in re-lation to the cooler support on the timing end.
Lock the snap-fit clamp of the rigid exhaust gas re-circulation pipe using the (Mot. 1567) .
Tighten to torque the mounting bolts of the rigidexhaust gas recirculation pipe ( 35 Nm ) ).
III - FINAL OPERATIONS
Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - Refitting ).
- the coolant circulation cover
- the coolant circulation cover mounting bolts
Tighten to torque the coolant circulation covermounting bolts ( 10 Nm )
Refit:
- the lifting bracket on the timing end,
- the bolts mounting the lifting bracket on the timingend.
Tighten to torque the bolts mounting the liftingbracket on the timing end ( 10 Nm )
Loosen the nut mounting the rail protector on themounting bracket.
Refit the bolts mounting the rail protector mountingbracket on the exhaust gas cooler assembly.
Tighten:
- the bolts mounting the rail protector mounting brac-ket on the exhaust gas cooler assembly,
- the nut mounting the rail protector on the mountingbracket.
Refit the damper valve (see 12A, Fuel mixture,Damper valve: Removal - Refitting ).
Connect the air inlet pressure sensor connector.
Refit the clip on the air inlet duct if necessary.
Position the air inlet duct.
Clip the air inlet duct onto the turbocharger.
Refit the air inlet duct mounting bolt.
Tighten the air inlet duct bolt.
Connect the exhaust gas recirculation solenoid val-ve connector.
Refit the oil vapour rebreathing pipe.
Connect the battery (see 80A, Battery: Removal -Refitting).
Bleed the coolant (see 19A, Cooling, Cooling cir-cuit: Bleeding ).
Refit:
- the engine undertray,
- the engine covers.
Clear any faults stored by the computer using thediagnostic tool .
WARNING
Ensure that you do not squeeze the exhaust gasinlet pipe before fitting the snap-fit clamp.
WARNING
Ensure that the water inlet and outlet hoses ofthe exhaust gas cooler are correctly aligned sothat they do not bend.
14A-36
ANTIPOLLUTIONExhaust gas recirculation mounting: Removal - Refitting
K9K, and 732
14AFor removing and refitting the supports for the exhaustgas recirculation (see 14A, Emission control, Ex-haust gas cooler: Removal - Refitting ).
14A-37
ANTIPOLLUTIONExhaust gas recirculation rigid pipe: Removal - Refitting
K9K, and 732
14A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove the engine covers.
Disconnect the battery (see 80A, Battery: Removal -Refitting
Remove:
- the engine undertray,
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter: Removal - refitting ).
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the mounting bolts (1) from the exhaust gas recir-culation pipe,
- the snap-fit clamp (2) using the (Mot. 1567) ,
- the rigid exhaust gas recirculation pipe (3) .
REFITTING
I - REFITTING PREPARATION OPERATION
All the bearing faces must be carefully cleaned.
II - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the rigid exhaust gas recirculation pipe with a newseal,
- the new exhaust gas recirculation pipe mountingbolts,
Fit a new snap-fit clamp.
Tighten the mounting bolts of the rigid exhaust gasrecirculation pipe on the manifold until they makecontact.
Adjust the exhaust gas inlet pipe in relation to thecooler support on the timing end.
Lock the snap-fit clamp of the rigid exhaust gas re-circulation pipe using the (Mot. 1567) .
Tighten to torque the mounting bolts of the rigidexhaust gas recirculation pipe on the manifold (35 Nm ) .
III - FINAL OPERATION
Refit:
- the catalytic converter (see 19B, Exhaust, Cataly-tic converter ),
- the engine undertray.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Refit the engine covers.
Special tooling required
Mot. 1567 Remote operationpliers for EGR clips
Tightening torquesm
mounting bolts of therigid exhaust gas recir-culation pipe on themanifold
35 Nm
113842
WARNING
Always replace:
- the exhaust gas inlet pipe, its seal on the cylin-der head and its snap-fit clamp,
- the seals between the catalytic converter andthe turbocharger.
WARNINGEnsure that you do not squeeze the exhaust gasinlet pipe before fitting the snap-fit clamp.
16A-1
STARTING - LOADAlternator: General information
F4R or F9Q or K4J or K4M or K9K or M9R
16AI - OPERATION
These vehicles are fitted with an alternator with internal ventilation and incorporated regulator, plus a warning light on the instrument panel, which operates as fol-lows:
- when the ignition is switched on, the warning light co-mes on,
- when the engine starts, the warning light goes out,
- if the warning light comes on while the engine is run-ning, this indicates a « charge » fault.
II - IDENTIFICATION
Engine Alternator Currentstrength
K4J and
K4M
VALEO : TG11 C011 110 A
VALEO : TG11 C027
BOSCH : LIE8 0 124 525028
150 A
F4R
VALEO : TG11 C040 110 A
VALEO : TG11 C049
VALEO : SG12 B092 125 A
VALEO : SG12 B098
K9K
VALEO : TG11 C041 110 A
VALEO : TG11 C034
BOSCH : LIE8 0 124 525082
150 A BOSCH : LIE8 0 124 525081
MELCO : 8GM A004 TJ0581
210 A MELCO : 8GM A004 TJ0481
F9Q
VALEO : TG11 C018
110 A VALEO : TG11 C040
VALEO : TG11 C049
VALEO : SG12 B078
125 A VALEO : SG12 B081
VALEO : SG15 B092
VALEO : SG15 B098
BOSCH : LIE8 0 124 525101 150 A
BOSCH : 0 124 525 044
VALEO : SG15 L027 155A
M9R
BOSCH : LIE6 0 124 0AC473B
120A
VALEO : TG15 C059 150 A
MELCO : 8GM A004 TJ0281
210 A
Note:
There is a configuration in the Protection and Swit-ching Unit for the alternator fitted to the vehicle (see87G, Engine compartment connection unit, Pro-tection and Switching Unit ).
Engine Alternator Currentstrength
16A-2
STARTING - LOADAlternator: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
16A
REMOVAL
REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove the engine cover.
Disconnect:
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the electrical connections.
Remove the alternator harness.
Remove:
- the front wheels,
- the right and left-hand wheel arch liners,
- the engine undertray,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
Fit the cooling assembly to the upper cross memberusing the safety belt .
Remove:
- the side stiffener mounting bolts,
- the side reinforcements (1) .
Remove:
- the half sub-frame mounting nuts and bolts (2) ,
- the half sub-frame.
Equipment required
safety belt
Tightening torquesm
alternator mountingbolts
21 Nm
air conditioning com-pressor mounting bolts
21 Nm
free pulley supportmounting bolts
21 Nm
half sub-frame moun-ting bolts
105 Nm
half sub-frame moun-ting nuts
21 Nm
wheel bolts 110 Nm
Note:
When fitting the safety strap, take care:
- not to crush the cooling hoses,
- not to strap up the half sub-frame.
101212
102008
16A-3
STARTING - LOADAlternator: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
16A
Disconnect:
- the pressostat connector (3) ,
- the air conditioning compressor connector (4) ,
Move the electric wiring harness to one side.Remove the air conditioning compressor mountingbolts (5) .
Remove the air conditioning compressor and attachit using a safety belt .
CA or CAREG
109537
19703
Note:
Take care not to constrain the compressor airconditioning pipes during this operation.
16A-4
STARTING - LOADAlternator: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
16A
Remove:
- the free pulley support mounting bolts (6) ,
- the idler pulley support.
OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the alternator mounting bolts (7) ,
- the alternator.
CHAUFO
11107919703
WARNING
Do not damage the cooling unit vanes (radiator,condenser, etc.) during handling.
Note:
To ease alternator removal, slightly move thecooling system towards the front.
16A-5
STARTING - LOADAlternator: Removal - Refitting
K9K, and 722 or 724 or 728 or 729 or 732
16AREFITTING
I - REFITTING PREPARATION OPERATION
Refit the rings (8) using pliers or a vice.
II - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the alternator,
- the alternator mounting bolts.
Torque tighten the alternator mounting bolts ( 21Nm ) .
III - FINAL OPERATION
Refit:
- The air conditioning compressor,
- the air conditioning compressor mounting bolts.
Tighten to torque the air conditioning compressormounting bolts ( 21 Nm )
Connect:
- the pressostat connector,
- the air conditioning compressor connector.
Refit:
- the free pulley support,
- the free pulley support mounting bolts.
Tighten to torque the free pulley support moun-ting bolts ( 21 Nm ) .
Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt ).
Apply a drop of LOCTITE - FRENEBLOC on thesub-frame mounting bolts.
Refit:
- the half sub-frame,
- the side reinforcements.
Tighten to torque:
- the half sub-frame mounting bolts ( 105 Nm ) ,
- the half sub-frame mounting nuts ( 21 Nm ) .
Refit:
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
- the engine undertray,
- the right and left-hand wheel arch liners,
- the front wheels.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect:
- the electrical connections,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Refit the engine cover.
18987
CA or CAREG
CHAUFO
16A-6
STARTING - LOADAlternator: Removal - Refitting
F4R, and 770 or 771 or 776
16A
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)at the windscreen washer fluid reservoir end.
Remove:
- the bumper mountings,
- the bumper.
Disconnect the windscreen washer fluid reservoir pi-pes.
Tightening torquesm
alternator mountingbolts
25 Nm
battery cover mountingbolts
4 Nm
wheel bolts 110 Nm
101212
1
16A-7
STARTING - LOADAlternator: Removal - Refitting
F4R, and 770 or 771 or 776
16A
Disconnect the two connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the front end panel,
- the accessories belt (See 11A, Top and front ofengine, Accessories belt ).
Disconnect the alternator electrical connections.
Remove:
- intercooler air duct (7) ,
- the accessories belt tension wheel.
102504
102365
4
3
2
5
2
666
F4R, and 776
104342
7
16A-8
STARTING - LOADAlternator: Removal - Refitting
F4R, and 770 or 771 or 776
16A
Remove:
- the alternator mounting bolts (8) ,
- the alternator using a screwdriver.
REFITTING
Refit the rings (9) using pliers or a vice to facilitate fit-ting.
Torque tighten the alternator mounting bolts ( 25Nm ) .
Replace the accessories belt.
Tension the accessories belt (see 11A, Top andfront of engine, Accessories belt ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
19703
WARNING
Do not force it against the air conditioning hose:there is a risk of refrigerant fluid escaping.
Note:
To facilitate removal of the alternator, shift thecooling assembly gently forward (be careful notto deform the condenser pipes).
88
18987
WARNING
When replacing the belt, be sure to replace thetension wheels and idler pulleys.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
99
16A-9
STARTING - LOADAlternator: Removal - Refitting
F9Q, and 800 or 804 or 808
16A
REMOVAL
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front wheels,
- the wheel arch liners,
- the half sub-frame side reinforcement (1) ,
- the bumper (see MR 365 Bodywork, 55A, Exte-rior protection, Front bumper ).
Disconnect the screen washer pipes.
Disconnect the connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the mounting (5) ,
- the front end panel mounting bolts (6) ,
- the front end panel,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ).
Disconnect the alternator electrical connections.
Remove the accessories belt tensioning roller.
Tightening torquesm
alternator mountingbolts
25 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
101212
1
102504
102365
54
322
666
16A-10
STARTING - LOADAlternator: Removal - Refitting
F9Q, and 800 or 804 or 808
16A
Remove:
- the alternator mountings (7) ,
- the alternator using a screwdriver.
To facilitate removal of the alternator, shift the coo-ling assembly forward gently (be careful not to da-mage the condenser pipes).
REFITTING
Refit the rings (8) using a vice to facilitate fitting.
Refit the alternator.
Torque tighten the alternator mounting bolts ( 25Nm ) .
Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt ).
Proceed in the reverse order to removal.
Tighten to torque the wheel bolts ( 110 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
19703
77
18987
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
88
16A-11
STARTING - LOADAlternator: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
16A
REMOVALPosition the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- radiator cross member side reinforcement (1) ,
- the bumper.
Disconnect:
- the fog lights connector (if fitted on vehicle),
- the headlight washer pipes (if the fitted on vehicle)at the windscreen washer fluid reservoir end.
Remove:
- the bumper mountings,
- the bumper.
Disconnect the windscreen washer fluid reservoir pi-pes.
Tightening torquesm
alternator mountingbolts
21 Nm
alternator strut moun-ting bolts
21 Nm
nut securing the strut tothe stud on the engineside
21 Nm
battery cover mountingbolts
4 Nm
wheel bolts 110 Nm
101212
1
16A-12
STARTING - LOADAlternator: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
16A
Disconnect the two connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- mounting (5) ,
- impact cross member mounting bolts (6) ,
- the front end panel,
- the accessories belt (See 11A, Top and front ofengine, Accessories belt ).
Disconnect the alternator electrical connections.
Remove the alternator retaining strut.
Remove:
- the alternator mounting bolts (7) ,
- the alternator using a screwdriver.
102504
102365
4
3
2
5
2
666
19703
WARNING
Do not force it against the air conditioning hose:there is a risk of refrigerant fluid escaping.
Note:
To facilitate removal of the alternator, shift thecooling assembly gently forward (be careful notto deform the condenser pipes).
77
16A-13
STARTING - LOADAlternator: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
16AREFITTING
Refit the rings (9) using pliers or a vice to facilitate fit-ting.
Tighten to torque:
- the alternator mounting bolts ( 21 Nm ) ,
- the alternator strut mounting bolts ( 21 Nm ) .
- the nut securing the strut to the stud on the en-gine side ( 21 Nm ) ,
Replace the accessories belt.
Tension the accessories belt (see 11A, Top andfront of engine, Accessories belt ).
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
18987
WARNING
When replacing the belt, be sure to replace thetension wheels and idler pulleys.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - refitting ).
99
16A-14
STARTING - LOADAlternator: Removal - Refitting
B84 or C84, and F4R, and 774
16A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine covers,
- the front right-hand wheel,
- the right-hand wheel arch liner,
- the side stiffener (1) ,
- the fog lights connector,
- the front bumper (see MR 365 Bodywork, 55A,Exterior protection, Front bumper: Removal -Refitting ).
Disconnect the two connectors (2) .
Unclip the bonnet opening cable (3) .
Remove:
- the clip (4) ,
- the mounting (5) ,
- the impact cross member mounting bolt (6) ,
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Disconnect the alternator electrical connections.
Remove the accessories belt tensioning roller.
Tightening torquesm
alternator mountingbolts
25 Nm
wheel mounting bolts 130 Nm
battery cover mountingbolts
4 Nm
Note:
The tensioning roller and the inertia reel must bereplaced when the accessories belt is replaced.
106077
102504
102365
16A-15
STARTING - LOADAlternator: Removal - Refitting
B84 or C84, and F4R, and 774
16A
Remove:
- the alternator mountings (7) ,
- the alternator using a screwdriver.
To ease alternator removal, slightly move the coo-ling system toward the front (be careful not to bendthe condenser pipes).
REFITTING
Refit the rings (8) using pliers or a vice to facilitate fit-ting.
Refit:
- the alternator,
- the alternator mounting bolts.
Tighten to torque the alternator mounting bolts (25 Nm ) .
Refit the new accessories belt.
Refit the accessories belt (see 11A, Top and frontof engine, Accessories belt: Removal - Refitting).
Tighten to torque the wheel mounting bolts ( 130Nm ) .
Proceed in the reverse order to removal.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting .
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
19703
WARNING
The belt must be replaced with a new one if ithas been removed.
18987
16A-16
STARTING - LOADAlternator: Removal - Refitting
M9R, and 700
16A
REMOVAL
I - REMOVAL PREPARATION STAGE
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine protector,
- the front right-hand wheel arch liner,
- the engine undertray.
Remove:
- the right-hand sub-frame side stiffener (1) ,
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ).
Remove the accessories belt (see 11A, Top andfront of engine, Accessories belt: Removal - Re-fitting ).
Tightening torquesm
alternator mountingbolts
25 Nm
positive terminal moun-ting nut
8 Nm
air inlet hose clip on thedamper valve
5.5 Nm
air inlet hose clip on theintercooler
5.5 Nm
turbocharger pressuresensor mounting nut
8 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm 101212
114855
16A-17
STARTING - LOADAlternator: Removal - Refitting
M9R, and 700
16A
Unclip the air inlet scoop (2) .
Remove the Protection and Switching Unit covermounting bolts (3) .
Disconnect the connectors (4) from the Protectionand Switching Unit.
Unfasten the bonnet opening cable (5) .
Remove:
- the clip (6) ,
- the front end panel upper mounting bolt (7) .
Disconnect the screen washer tubes.
Remove:
- the front end panel lower mounting bolts (8) ,
- the front end panel.
Remove the « cooling radiator - condenser -intercooler » assembly from its housing and push itforwards.
114933
112658
102504
102365
16A-18
STARTING - LOADAlternator: Removal - Refitting
M9R, and 700
16A
Disconnect the turbocharging pressure sensor con-nector (9) .
Remove the turbocharger pressure sensor mountingnut on the air inlet valve stay.
Undo the air inlet hose clip on the damper valve.
Remove:
- the air inlet duct clip (10) from the intercooler,
- the air inlet clip mounting bolt (11) from the conden-ser,
- the air inlet duct.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Disconnect the alternator's electrical connector (12).
Remove the positive terminal mounting nut (13) .
Remove the alternator mounting bolts (14) .
Remove the alternator.
114409
114649
114860
114859
16A-19
STARTING - LOADAlternator: Removal - Refitting
M9R, and 700
16AREFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the rings (15) using pliers or a vice to facilitatefitting.
Fit the alternator in place.
Tighten to torque
- the alternator mounting bolts ( 25 Nm ) ,
- the positive terminal mounting nut ( 8 Nm ) .
Connect the alternator electrical connector.
II - FINAL OPERATION
Refit the « Cooling radiator - condenser -intercooler » group in its housing.
Refit the air inlet duct.
Tighten to torque:
- the air inlet hose clip on the damper valve ( 5.5Nm ) ,
- the air inlet hose clip on the intercooler ( 5.5 Nm) .
Tighten the air inlet clip mounting bolt on the con-denser.
Refit the turbocharger pressure sensor on the dam-per valve stay.
Tighten to torque the turbocharger pressure sen-sor mounting nut ( 8 Nm ) .
Connect the turbocharging pressure sensor connec-tor.
Connect the screen washer pipes.
Refit:
- the front end panel,
- front end panel mounting bolts,
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) .
Clip:
- the bonnet opening cable,
- the air inlet scoop.
Refit clips.
Refit:
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting )
- the half sub-frame side stiffener,
- the front right-hand wheel arch liner,
- the engine undertray,
- the engine protector.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
18987
16A-20
STARTING - LOADAlternator pulley: Removal - Refitting
K4J or K4M or K9K, and CA
16A
Parts always to be replaced:
- the accessories belt,
- the tensioning roller,
- the tensioning roller mounting bolts.
essential equipment
- tool box for removing and refitting the alternator pulley(Mot. 1732)
It is essential to replace an alternator decouplingpulley with a decoupling pulley.
REMOVAL
I - REMOVAL PREPARATION OPERATION
Remove the alternator (see 16A, Starting - Char-ging, Alternator: Removal - Refitting ).
Hold the alternator in a vice.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Fit the hexagon socket (1) from the tool box for re-moving and refitting the alternator pulley (Mot. 1732)into the alternator pulley.
Special tooling required
Mot. 1732 Tool for removing andrefitting the alternatorpulley
Tightening torquesm
alternator decouplingpulley
80 Nm
110276
110266
110267
16A-21
STARTING - LOADAlternator pulley: Removal - Refitting
K4J or K4M or K9K, and CA
16A
Fit the drive (2) from the tool box for removing andrefitting the alternator pulley (Mot. 1732) (correspon-ding to the alternator mark) into the hexagon socket(3) .
Position the drive adapter (4) in socket (5) .
Hold the hexagon socket (6) using an open-jawedspanner (7) .
Loosen the decoupling pulley (8) using a ratchet (9)(turning the ratchet clockwise).
Remove the decoupling pulley.
110268
110269
110270
16A-22
STARTING - LOADAlternator pulley: Removal - Refitting
K4J or K4M or K9K, and CA
16AREFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Screw the new decoupling pulley onto the alternatorrotor.
Fit:
- the hexagon socket (10) in the alternator,
- the drive (11) (corresponding to the socket in thealternator rotor),
- the drive adapter (12) onto the drive (11) .
110266
110269
Note:
Check that the torque wrench is capable of tigh-tening in an anticlockwise direction.
16A-23
STARTING - LOADAlternator pulley: Removal - Refitting
K4J or K4M or K9K, and CA
16A
Tighten to torque the alternator decoupling pulley( 80 Nm ) using a torque wrench.
II - FINAL OPERATION
Refit the alternator to the vehicle (see 16A, Starting- Charging, Alternator: Removal - Refitting ).
110266
16A-24
STARTING - LOADStarter: Identification 16A
Engine Starter motor
K4J and K4M VALEO : D7E27
K9K MITSUBISHI
F9Q and F4R VALEO : D7R49
16A-25
STARTING - LOADStarter: Removal - Refitting
F4R, and 770 or 771
16A
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the engine covers.
Disconnect:
- the oil level sensor connector,
- the starter connections,
Remove:
- the starter motor mounting bolts,
- the starter motor.
REFITTING
Check that the centring dowel (1) is in place.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the starter mounting bolts ( 38 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Tightening torquesm
starter mounting bolts 38 Nm
battery cover mountingbolts
4 Nm
14853
101482
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
16A-26
STARTING - LOADStarter: Removal - Refitting
F9Q, and 800 or 808
16A
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front right wheel,
- the battery,
- the battery tray,
- the air hose between the air filter and turbochargerduct,
Remove:
- the air hose (1) and gently separate the hose (2) ,
- the engine tie-bar.
Remove:
- the bracket (3) ,
- the catalytic converter (4) mounting plate on thegearbox,
- the catalytic converter (5) (see 19B, Exhaust, Ca-talytic converter ).
Disconnect the starter motor electrical connections.
Remove:
- the starter motor mounting bolts (6) ,
- the starter motor.
Tightening torquesm
wheel bolts 110 Nm
engine cover mountingbolts
4 Nm
102421
21
101120
102427
3
4
5
6
16A-27
STARTING - LOADStarter: Removal - Refitting
F9Q, and 800 or 808
16AREFITTING
Check that the centring dowel is in place.
Proceed in the reverse order to removal.
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the engine cover mounting bolts ( 4 Nm ) .
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
16A-28
STARTING - LOADStarter: Removal - Refitting
K9K, and 722
16A
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front right-hand wheel.
Remove:
- the catalytic converter stay (1) ,
- catalytic converter stay (2) on the gearbox,
- the catalytic converter (3) (see 19B, Exhaust, Ca-talytic converter ).
Disconnect the starter motor electrical connections.
Remove:
- the starter mountings (4) ,
- the starter (5) .
REFITTING
Check that the centring dowel is in place.
Proceed in the reverse order to removal.
Tighten to torque the starter mounting bolts ( 44Nm ) .
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the wheel bolts ( 110 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Tightening torquesm
starter mounting bolts 44 Nm
wheel bolts 110 Nm
battery cover mountingbolts
4 Nm
104175
1
2
3
102268
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
5
4
16A-29
STARTING - LOADStarter: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
16A
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the air resonator mounting (K4J),
- the air filter outlet duct (K4M),
Disconnect:
- the oil level sensor connector,
- the starter connections,
Remove:
- the starter motor mounting bolts,
- the starter motor.
REFITTING
Check that the centring dowel (1) is in place.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the starter mounting bolts ( 38 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
Tightening torquesm
starter mounting bolts 38 Nm
battery cover mountingbolts
4 Nm
14853
101482
WARNING
carry out the necessary programming (see 80A,Battery: Removing - refitting ).
1
16A-30
STARTING - LOADStarter: Removal - Refitting
F4R, and 776
16A
REMOVALThe engine needs to be removed if the starter motoris being replaced (see 10A, Engine and periphe-rals, Engine - gearbox ).
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter ).
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
Remove:
- the starter mountings (3) ,
- the starter motor.
Tightening torquesm
starter mounting bolts 38 Nm
the catalytic converterdownstream strut nut
21 Nm
heat shield mountingbolts
8.5 Nm
battery cover mountingbolts
4 Nm
106249
2 111
21921
333
16A-31
STARTING - LOADStarter: Removal - Refitting
F4R, and 776
16AREFITTING
Check that the centring dowel (4) is in place.
Proceed in the reverse order to removal.
Tighten to torque:
- the starter mounting bolts ( 38 Nm ) ,
- the the catalytic converter downstream strutnut ( 21 Nm ) ,
- the heat shield mounting bolts ( 8.5 Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
21935
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
4
16A-32
STARTING - LOADStarter: Removal - Refitting
K9K, and 728 or 729
16A
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the engine covers.
Disconnect:
- the starter electrical connections (1)
- the rail pressure sensor (2) .
Disconnect the gearbox earth.
Disconnect the oil level sensor.
Tightening torquesm
starter mounting bolts 44 Nm
battery cover mountingbolts
4 Nm
106205
1
2
106203
106201
16A-33
STARTING - LOADStarter: Removal - Refitting
K9K, and 728 or 729
16A
Remove:
- the starter mountings,
- the starter motor.
REFITTING
Check that the centring dowel is in place.
Proceed in the reverse order to removal.
Tighten to torque the starter mounting bolts ( 44Nm ) .
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
106191
WARNING
carry out the necessary programming (see 80A,Battery: Removal - refitting ).
16A-34
STARTING - LOADStarter: Removal - Refitting
F9Q, and 804
16A
REMOVALPosition the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front right-hand wheel,
- the battery,
- the battery tray,
- the air hose between the air filter and turbochargerduct,
Remove the catalytic pre-converter. (see 19B; Ex-haust, Catalytic pre-converter: Removal - Refit-ting ).
Remove the air duct (1) from the turbocharger.
Remove the turbocharger oil return pipe (2) .
Disconnect the wiring harness from the starter mo-tor.
Remove the starter motor mounting bolts (3) .
Remove the starter motor.
REFITTING
Check that the centring dowel is in place.
Tighten to torque the starter motor mounting bolts( 44 Nm ) .
Tightening torquesm
starter motor mountingbolts
44 Nm
turbocharger oil returnpipe mounting bolts
12 Nm
battery cover mountingbolts
4 Nm
wheel bolts 110 Nm
111860
111865
111868
16A-35
STARTING - LOADStarter: Removal - Refitting
F9Q, and 804
16AProceed in the reverse order to removal.
Replace the turbocharger oil return pipe seals.
Tighten to torque the turbocharger oil return pipemounting bolts ( 12 Nm ) .
Refit the catalytic converter (see 19B, Exhaust, Ca-talytic converter ).
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
16A-36
STARTING - LOADStarter: Removal - Refitting
M9R, and 700
16A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove:
- the engine protectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
- the engine undertray,
- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ).
Drain the coolant circuit using the filling station(see 62A, Air conditioning, Maintenance ).
Remove:
- the Protection and Switching Unit cover mountingbolts (1) ,
- the Protection and Switching Unit cover.
Disconnect the connectors (2) from the Protectionand Switching Unit.
Unfasten the bonnet opening cable (3) .
Remove:
- the clips (4) ,
- the front end panel upper mounting bolts (5) ,
Disconnect the screen washer tubes.
Equipment required
filling station
Tightening torquesm
starter motor mountingbolts
44 Nm
starter base mountingnut
8 Nm
solenoid excitationmounting nut
5 Nm
intercooler downs-tream duct clip on theintercooler
5.5 Nm
intercooler downs-tream duct clip on thedamper valve
5.5 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
battery tray mountingbolts
21 Nm
wiring harness moun-ting nut on the batterytray
8 Nm
112658
102504
16A-37
STARTING - LOADStarter: Removal - Refitting
M9R, and 700
16A
Disconnect the injection computer connector (6) .
Remove:
- the battery tray mounting bolts (7) ,
- the wiring harness mounting nut (8) .
Move the electric wiring harness to one side.
Unclip the wiring harness (9) from the battery - termi-nal.
Remove the battery tray.
Unclip the air inlet scoop (10) .
Remove:
- the front end panel lower mounting bolts (11) .
- the front end panel.
Remove the intercooler downstream duct mountingbolt (12) on the cooling radiator.
Loosen:
- the intercooler downstream duct clip (13) on the in-tercooler,
- the intercooler downstream duct clip on the dampervalve.
Remove the intercooler downstream duct from theintercooler.
Remove the cooling assembly from its housing andpush the assembly forwards.
112659
114933
102365
114649
16A-38
STARTING - LOADStarter: Removal - Refitting
M9R, and 700
16A
Remove the air dehydration canister conditioningpipe mounting bolt (14) from the air conditioningcompressor.
Remove the air dehydration canister conditioningpipe from the air conditioning compressor.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the mounting nut (15) from the starter base,
- the mounting nut (16) from the solenoid excitation.
Remove the earth wire mounting bolt (17) on thestarter.
Move the starter motor wiring harness to one side.
109537
Note:
Plugs must be fitted to the pipe and the compres-sor to prevent moisture from entering the system.
114628
114998
16A-39
STARTING - LOADStarter: Removal - Refitting
M9R, and 700
16A
Remove:
- the starter mounting bolts (18) .
- the starter motor.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Fit the starter.
Tighten to torque the starter motor mounting bolts( 44 Nm ) .
Refit:
- the starter base wire,
- the starter base mounting nut,
- the solenoid excitation wire,
- the solenoid excitation mounting nut,
- the earth wire,
- the earth wire mounting bolt.
Tighten to torque:
- the starter base mounting nut ( 8 Nm ) ,
- the solenoid excitation mounting nut ( 5 Nm ) .
113312
16A-40
STARTING - LOADStarter: Removal - Refitting
M9R, and 700
16AII - FINAL OPERATION
Refit:
- the air dehydration canister conditioning pipe ontothe air conditioning compressor,
- the air dehydration canister conditioning pipemounting bolt onto the air conditioning compressor(see 62A, Air conditioning, Compressor: Remo-val - Refitting ).
Fit the cooling assembly.
Refit:
- the intercooler downstream duct onto the intercoo-ler and damper valve,
- the intercooler downstream duct mounting boltonto the cooling radiator.
Tighten to torque:
- the intercooler downstream duct clip on the in-tercooler ( 5.5 Nm ) ,
- the intercooler downstream duct clip on thedamper valve ( 5.5 Nm ) .
Refit:
- the front end panel,
- the front end panel mounting bolts.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) ,
Clip:
- the air inlet scoop,
- the bonnet opening cable.
Refit:
- the battery tray,
- the battery tray mounting bolts,
- the wiring harness mounting nut onto the batterytray.
Tighten to torque:
- the battery tray mounting bolts ( 21 Nm ) ,
- the wiring harness mounting nut on the batterytray ( 8 Nm )
Clip the battery - terminal wiring harness.
Connect:
- the screen washer pipes,
- the Protection and Switching Unit connectors,
- the injection computer connectors.
Refit:
- the clips,
- the Protection and Switching Unit cover mountingbolts,
- the front bumper (see MR365, Bodywork, 55A,Exterior protection, Front bumper ),
- the engine undertray,
- the engine protectors,
- the battery (see 80A, Battery, Battery: Removal -Refitting ).
Fill the coolant circuit using the filling station (see62A, Air conditioning, Maintenance ).
16A-41
STARTING - LOADStarter: Removal - Refitting
K9K, and 732
16A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment; underbody lift ).
Remove the engine cover.
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove the engine undertray.
Disconnect:
- the oil pressure sensor connector (1) ,
- the oil level sensor connector (2) .
Unclip the diesel fuel drain pipe.
Tightening torquesm
starter motor mountingbolts
44 Nm
113863
106201
16A-42
STARTING - LOADStarter: Removal - Refitting
K9K, and 732
16A
Remove the starter electrical connections (3) .
Disconnect the injector rail pressure sensor connec-tor.
Move the wiring harness against the cylinder block.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the starter mounting bolts (4) .
- the starter motor.
REFITTING
I - REFITTING PREPARATION OPERATION
Check that the centring dowel is in place.
II - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the starter motor,
- the starter mounting bolts.
Tighten to torque the starter motor mounting bolts( 44 Nm ) .
III - FINAL OPERATION
Refit the starter nuts.
Clip on the diesel fuel drain pipe.
Connect:
- injection rail pressure sensor connector,
- the oil level sensor connector,
- the oil pressure sensor connector.
Refit the engine undertray.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Refit the engine cover.
106205
106191
16A-43
STARTING - LOADStarter: Removal - Refitting
B84 or C84, and F4R, and 774
16A
REMOVALDisconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Removal of the starter requires the engine to be re-moved (see 10A, Engine and peripherals, Gear-box - motor assembly: Removal - Refitting ).
Remove the catalytic converter (see 19B, Exhaust,Catalytic converter: Removal - Refitting ).
Remove:
- the heat shield mountings (1) ,
- the heat shield,
- the catalytic converter downstream strut (2) .
Disconnect the starter supply.
Remove:
- the starter mountings (3) ,
- the starter motor.
Tightening torquesm
starter mountings 38 Nm
catalytic converterdownstream stay nut
44 Nm
heat shield mountings 8.5 Nm
106249
21921
16A-44
STARTING - LOADStarter: Removal - Refitting
B84 or C84, and F4R, and 774
16AREFITTING
Check that the centring dowel (4) is in place.
Proceed in the reverse order to removal.
Tighten to torque:
- the starter mountings ( 38 Nm ) ,
- the catalytic converter downstream stay nut (44 Nm ) ,
- the heat shield mountings ( 8.5 Nm ) .
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
21935
17A-1
IGNITIONCoils Removal - Refitting
F4R, and 770 or 771 – K4J, and 730 or 732 – K4M, and 760 or 761
17A
The power module is incorporated in the injection com-puter. The ignition system uses the same sensors asthe injection system.
There are four ignition coils secured directly onto thespark plugs by bolts on the cylinder head cover.
The coils are in series in pairs by the injection com-puter:
- track C M4 for cylinders 1 and 4,
- track C M3 for cylinders 2 and 3.
REMOVAL
Remove the engine covers.
Disconnect:
- the battery starting with the negative terminal.
- the connectors (1) from the ignition coils.
Remove the coil mounting screws (2) .
REFITTING
To refit, proceed in the reverse order of removal.
If necessary, replace the coil O-rings.
Tighten the ignition coil mounting screws to tor-que ( 1.5 daNm ) .
Tighten the battery cover mounting bolts to ( 0.4daNm ) .
Tightening torquesm
ignition coil mountingscrews to torque
1.5 daNm
the battery cover moun-ting bolts to
0.4 daNm
14851
101490
WARNING
Damaged connectors must be replaced.
WARNINGConnect the battery; carry out the necessary pro-gramming ( (see 80A, Battery) ).
2
1
17A-2
IGNITIONCoils Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
17A
The power module is built into the injection computer.The ignition system uses the same sensors as the in-jection system.
There are four ignition coils, and they are mounteddirectly onto the spark plug by a bolt on the rockercover.
The coils are supplied in series two by two by the in-jection computer:
- track C M4 for cylinders 1 and 4,
- track C M3 for cylinders 2 and 3.
REMOVAL
Remove the engine covers.
Disconnect:
- the battery, starting with the negative terminal,
- the ignition coil connectors (1) .
Remove the coil mounting bolts (2) .
Tightening torquesm
ignition coil mountingbolts
15 Nm
battery cover mountingbolts
4 Nm
14851
101490
17A-3
IGNITIONCoils Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
17A
Remove the coil mounting bolts (3) .
REFITTING
Proceed in the reverse order to removal.
F4R, and 776
106589
WARNING
Be sure to replace any damaged connectors.
3333
17A-4
IGNITIONCoils Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
17A
Apply to the four ignition coils a bead (4) of FLUORI-NE GREASE (PART NO. 82 00 168 855) , 2 mm indiameter around the inner edge of the high tensioncap.
If necessary, replace the coil O-rings.
Tighten to torque:
- the ignition coil mounting bolts ( 15 Nm ) ,
- the battery cover mounting bolts ( 4 Nm ) .
106443
4
17A-5
IGNITIONSpark plugs
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
17A
Remove:
- the ignition coils (see 17A, Ignition, Coils ),
- the spark plugs.
Special tooling required
Ele. 1382 Spark plug kit
Tightening torque
Spark plugs
25 to 30 Nm
Engines Brand Type
K4J and K4M EYQUEM RFN58LZ
CHAMPION RC87YCL
Flat skirt with seal
Gap: 0.95 ( ±±±± 0.05 mm )
F4R 770 / 771 CHAMPION RC87YCL
Flat skirt with seal
Gap 0.90 ( ±±±± 0.05 mm )
F4R 776 NGK PFR6G-9
Flat skirt with seal
Gap 0.85 ( ±±±± 0.05 mm )
17B-1
PETROL INJECTIONLocation of components
K4J, and 730 or 732 – K4M, and 760 or 761
17B
K4J, and 730 or 732
101099
31
10 9 8 7
2 654
(1) Fuel vapour recirculation sole-noid valve
(2) Manifold pressure sensor
(3) Motorised throttle valve
(4) Ignition coil
(5) Injection computer
(6) Protection and Switching Unit
(7) Coolant temperature sensor
(8) Pinking sensor
(9) Air temperature sensor
(10) Injector rail and injectors
17B-2
PETROL INJECTIONLocation of components
K4J, and 730 or 732 – K4M, and 760 or 761
17B
K4M, and 760 or 761
101804
11
22 21 20 19
1817
16
15141312
(11) Fuel vapour recirculation sole-noid valve
(12) Camshaft dephaser solenoidvalve
(13) Manifold pressure sensor
(14) Ignition coil
(15) Camshaft position sensor
(16) Motorised throttle valve
(17) Injection computer
(18) Protection and Switching Unit
(19) Coolant temperature sensor
(20) Pinking sensor
(21) Air temperature sensor
(22) Injector rail and injectors
K4J, and 730 or 732
102107
(23) Injection computer
2323
17B-3
PETROL INJECTIONLocation of components
K4J, and 730 or 732 – K4M, and 760 or 761
17B
101493
(24) Injector rail
(25) Injectors
101800
(26) Motorised throttle valve
2525
2525
24
26
101101
(27) Fuel vapour recirculation sole-noid valve
(28) Air temperature sensor
(29) Manifold pressure sensor
(30) Ignition coils
101498
(31) Coolant temperature sensor
(32) Pinking sensor
29
28
30
27
3231
17B-4
PETROL INJECTIONLocation of components
K4J, and 730 or 732 – K4M, and 760 or 761
17B
K4M, and 760 or 761
101810
(33) Injector rail
(34) Injectors
101796
(35) Fuel vapour recirculation sole-noid valve
(36) Manifold pressure sensor
(37) Air temperature sensor
(38) Ignition coils
33
3434
3434
3635
37
3838
3838
101809
(39) Pinking sensor
(40) Camshaft dephaser solenoidvalve
(41) Camshaft position sensor
(42) Coolant temperature sensor
101811
(43) Injection computer
39
40
42
41
43
17B-5
PETROL INJECTIONLocation of components
K4J, and 730 or 732 – K4M, and 760 or 761
17B
K4M, and 760 or 761
102735
(44) Motorised throttle valve
101105
(45) Protection and Switching Unit
44
45
102144
(46) Engine speed and position sen-sor
102204
(47) Accelerator pedal potentiometer
46
47
17B-6
PETROL INJECTIONLocation of components
K4J, and 730 or 732 – K4M, and 760 or 761
17B
101798
(48) Upstream oxygen sensor
101501
(49) Downstream oxygen sensor
(50) Catalytic converter
48
50
49
102483
(51) Fuel vapour recirculation absor-ber
51
17B-7
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
F4R, and 770 or 771
102722
21
11 10 9 8
76543
(1) Fuel vapour recirculation sole-noid valve
(2) Camshaft dephaser solenoidvalve
(3) Manifold pressure sensor
(4) Ignition coil
(5) Motorised throttle valve
(6) Injection computer
(7) Protection and Switching Unit
(8) Coolant temperature sensor
(9) Pinking sensor
(10) Air temperature sensor
(11) Injector rail and injectors
17B-8
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
F4R, and 776
106078
21 20 19 18 17 16
1514132312
22
(12) Ignition coil
(13) Fuel vapour recirculation sole-noid valve
(14) Injection computer
(15) Protection and Switching Unit
(16) Air temperature sensor
(17) Turbocharging pressure sensor
(18) Coolant temperature sensor
(19) Motorised throttle valve
(20) Injector rail and injectors
(21) Pinking sensor
(22) Manifold pressure sensor
(23) Electric water pump
106280
(24) Injection computer
24
17B-9
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
F4R, and 770 or 771
101809
(25) Pinking sensor
(26) Camshaft dephaser solenoidvalve
(27) Camshaft position sensor
(28) Coolant temperature sensor
102730
(29) Injector rail
(30) Injectors
25
26
27
28
29
3030
3030
102732
(31) Pinking sensor
(32) Camshaft dephaser solenoidvalve
102724
(33) Fuel recirculation solenoid valve
(34) Manifold pressure sensor
(35) Air temperature sensor
(36) Ignition coil
31
32
33
34
35
3636
3636
17B-10
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
102735
(37) Throttle valve
102144
(38) Engine speed and position sen-sor
37
38
F4R, and 776
101809
(39) Pinking sensor
(40) Coolant temperature sensor
106269
(41) Injector rail
(42) Injectors
4039
42424242
41
17B-11
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
106633
(43) Motorised throttle valve
106278
(44) Fuel vapour recirculation sole-noid valve
43
44
106787
(45) Manifold pressure sensor
(46) Ignition coils
106279
(47) Turbocharging pressure sensor
(48) Air temperature sensor
46
45
48
47
17B-12
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
101105
(49) Protection and Switching Unit
102204
(50) Accelerator pedal potentiometer
49
50
102483
(51) Fuel vapour recirculation absor-ber
F4R, and 770 or 771
101798
(52) Upstream oxygen sensor
51
52
17B-13
PETROL INJECTIONLocation of components
F4R, and 770 or 771 or 776
17B
101501
(53) Downstream oxygen sensor
(54) Catalytic converter
F4R, and 776
106244
(55) Upstream oxygen sensor
53
54
55
106253
(56) Downstream oxygen sensor
56
17B-14
PETROL INJECTIONOxygen sensors: Removal - Refitting
F4R, and 770 or 771 – K4M, and 760 or 761 – K4J, and 730 or 732
17B
REMOVAL
I - UPSTREAM OXYGEN SENSORS
Remove lambda sensor (1) using the tool (Mot.1495-01) .
II - DOWNSTREAM OXYGEN SENSOR
Remove lambda sensor. (2)
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the oxygen sensor ( 45 Nm )using a 24 mm fork socket for the downstream sen-sor and tool (Mot. 1495-01) for the upstream oxygensensor.
Special tooling required
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Tightening torquesm
oxygen sensor 45 Nm
101798
1
101501
2
17B-15
PETROL INJECTIONOxygen sensors: Removal - Refitting
F4R, and 776
17B
REMOVAL
I - UPSTREAM OXYGEN SENSORS
Remove the front engine cover.
Disconnect the oxygen sensor.
Remove the oxygen sensor (1) using the tool (Mot.1495-01) .
II - DOWNSTREAM OXYGEN SENSOR
Remove:
- the engine undertray,
- the oxygen sensor (2) using (Mot. 1495-01) .
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the oxygen sensors ( 34 Nm )using tool (Mot. 1495-01) .
Special tooling required
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Tightening torquesm
oxygen sensors 34 Nm
106244
1
21926
2
17B-16
PETROL INJECTIONAccelerator pedal potentiometer: Removal - Refitting
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17B
The accelerator pedal potentiometer is incorporated inthe accelerator pedal. If it is replaced, the acceleratorpedal must also be replaced.
There are two types of pedal: with or without a resis-tance point .
Vehicles equipped with cruise control/speed limiterhave an accelerator pedal with a point of resistance atthe end of their travel (kickdown)
This kickdown point is used for exiting the speed limiterfunction if the driver has to increase his speed.
REMOVAL
Disconnect:
- the battery, starting with the negative terminal,
- the accelerator pedal connector.
Remove:
- pedal mounting bolts ,
- the pedal.
REFITTINGProceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Torque tighten the battery cover mounting bolts (4 Nm ) .
Tightening torquesm
battery cover mountingbolts
4 Nm
WARNING
A pedal fitted with a kickdown point may be fitted inplace of a pedal without a kickdown point. Fitting apedal without a resistance point in place of a pedalwith a resistance point is not permitted.
102204
WARNINGCarry out the necessary programming (see 80A,Battery: Removal - refitting ).
Note:
A fault on the accelerator pedal position potentio-meter results in changes in the idle speed orengine operation (see 17B, Petrol injection, Idlespeed correction ).
17B-17
PETROL INJECTIONPosition and speed sensor
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17B
Program the engine flywheel target, after replacingspeed and position sensor (1) or the engineflywheel.
Program with the engine flywheel target after repla-cing speed and position sensor (1) or the engineflywheel
In third gear, accelerate twice in succession to 4000rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, duringdeceleration under no load with the injection cut out,the computer authorises injection again.
Use the diagnostic tool to check that programminghas been carried out correctly ET089: « Programengine flywheel target » .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is working correctly.
Equipment required
diagnostic tool
F4R, and 770 – K4M, and 760 – K4J, and 730 or732
102144
1
F4R, and 776
102485
1
17B-18
PETROL INJECTIONPosition and speed sensor
F4R, and 771 – K4M, and 761
17B
Program the engine flywheel target, after replacingspeed and position sensor (1) or the engineflywheel.
In third gear, accelerate twice in succession to 4000rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, duringdeceleration under no load with the injection cut out,the computer authorises injection again.
Use the diagnostic tool to check that programminghas been carried out correctly ET089: « Programengine flywheel target » .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is operating correctly.
Equipment required
diagnostic tool
102144
Note:
Do not shift the gear lever to « D »
1
17B-19
PETROL INJECTIONPetrol injection computer: Removal - Refitting
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17B
REMOVALRemove the engine covers.
Disconnect the battery, starting with the negativeterminal.
Disconnect the injection computer connectors (1) .
Remove:
- the bolts securing the computer to the mounting,
- the computer.
Remove the battery.
Disconnect the injection computer connectors (2) .
Remove:
- the battery tray (3) mounting bolts,
- the electrical wiring harness (4) .
Unclip the wiring harnesses from the battery tray.
Remove the battery tray.
Equipment required
diagnostic tool
Tightening torquesm
battery tray mountingbolts
21 Nm
battery cover mountingbolts
4 Nm
K4M, and 760 or 761 – K4J, and 730 or 732
102107
1
F4R, and 770 or 771 or 776
101822
222
4
333
17B-20
PETROL INJECTIONPetrol injection computer: Removal - Refitting
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17B
Remove the injection computer (5) and its mounting.
Remove the four computer mounting bolts.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the battery tray mounting bolts (21 Nm ) .
Connect the battery, starting with the positive termi-nal.
Use the diagnostic tool to check that this program-ming has been completed correctly ET051: Throttlestop programming .
Perform flywheel target programming during a roadtest.
In third gear, accelerate twice in succession to 4000rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, duringdeceleration under no load with the injection cut out,the computer authorises injection again.
Use the diagnostic tool to check that programminghas been carried out correctly ET089: « Programengine flywheel target » .
Read the fault codes.
Repair if necessary.
Clear the fault codes.
Check that the vehicle is functioning correctly.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
101811
101890
5 WARNINGCarry out the necessary programming (see 80A,Battery: Removal - Refitting ).
Note:
When the ignition is switched on, the motorisedthrottle valve should go through a cycle of pro-gramming for its minimum and maximum posi-tions.
17B-21
PETROL INJECTIONSpecial notes
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17BSPECIAL NOTES FOR MULTIPOINT INJECTION SAGEM « S3000 »
1 - 128-track computer
It is marked SAGEM and is a type « S3000 » FLASHEEPROM controlling the injection and ignition.
2 - Multipoint injection functioning in sequential mode.
Without cylinder n˚1 marking sensor on the camshaftTherefore, engine phasing is carried out by softwareusing the TDC sensor. Starting the engine in semi-se-quential mode (for engine phasing) then enteringphased sequential mode.
With cylinder n˚1 marking sensor on the camshaft The-refore, engine phasing (cylinder n˚1 recognition) is car-ried out using the cylinder marking sensor signal.Starting the engine in semi-sequential mode (for engi-ne phasing) then entering phased sequential mode.
3 - Injection warning light on the instrument panel
Installation of a special injection warning light (OBD in-dicator light « On Board Diagnostic » ) warning light. Itis part of the « on board diagnostic » OBD fault findingsystem.
4 - Special notes relating to the engine immobiliser
Installation of a third generation engine immobiliser, in-volving a specific computer replacement procedure.
5 - Fuel circuit without return to the tank.
The pressure regulator is located on the « pump/sen-der unit » assembly.
6 - Idle speed (warm engine)
Nominal idle speed
The idle speed is corrected depending on:
- the engine coolant temperature,
- the battery voltage,
- the air conditioning,
- the engine oil pressure (K4M engine).
- the position of the automatic gearbox selector lever(F4R engine).
7 - Maximum speed
a - Engine overspeed protection, cold engine
When the coolant temperature is below 60˚C or for 10seconds after starting, the cut-off value is 5800 rpm .
When the coolant temperature is below 75˚C or for 10seconds after starting, the cut-off value is 5800 rpm .
When the coolant temperature is below 75˚C or for amaximum of 17 minutes after starting, the cut-off valueis 5900 rpm .
F4R, and 770 or 771 or 776 – K4J, and 730 or 732
K4M, and 760 or 761
Engine Engine speed (rpm)
K4J 730 /732
750 +/- 50
K4M 760
K4M 761
700 +/- 30
F4R 770
F4R 771
F4R 776
750 +/- 50
K4J, and 730 or 732
K4M, and 760 or 761
F4R, and 770 or 771 or 776
17B-22
PETROL INJECTIONSpecial notes
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17Bb - Engine overspeed protection, warm engine
Once the engine is warm, the cut-off returns to its nor-mal value:
The cut-off speed is 6500 rpm whichever gear is enga-ged (manual or automatic gearbox).
The cut-off speed is 6000 rpm whichever gear is enga-ged (manual gearbox), and 6300 rpm (automatic gear-box).
8 - Camshaft dephaser
It is continuously varied from 0 to 43˚ of the crankshaft.It is controlled by a solenoid valve supplied by an ope-ning cyclic ratio signal operated by the injection com-puter.
It is controlled by a solenoid valve which is supplied byan all or nothing system from the injection computer.
9 - Operation of the engine cooling fan and the coolant temperature warning light
The request is made from the injection computer throu-gh the multiplex network (coolant temperature centra-lised control function). The engine cooling fan issupplied by the Protection and Switching Unit.
10 - Air conditioning compressor operation
The request is made by the injection computer throughthe multiplex network. The request depends on the airconditioning , but also the coolant temperature. The airconditioning compressor is supplied by the Protectionand Switching Unit.
11 - Operation of the fuel pump
The request is made by the injection computer. It recei-ves its power supply from the Protection and SwitchingUnit.
12 - Cruise control / speed limiter
The configuration of the cruise control / speed limiterand the air conditioning is automatic.
13 - Oxygen sensor
Use of two oxygen sensors located upstream anddownstream of the catalytic converter.
14 - Throttle valve
Correction of the air flow and the idle speed is carriedout by the motorised throttle valve.
15 - Protection and switching unit
It supplies:
- the ignition coils,
- the fuel pump,
- the air conditioning compressor,
- the fan assembly,
- various injection actuators (injectors, fuel vapour ab-sorber solenoid valve, etc.).
The protection and switching unit is located in the engi-ne compartment near the battery. It contributes to theprotection of certain electrical components.
In this capacity, it comprises:
- fuses,
- several internal relays including:
• the « + after ignition feed » relay,
• the fuel pump relay,
• the air conditioning compressor relay
• the engine cooling fan relays,
• the starter relay (starter motor solenoid operation)
These relays cannot be removed.
16 - Injection computer
It constantly receives from the multiplex network, thesignal indicating the electrical power available from thealternator. This is to prevent the vehicle's electricalconsumption from exceeding the capacity of the alter-nator. The aim is to give priority to charging the battery.
K4J, and 730 or 732 – K4M, and 760 or 761
F4R, and 770 or 771 or 776
K4M, and 760 or 761
F4R, and 770 or 771 or 776
17B-23
PETROL INJECTIONSpecial notes
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17B17 - Accelerator pedal
Replacement of the accelerator pedal poses no parti-cular problems.
The computer adopts the value read when the ignitionwas switched on as the no load position reference va-lue.
A twin-track potentiometer is used to inform the com-puter of the accelerator pedal position. It has two trackswith different resistance values. The first track suppliesa voltage of ( 0 to 5 V ) which is double the secondtrack ( 0 to 2.5 V ). The comparison between the twoprovides a check on the consistency of the signal sup-plied.
18 - Idle speed
It is increased by a maximum of 160 rpm if the batteryvoltage is below 12.7 V .
If a manifold pressure sensor fault is present or stored, the idle speed setpoint is:
- 896 rpm (K4J and K4M engines),
- 1024 rpm (F4R engine).
17B-24
PETROL INJECTIONInjection warning light
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17BThe S 3000 injection system manages the lighting ofthree warning lights and the display of warning messa-ges according to the severity of the faults detected,with the aim of informing the customer and directingfault finding.
The injection computer controls the lighting of warninglights and message displays on the instrument panel.These warning lights are lit during the starting phase, inthe event of an injection fault or engine overheating.
The signals to light up the warning lights reach the ins-trument panel via the multiplex network.
WARNING LIGHT OPERATING PRINCIPLE
1 - During the starting phase, press the starter button ( « start » )
The « on board diagnostic » indicator light comes onfor approximately 3 seconds , then goes out.
2 - When there is an injection fault (level 1)
The « check injection » message lights up, followed bythe « service » warning light. This means a reduced le-vel of operation and a limited safety level. Repairsshould be carried out as soon as possible.
These faults are linked to:
- the motorised throttle valve,
- the accelerator pedal potentiometer,
- the inlet pressure sensor,
- the computer,
- the actuator supply,
- the computer supply.
3 - When there is a severe injection fault (level 2)
The red symbol depicting an engine and the « stop »message (display with matrix only) appears with the« faulty injection » text message followed by the« stop » warning light and a buzzer.
4 - When the engine is overheating
The engine temperature fault symbol (display with ma-trix only) lights up with the « engine overheating » textmessage followed by the « stop » warning light and abuzzer. If this happens, the vehicle will stop immedia-tely.
5 - When a fault causing excessive exhaust gas pollution levels is detected
The « on board diagnostic » indicator light depicting an engine lights up:
- « flashing » in the event of a fault which might causedestruction of the catalytic converter (destructive mis-fires). If this happens, the vehicle will stop immedia-tely.
- « continuously » in the event that depollution stan-dards have not been adhered to (polluting enginemisfires, catalytic converter fault, oxygen sensor fault,inconsistency between the oxygen sensors and fuelvapour absorber fault).
17B-25
PETROL INJECTIONImmobiliser function
F4R, and 770 or 771 or 776 – K4M, and 760 or 761 – K4J, and 730 or 732
17BThis vehicle is equipped with an immobiliser which re-quires a specific procedure for replacing the computer.
REPLACING AN INJECTION COMPUTER
To program the immobiliser code (see 82A, Engineimmobiliser, Injection computer: Programming:).
WARNING- The injection computer retains its immobilisercode for life.
- The system has no security code.
- It is forbidden to perform tests with computersborrowed from the Parts Department or fromanother vehicle which must then be returned.
- These computers are permanently coded.
17B-26
PETROL INJECTIONInjection - air conditioning programming
F4R, and 770 or 771 or 776
17BI - INJECTION COMPUTER - AIR CONDITIONING COMPUTER CONNECTION
Climate control is managed by several computers.
The injection computer is responsible for:
- managing the request for cold air in response to pas-senger compartment controls and the circuit pressurelevel.
- determining the power absorbed by the air conditio-ning compressor based on the pressure of the circuit,
- authorising the fan assembly control according to ve-hicle speed and circuit pressure.
- authorising or disables the compressor clutch.
When climate control is activated, the climate controlpanel requests authorisation for air conditioning com-pressor operation.
The injection computer authorises or prevents:
- air conditioning compressor operation,
- fan assembly operation,
- an accelerated idle speed.
This speed depends on the power absorbed by the compressor:
- 900 rpm .
The request to run the fan assembly and compressor ismade by the injection computer via the multiplexnetwork. This request depends on the air conditioningbut also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup-plied by the Protection and Switching Unit.
The data used for the function is exchanged via the multiplex network:
- Track A A4 « CAN HIGH » multiplex connection,
- Track A A3 « CAN LOW » multiplex connection.
The injection computer also receives the refrigerant pressure sensor signal on tracks:
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
II - COMPRESSOR FUNCTION PROGRAMMING
In certain operating phases, the injection computer di-sables the air conditioning compressor.
1 - Performance return programming for hill starts
To facilitate starting on a hill, operation of the air condi-tioning compressor is prevented for 20 seconds .
2 - Maximum engine speed protection programming
Operation of the air conditioning compressor is preven-ted if:
- the instantaneous engine speed is above 6300 rpm ,
- the constant engine speed is above 5760 rpm formore than 10 seconds .
3 - Thermal protection programming
Operation of the air conditioning compressor is preven-ted if the coolant temperature is above 115˚C at highspeed and high load.
Entry conditions:
- Engine speed greater than 4512 rpm ,
- « and » inlet manifold pressure below 700 mbar .
Exit conditions:
- for a time of 10 seconds ,
- « and » certain conditions of the coolant temperaturecentralised management function.
WARNING
The value of parameter PR044: « power absorbedby the AC compressor » is never 0 , irrespectiveof the status of the compressor. The minimum valuereading is approximately 250 to 300 W .
17B-27
PETROL INJECTIONInjection - air conditioning programming
K4J, and 730 or 732
17BI - INJECTION COMPUTER - AIR CONDITIONING COMPUTER CONNECTION
Climate control is managed by several computers.
The injection computer is responsible for:
- managing the request for cold air in response to pas-senger compartment controls and the circuit pressurelevel.
- determining the power absorbed by the air conditio-ning compressor based on the pressure value of thecircuit,
- authorising the fan assembly control according to ve-hicle speed and circuit pressure.
- authorising or disables the compressor clutch.
When climate control is activated, the climate controlpanel requests authorisation for air conditioning com-pressor operation.
The injection computer authorises or prevents:
- air conditioning compressor operation,
- fan assembly operation,
- an accelerated idle speed.
This speed depends on the power absorbed by the compressor:
- 850 rpm .
The request to run the fan assembly and compressor ismade by the injection computer via the multiplexnetwork. This request depends on the air conditioningbut also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup-plied by the Protection and Switching Unit.
The data used for the function is exchanged via the multiplex network:
- Track A A4 « CAN HIGH » multiplex connection,
- Track A A3 « CAN LOW » multiplex connection.
The injection computer also receives the refrigerant pressure sensor signal on tracks:
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
II - COMPRESSOR FUNCTION PROGRAMMING
In certain operating phases, the injection computer di-sables the air conditioning compressor.
1 - Performance return programming for hill starts
To facilitate starting on a hill, operation of the air condi-tioning compressor is prevented for 10 seconds .
2 - Maximum engine speed protection programming
The compressor does not work if:
- the instantaneous engine speed is above 6688 rpm ,
- the constant engine speed is above 6112 rpm formore than 10 seconds .
3 - Thermal protection programming
The compressor does not work if the coolant tempera-ture is above 119˚C at high speed and high load.
Entry conditions:
- engine speed greater than 6496 rpm ,
- « and » inlet manifold pressure below 1046 mbar .
Exit conditions:
- engine speed below 6496 rpm ,
- « and » coolant temperature below 119˚C ,
- « and » inlet manifold pressure below 1046 mbar .
4 - Performance return programming
The compressor is prevented from operating for 5 se-conds .
Entry conditions:
- throttle fully open,
- « and » engine speed below 2016 rpm ,
- « and » engine speed below 10 mph (16 km/h) .
Exit conditions:
- throttle not fully open,
- « or » for a time of 5 seconds ,
- « or » engine speed at or above 2048 rpm ,
- « or » vehicle speed greater than 16 mph (26 km/h) .
5 - Performance return programming for hill starts
To facilitate hill-starting, under certain load and engineoperating conditions, operation of the air conditioningcompressor is prevented for 5 seconds .
WARNING
The value of parameter PR044: « power absorbedby the AC compressor » is never 0 , irrespectiveof the status of the compressor. The minimum valuereading is approximately 250 to 300 W .
17B-28
PETROL INJECTIONInjection - air conditioning programming
K4J, and 730 or 732
17B6 - Maximum engine speed protection programming
The air conditioning compressor does not work if theengine speed is above 6496 rpm .
7 - Thermal protection programming
The air conditioning compressor does not work if thecoolant temperature is above 119˚C at high speed andhigh load.
17B-29
PETROL INJECTIONInjection - air conditioning programming
K4M, and 760 or 761
17BI - INJECTION COMPUTER - AIR CONDITIONING COMPUTER CONNECTION
Climate control is managed by several computers.
The injection computer is responsible for:
- managing the request for cold air in response to pas-senger compartment controls and the circuit pressurelevel.
- determining the power absorbed by the air conditio-ning compressor based on the pressure value of thecircuit,
- authorising the fan assembly control according to ve-hicle speed and circuit pressure.
- authorising or disables the compressor clutch.
When climate control is activated, the climate controlpanel requests authorisation for air conditioning com-pressor operation.
The injection computer authorises or prevents:
- air conditioning compressor operation,
- fan assembly operation,
- an accelerated idle speed.
This speed depends on the power absorbed by the compressor:
- 850 rpm .
The request to run the fan assembly and compressor ismade by the injection computer via the multiplexnetwork. This request depends on the air conditioningbut also on the coolant temperature and vehicle speed.
The engine cooling fan and the compressor are sup-plied by the Protection and Switching Unit.
The data used for the function is exchanged via the multiplex network:
- Track A A4 « CAN HIGH » multiplex connection,
- Track A A3 « CAN LOW » multiplex connection.
The injection computer also receives the refrigerant pressure sensor signal on tracks:
- B J3 refrigerant pressure sensor signal,
- B J2 refrigerant pressure sensor + 5 V supply,
- B K2 refrigerant pressure sensor earth.
The compressor is of variable displacement type.
II - COMPRESSOR FUNCTION PROGRAMMING
In certain operating phases, the injection computer di-sables the air conditioning compressor.
1 - Engine start programming
The compressor is prevented from operating for 10 se-conds after engine start.
2 - Performance return programming
The compressor is prevented from operating for 5 se-conds .
Entry conditions:
- throttle fully open,
- « and » engine speed below 2016 rpm ,
- « and » engine speed below 10 mph (16 km/h) .
Exit conditions:
- throttle not fully open,
- « or » for a time of 5 seconds ,
- « or » engine speed at or above 2048 rpm ,
- « or » vehicle speed greater than 16 mph (26 km/h) .
3 - Performance return programming for hill starts
To facilitate hill-starting, under certain load and engineoperating conditions, operation of the air conditioningcompressor is prevented for 5 seconds .
4 - Maximum engine speed protection programming
The air conditioning compressor does not work if theengine speed is above 6496 rpm .
5 - Thermal protection programming
The air conditioning compressor does not work if thecoolant temperature is above 119˚C at high speed andhigh load.
WARNING
The value of parameter PR044: « power absorbedby the AC compressor » is never 0 , irrespectiveof the status of the compressor. The minimum valuereading is approximately 250 to 300 W .
17B-30
PETROL INJECTIONThrottle valve: Operating
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
17BI - THROTTLE BODY
The throttle valve ensures that idle speed regulationand engine air intake modulation are performed cor-rectly. It is composed of an electric motor and twothrottle position potentiometers.
When the engine is idling, the throttle position is regu-lated according to the idle speed setpoint. This setpointtakes into account the major power consumers (airconditioning) and operating conditions (air temperatureand coolant temperature).
When the driver depresses the accelerator pedal, hisrequest is translated into an angle of throttle opening.
However, to improve driving pleasure, the throttle ope-ning is not directly proportional to the driver’s request.
To eliminate misfires, facilitate gear changes and per-form the safety functions, the throttle valve modulatesthe engine torque.
II - THROTTLE VALVE DEFECT MODES
There are four types of defect mode for the throttle val-ve.
1 - Reduced performance mode
This mode covers electrical faults for which there is aviable backup solution for the injection system (loss ofone of the two tracks on the pedal potentiometer or thethrottle valve). This mode limits acceleration and res-tricts maximum throttle opening (maximum speed of 56mph (90 km/h) (manual gearbox) and 62 mph (100km/h) (automatic transmission).
2 - Loss of driver intervention mode:
This mode is also known as « electrical defect mode ». This mode is applied when the accelerator pedal si-gnal disappears completely, but the injection computerstill controls the intake of air to the engine (automaticthrottle control is still operational). In this mode, the in-jection computer imposes a set accelerator pedal posi-tion for each gear ratio and imposes the idle speedwhen the brake pedal is depressed. In this case themaximum engine speed in neutral is 2500 rpm .
3 - Mechanical limp home mode
This mode covers faults resulting in loss of automaticthrottle control (ie it is impossible to operate the thrott-le). In this case, the throttle is returned to its mechani-cal rest position, the injection computer limits theengine speed by cutting injection and limits torque bycutting out the cylinders (ignition and injection) accor-
ding to the position of the accelerator. Therefore, themaximum engine speed under full load or in neutral is2500 rpm .
4 - Pedal information mode
If the signal from the inlet manifold vacuum is lost, ope-ning of the throttle is directly proportional to pressureon the accelerator pedal.
Note:
Each of these modes results in the injection faultwarning light on the instrument panel lighting up.
17B-31
PETROL INJECTIONIdle speed correction
F4R, and 770 or 771 or 776
17BI - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
(1) Except when starting between 15˚C and 30˚C .
II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE
The purpose of this correction is to compensate for thedrop in voltage due to a power consumer being swit-ched on when the battery is not sufficiently charged. Itstarts when the voltage falls below 12.7 V and may in-crease the engine speed by a maximum of 160 rpm ,i.e. 910 rpm .
III - IDLE SPEED ADJUSTMENT WHEN THERE IS A MANIFOLD PRESSURE SENSOR FAULT
In the event of a manifold pressure sensor fault is set at1024 rpm .
Coolant temperature
( ˚C )
Engine speed
( rpm )
- 20 1072
20 976 (1)
40 896
80 752
100 752
120 848
Note:
If the engine is started when the coolant tempera-ture is between 15˚C and 30˚C and, as a result, theengine speed remains at idle speed, the enginespeed will decrease progressively. This drop inengine speed is due to an antipollution functionwhen the engine is started (oxygen sensor heatingresistors starting).
17B-32
PETROL INJECTIONIdle speed correction
K4J, and 730 or 732
17BI - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
(1) Except when starting between 15˚C and 30˚C .
II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE
The purpose of this correction is to compensate for thedrop in voltage due to a power consumer being swit-ched on when the battery is not sufficiently charged. Itstarts when the voltage falls below 12.7 V and may in-crease the engine speed by a maximum of 160 rpm ,i.e. 910 rpm .
III - IDLE SPEED ADJUSTMENT WHEN THERE IS A MANIFOLD PRESSURE SENSOR FAULT
If the manifold pressure sensor is faulty, the idle speedis set at 896 rpm .
Coolant temperature
( ˚C )
Engine speed
( rpm )
- 20 1152
20 1008 (1)
40 960
80 752
100 752
120 896
Note:
If the engine is started when the coolant tempera-ture is between 15˚C and 30˚C and, as a result, theengine speed remains at idle speed, the enginespeed will decrease progressively. This drop inengine speed is due to an antipollution functionwhen the engine is started (oxygen sensor heatingresistors starting).
17B-33
PETROL INJECTIONIdle speed correction
K4M, and 760 or 761
17BI - IDLE SPEED CORRECTION ACCORDING TO COOLANT TEMPERATURE
(1) Except when starting between 15˚C and 30˚C .
II - ELECTRICAL CORRECTION ACCORDING TO BATTERY VOLTAGE AND ELECTRIC POWER BALANCE
The purpose of this correction is to compensate for thedrop in voltage due to a power consumer being swit-ched on when the battery is not sufficiently charged. Itstarts when the voltage falls below 12.7 V and may in-crease the engine speed by a maximum of 160 rpm ,i.e. to 860 rpm .
III - IDLE SPEED ADJUSTMENT WHEN THERE IS A MANIFOLD PRESSURE SENSOR FAULT
If the manifold pressure sensor is faulty, the idle speedis set at 896 rpm .
Coolant temperature
( ˚C )
Engine speed
rpm )
- 20 1150
20 944 (1)
40 850
80 700
100 700
120 752
Note:
If the engine is started when the coolant tempera-ture is between 15˚C and 30˚C and, as a result, theengine speed remains at idle speed, the enginespeed will decrease progressively. This drop inengine speed is due to an antipollution functionwhen the engine is started (oxygen sensor heatingresistors starting).
17B-34
PETROL INJECTIONAdaptive idle speed correction
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
17BI - ADAPTIVE IDLE SPEED CORRECTION
Principle
In normal warm-engine operating conditions, the idlespeed OCR PR091 varies between a high and low va-lue to obtain the nominal idle speed.
It is possible that following variations in the operation ofthe vehicle (running in, fitting the engine, etc.), that theidle speed opening cyclic ratio could approach to thehighest or lowest values.
Adaptive correction PR090 on the idle speed OCRenables the engine's air requirement to be variedslowly by bringing the opening cyclic ratio back to anaverage nominal value.
This adjustment only takes effect if the coolant tempe-rature is above 75˚C and for 1 minute after enginestart and during the idle speed regulation phase.
II - IDLE SPEED OPENING CYLIC RATIO AND ITS ADAPTIVE CORRECTION
- PR055: « engine speed »
• 750 rpm
- PR032: « Intake pressure »
• 300 mbar < or = X < or = 400 mbar
- PR091: « idle speed regulation theoretic opening cyclic ratio »
• 6 % < or = X < or = 22 %
- PR090: « Idling speed regulation programmed value »
• minimum stop: - 6.25 %
• maximum stop: + 6.25%
III - INTERPRETATION OF THESE PARAMETERS
« If there is excess air » (air leak, incorrectly adjustedthrottle stop, etc.), the engine speed increases at idlingspeed. The idle opening cyclic ratio value decreases toreturn to nominal idle speed; the idle opening cyclic ra-tio adaptive correction decreases to recentre the idleopening cyclic ratio.
« If there is insufficient air » (clogging, etc.), the logic isreversed: the idle opening cyclic ratio and the adaptivecorrection increase, to refocus operation of the idlespeed regulation.
WARNING
After the computer memory has been cleared, it isimperative to start the engine, stop it, then leave itrunning at idle speed so that the adaptive correctioncan recalibrate itself correctly.
17B-35
PETROL INJECTIONRichness regulation
F4R, and 770 or 771 or 776 – K4M, and 760 or 761
17B
An engine operating with the S 3000 computer is fittedwith two oxygen sensors called the upstream sensorand the downstream sensor after their position on thecatalytic converter.
I - SENSOR HEATING
Oxygen sensor heating is controlled by the computer if all of the following conditions are met:
- the inlet manifold pressure is below a threshold whichdepends on a function table of the engine speed,
- the road speed is below ( 84 mph (135 km/h) ,
- after a certain mapped engine operating time whichdepends on the engine's top dead centre (excludingno load operation) and the coolant temperature.
Oxygen sensor heating is stopped if the following con-ditions are met:
- the vehicle speed is greater than 85 mph (140 km/h)(value given for information only),
- when the engine is under heavy load.
II - UPSTREAM SENSOR VOLTAGE
Reading parameter PR098: « upstream oxygen sensor voltage » on the diagnostic tool
The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter. It is expressed in millivolts. Witha « looped engine » (when the engine corrects the rich-ness according to the two sensors, the engine is said tobe « looped » ); the voltage should oscillate quicklybetween two values:
- 100 mV and 450 mV for a lean mixture,
- 450 mV and 900 mV for a rich mixture.
III - DOWNSTREAM SENSOR VOLTAGE
Reading parameter PR099: « downstream oxygen sensor voltage » on the diagnostic tool
The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter, expressed in millivolts.
The function of this sensor is to locate faults on the ca-talytic converter and to perform a second, more preci-se, check on the richness. This second richness checkis called the « slow regulation loop » . This function isactivated only after the engine has been operating for acertain time.
When the engine is « looped » (when the computercorrects the richness according to the two sensors, theengine is said to be « looped » ), the voltage should bein the region of 600 mV (except at idle speed when itmay be difficult to stabilise). When the vehicle is dece-lerating, the voltage should be approximately 100 mV .
IV - RICHNESS CORRECTION
The richness correction value read on the diagnostictool i n p a r a m e t e r PR 138: « RICHNESSCORRECTION » represents the average of the rich-ness corrections applied by the computer dependingon the richness of the fuel mixture as determined bythe oxygen sensor located upstream of the catalyticconverter (the oxygen sensor in fact analyses the oxy-gen content of the exhaust gas).
The centre point of the correction value is 50% and theend value 0 to 100% .
- value less than 50% : request for decrease in rich-ness,
- value above 50% : request for increase in richness.
V - ENTERING RICHNESS REGULATION MODE
1 - Loop mode
Richness regulation starts after a maximum delay of 10seconds and if the coolant temperature is above 10˚C(manual gearbox) and 2.5˚C (automatic gearbox).
Equipment required
diagnostic tool
Note:
The smaller the difference between the minimumand maximum values, the poorer the signal fromthe sensor.
If the difference is small, check the sensor heater.
Note:
Do not take into account the voltage on the dia-gnostic tool at idle speed.
17B-36
PETROL INJECTIONRichness regulation
F4R, and 770 or 771 or 776 – K4M, and 760 or 761
17B2 - Non-loop mode
In mixture regulation mode, the phases of operation during which the computer ignores the value of the vol-tage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
VI - DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT
When the voltage from the oxygen sensor is incorrect(varying only slightly or not at all) during mixture regu-lation, the computer will only enter defect mode if thefault has been recognised as present for 3 minutes .When this happens, parameter PR138: « RICHNESSCORRECTION » is 45 or 60% .
If an oxygen sensor fault is present and recognisedand if the fault has already been stored, the system en-ters the open loop mode directly.
17B-37
PETROL INJECTIONRichness regulation
K4J, and 730 or 732
17B
An engine operating with the S 3000 computer is fittedwith two oxygen sensors called the upstream sensorand the downstream sensor after their position on thecatalytic converter.
I - SENSOR HEATING
Oxygen sensor heating is controlled by the computer if all of the following conditions are met:
- the inlet manifold pressure is below a threshold whichdepends on a function table of the engine speed,
- the speed is below ( 84 mph (135 km/h) ,
- after a certain mapped engine operating time whichdepends on the engine's top dead centre (excludingno load operation) and the coolant temperature.
Oxygen sensor heating is stopped if the following con-ditions are met:
- the vehicle speed is greater than 85 mph (140 km/h)(value given for information only),
- when the engine is under heavy load.
II - UPSTREAM SENSOR VOLTAGE
Reading parameter PR098: « upstream oxygen sensor voltage » on the diagnostic tool
The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter. It is expressed in millivolts. Witha « looped engine » (when the engine corrects the rich-ness according to the two sensors, the engine is said tobe « looped » ); the voltage should oscillate quicklybetween two values:
- 100 mV and 450 mV for a lean mixture,
- 450 mV and 900 mV for a rich mixture.
III - DOWNSTREAM SENSOR VOLTAGE
Reading parameter PR099: « downstream oxygen sensor voltage » on the diagnostic tool
The value read represents the voltage supplied to thecomputer by the oxygen sensor located upstream ofthe catalytic converter, expressed in millivolts.
The function of this sensor is to locate faults on the ca-talytic converter and to perform a second, more preci-se, check on the richness. This second richness checkis called the « slow regulation loop » . This function isactivated only after the engine has been operating for acertain time.
When the engine is « looped » (when the computercorrects the richness according to the two sensors, theengine is said to be « looped » ), the voltage should bein the region of 600 mV (except at idle speed when itmay be difficult to stabilise). When the vehicle is dece-lerating, the voltage should be approximately 100 mV .
IV - RICHNESS CORRECTION
The richness correction value read on the diagnostictool i n p a r a m e t e r PR 138: « RICHNESSCORRECTION » represents the average of the rich-ness corrections applied by the computer dependingon the richness of the fuel mixture as determined bythe oxygen sensor located upstream of the catalyticconverter (the oxygen sensor in fact analyses the oxy-gen content of the exhaust gas).
The centre point of the correction value is 50% and theend value 0 to 100% .
- value less than 50% : request for decrease in rich-ness,
- value above 50% : request for increase in richness.
V - ENTERING RICHNESS REGULATION MODE
1 - Loop mode
The start of richness regulation is effective following aperiod which depends on the engine coolant tempera-ture when the engine is started. At 20˚C , the start ofthe richness loop is effective after approximately 8 se-conds .
Equipment required
diagnostic tool
Note:
The smaller the difference between the minimumand maximum values, the poorer the signal fromthe sensor.
If the difference is small, check the sensor heater.
Note:
Do not take into account the voltage on the dia-gnostic tool at idle speed.
17B-38
PETROL INJECTIONRichness regulation
K4J, and 730 or 732
17B2 - Non-loop mode
In mixture regulation mode, the phases of operation during which the computer ignores the value of the vol-tage from the sensor are:
- at full load,
- under significant loads and at high engine speeds,
- when decelerating with a no load signal,
- when the oxygen sensor is faulty.
VI - DEFECT MODE IN THE EVENT OF AN OXYGEN SENSOR FAULT
When the voltage from the oxygen sensor is incorrect(varying only slightly or not at all) during mixture regu-lation, the computer will only enter defect mode if thefault has been recognised as present for 3 minutes .When this happens, parameter PR138: « RICHNESSCORRECTION » is 45 or 60% .
If an oxygen sensor fault is present and recognisedand if the fault has already been stored, the system en-ters the open loop mode directly.
17B-39
PETROL INJECTIONAdaptive richness correction
K4J, and 730 or 732 – K4M, and 760 or 761
17BI - PRINCIPLE
In looping phase, the richness regulation corrects theinjection time to obtain fuel dosing as close as possibleto a richness of 1. Richness correction value PR138 isclose to 50% , with stop values of 0 and 100% .
Adaptive richness corrections PR143 and PR144 allowthe injection map to be shifted to recentre richness re-gulation at 50 % .
Adaptive corrections take 50% as the average valueafter reinitialising the computer (clearing the memory),and have end values.
Deactivation of the adaptive programs in the case of prolonged idle speed regulation with a hot engine
If the coolant temperature is above 90˚C while idling formore than 10 minutes (K4M engine) and 1 minute(K4J engine), the adaptives are fixed until the end ofidling.
Programming conditions for adaptive richness correction
- Warm engine: coolant temperature above 80˚C ,
- do not exceed an engine speed of 4640 rpm
- disconnect the fuel vapour absorber by the solenoidvalve or block the inlet pipe on the engine.
Following this test the adjustments will be operational.The test should be followed by normal, smooth and va-ried driving over a distance of 3 to 6 miles (5 to 10 km). After the test, read the adaptive values. Initially 50% ,they should have changed. If not, take the readingsagain, taking care to observe the test conditions strict-ly.
Pressure zones which must be passed through during the test
There are five pressure zones to scan during road tes-ting. These zones are defined by the following calibra-tions:
II - INTERPRETING VALUES OBTAINED FROM A ROAD TEST
In the event of a lack of fuel (injectors clogged, pressu-re and fuel flow too low, etc), the richness regulation in-creases to obtain a richness as close as possible to 1and the richness adaptive corrections increase until therichness correction is again fluctuating around 50% .
If there is an excess of fuel, the logic is inverted.
PR138 Richness correction 30%
< or = X < or =
98%
PR143 Richness adaptivegain
25%
< or = X < or =
63%
PR144 Richness adaptiveoffset
25%
< or = X < or =
63%
Range mbar
N˚1 258 to 458 Average 358
N˚2 458 to 536 Average 497
n˚3 536 to 614 Average 575
N˚4 614 to 692 Average 653
N˚5 692 to 813 Average 752
17B-40
PETROL INJECTIONAdaptive richness correction
F4R, and 770 or 771 or 776
17BI - PRINCIPLE
In looping phase, the richness regulation corrects theinjection time to obtain fuel dosing as close as possibleto a richness of 1. Richness correction value PR138 isclose to 50% , with stop values of 0 and 100% .
Adaptive richness corrections PR143 and PR144 allowthe injection map to be shifted to recentre richness re-gulation at 50 % .
Adaptive corrections take 50% as the average valueafter reinitialising the computer (clearing the memory),and have end values.
Deactivation of the adaptive programs in the case of prolonged idle speed regulation with a hot engine
If the coolant temperature is above 80˚C while idling formore than 1 minute , the adaptives are fixed until theend of idling.
Programming conditions for adaptive richness correction
- Warm engine: coolant temperature above 80˚C ,
- Do not exceed an engine speed of 4512 rpm .
- disconnect the fuel vapour absorber by the solenoidvalve or block the inlet pipe on the engine.
Following this test the adjustments will be operational.The test should be followed by normal, smooth and va-ried driving over a distance of 3 to 6 miles (5 to 10 km). After the test, read the adaptive values. They shouldhave changed from their original value of 50 % . If not,take the readings again, taking care to observe the testconditions strictly.
Pressure zones which must be passed through during the test
There are five pressure zones to scan during road tes-ting. These zones are defined by the following calibra-tions:
II - INTERPRETING VALUES OBTAINED FROM A ROAD TEST
In the event of a lack of fuel (injectors clogged, pressu-re and fuel flow too low, etc), the richness regulation in-creases to obtain a richness as close as possible to 1and the richness adaptive corrections increase until therichness correction is again fluctuating around 50% .
If there is an excess of fuel, the logic is inverted.
PR138 Richness correction 23%
< or = X < or =
74%
PR143 Richness adaptivegain
12.5%
< or = X < or =
87.5%
PR144 Richness adaptiveoffset
32%
< or = X < or =
87.5%
Range mbar
N˚1 276 to 398 Average 337
N˚2 398 to 516 Average 457
n˚3 516 to 637 Average 576
N˚4 637 to 753 Average 695
N˚5 753 to 872 Average 812
17B-41
PETROL INJECTIONCentral coolant temperature management 17B
The fan assembly is controlled by the injection compu-ter.
I - ANTI-PERCOLATION FUNCTION
The anti-percolation function is controlled by the injec-tion computer.
The coolant temperature signal used is that from the in-jection system.
After switching the ignition off, the system enters moni-toring mode. If the coolant temperature exceeds thethreshold 103˚C for 5 minutes after the engine hasbeen switched off, the low-speed fan assembly is acti-vated.
After switching the ignition off, the system enters moni-toring mode. If the coolant temperature exceeds 110˚Cfor 2 minutes after the engine has been switched off,the low-speed fan assembly is activated.
If the coolant temperature falls below 100˚C again, thefan assembly relay is cut-out (the fan assembly cannotbe activated for more than 10 minutes ).
II - FAN ASSEMBLY OPERATION
The fan unit is operated at low speed if the coolant tem-perature exceeds 98˚C and stops when the temperatu-re falls below 96˚C .
The fan assembly is operated at high speed if the coo-lant temperature exceeds 102˚C and stops when thetemperature falls below 99˚C .
III - OPERATION OF THE TEMPERATURE WARNING LIGHT
The temperature warning light comes on if the coolanttemperature exceeds 119˚C and goes out when thetemperature falls below 115˚C .
K4J, and 730 or 732 – K4M, and 760 or 761
F4R, and 770 or 771 or 776
17B-42
PETROL INJECTIONCamshaft dephaser: Description
F4R, and 770 or 771 – K4M, and 760 or 761
17BI - SPECIAL NOTES
Its role is to modify the valve timing.
To improve cylinder filling at all speeds, K4M and F4Rengines are fitted with an inlet camshaft dephaser (1) .
Dephasing at the moment when the inlet valves closeoptimises filling according to engine speed. Midrangetorque and output are improved.
Leaving the inlet valves open for longer at high enginespeed allows the mixture to be continually admittedowing to its high speed.
However, at lower engine speeds the gases do nothave a high level of inertia. It is therefore preferable toclose the inlet valves earlier to avoid incorrect fillingand a loss of torque due to the reflux of fresh gases.
The higher the engine speed, the later the inlet valvesmust be closed.
II - OPERATION AND PROGRAMMING
The oil is supplied to the dephaser by a solenoid valve(2) located on the cylinder head.
The supply by a variable opening cyclic ratio signal(amplitude 12 V , frequency 250 Hz ) enables oil to bedistributed to the mechanism and the dephaser angleto be adjusted.
The operation of the camshaft dephaser varies conti-nuously.
The computer supplies the solenoid valve with a varia-ble opening cyclic ratio proportional to the desired de-phasing.
Dephasing is varied continuously from 0 to 43˚ of thecrankshaft.
The camshaft dephaser control solenoid valve is con-trolled if the following conditions are met:
- no speed sensor fault,
- no camshaft position sensor fault,
- no injection system faults,
- after the engine has started,
- outside idling speed and no load,
- threshold of mapping according to load and enginespeed reached,
F4R, and 770 or 771 – K4M, and 760 or 761
102943
K4M, and 760 or 761
1
15200
101814
2
17B-43
PETROL INJECTIONCamshaft dephaser: Description
F4R, and 770 or 771 – K4M, and 760 or 761
17B- coolant temperature between 10 and 120˚C ,
- engine oil temperature too high.
Defect modes:
- dephaser returns to initial position,
- zero dephasing.
III - OPERATION AND PROGRAMMING
The dephaser is controlled in an all or nothing systemby the injection computer using a solenoid valve (3) lo-cated on the rocker cover.
From 1,500 to 4,300 rpm , the computer supplies thesolenoid valve.
Above 4,300 rpm , the solenoid valve is not supplied.The position of the mechanism improves filling at highspeeds. In this position, a locking piston locks the me-chanism.
At rest, the solenoid valve is in the closed position. It authorises the flow of oil to control the dephaser when the following conditions are met:
- no speed sensor fault,
- no camshaft position sensor fault,
- no injection system faults,
- after the engine has started,
- outside idling speed,
- battery voltage > 11.4 V ,
- coolant temperature above 30˚C ,
- engine speed between 1,500 and 4,300 rpm ,
- charge > 87% (approximately 900 mbar ).
WARNING
A solenoid valve jammed open causes an unstableidle speed, manifold pressure which is too high atidle speed and significant engine operating noise.
F4R, and 770 or 771
102732
3
Note:
Up to 1,500 rpm , the solenoid valve is no longersupplied. The mechanism is locked by the piston.As soon as the solenoid valve is supplied, atspeeds above 1,500 rpm , the oil pressure pushesthe locking piston and releases the mechanism.
102736
WARNING
A solenoid valve which is blocked open leads to anunstable idle speed and too high a pressure in themanifold at idling speed.
17B-44
PETROL INJECTIONFault finding warning light activation conditions (when driving) 17B
I - FAULTS CAUSING ACTIVATION OF THE ONBOARD DIAGNOSTIC WARNING LIGHT
1 - Electrical fault
Continuous illumination of the light after several conse-cutive detections of a fault (depending on the compo-nent).
2 - Combustion misfiring that could destroy the catalytic converter
Immediate illumination and flashing of the warning li-ght.
3 - Catalytic converter or oxygen sensor fault, polluting misfires
Continuous illumination of the light after a fault is de-tected three times consecutively.
II - MANAGEMENT OF THE ONBOARD DIAGNOSTIC (OBD) WARNING LIGHT
1 - Warning light comes on
If the same OBD fault is detected during three conse-cutive journeys or there is an electrical fault.
2 - Warning light flashes
If misfires that could destroy the catalytic converter aredetected.
3 - Light goes out
If the OBD fault does not reappear in three consecutivejourneys the warning light goes out, but the fault will bestored in the injection computer.
The fault must not be detected for 40consecutive journeys for the a stored fault to be clea-red from the computer without using the fault finding to-ol.
WARNING
The diagnostics of the catalytic converter and ups-tream oxygen sensor are sequential and are run:
- once when driving (they take several seconds pertest),
- only under certain specific driving conditions.
Under certain driving conditions, it may be the casethat fault finding for certain functions are not perfor-med (e.g. when in a traffic jam).
Note:
The fault may not be re-detected:
- if the fault is fleeting in nature,
- due to the driving style of the customer, which maynot always cover all of the fault detection condi-tions.
17B-45
PETROL INJECTIONConditions for carrying out fault finding (when driving) 17B
I - CONDITIONS FOR ENTERING FAULT FINDING MODE
If, when the ignition is switched on and when driving,the air temperature read by the temperature sensor isnot between -7.5˚C and 119.39˚C , if the coolant tem-perature read by the sensor is not between -7.5˚C and119.39˚C , or if the difference between 1046 mbar andthe manifold pressure is greater than 273 mbar (altitu-de of about 2500 metres), OBD is not authorised untilthe ignition is switched on again.
In order for the On Board Diagnostic system to functioncorrectly, there must be no electrical fault in the injec-tion system, even if the OBD warning light does notcome on.
Fault finding of the oxygen sensor and the catalyticconverter can never be performed at the same time.
When the catalytic converter and oxygen sensor faultfinding procedures are in progress, the fuel vapour ab-sorber bleed is closed and the richness adaptive para-meters are frozen at their last value.
II - TEST PROCEDURE
Before performing the tests, carry out the following in the sequence shown:
- repair all electrical faults,
- clear all faults,
- carry out injection system programming,
- check the OBD system.
III - COMPLETE INITIALISATION OF THE OBD
In order to reinitialise the OBD function, it is necessary to carry out following operations:
- clear stored faults,
- clear OBD faults,
- clear all programming.
IV - PROGRAMMING NECESSARY FOR OBD
Programming must be reinitialised when replacing:
- an injection computer,
- an engine flywheel target,
- an engine speed sensor.
1 - Engine flywheel target programming
In third gear, accelerate twice in succession to 4000rpm , then decelerate to power take-up speed.
Power take-up speed is the moment when, during de-celeration under no load and the injection cut out, thecomputer authorises injection again.
2 - Programming of richness adaptive parameters
To perform this programming, the vehicle must be dri-ven within the pressure ranges (see 17A, Petrol injec-tion, Adaptive richness correction ).
17B-46
PETROL INJECTIONCombustion misfire fault finding 17B
The purpose of detecting misfiring is to detect any mal-functions which could cause hydrocarbon pollutantemissions to exceed the OBD limit, or cause damageto the catalytic converter.
I - THE FAULT FINDING SYSTEM CAN DETECT:
- clogging or flooding of a spark plug,
- clogging of the injectors or an injector flow fault,
- incorrect operation of the supply system (pressure re-gulator, fuel pump, etc.),
- a faulty connection in the petrol or injection circuits(coil secondary, etc.).
II - MEASUREMENT OF ENGINE MISFIRINGS
Fault finding is performed by measuring the instanta-neous variations in engine rotation speed.
If a drop in torque is detected, this is an indication ofmisfiring. Misfiring results in a drop in engine torquebelow a predetermined threshold.
This fault finding is practically continuous while the caris being driven. If it is not carried out, or if a fault is de-tected, all other OBD fault finding (catalytic converterand upstream oxygen sensor) will be prevented.
III - THE FAULT FINDING STRATEGY ENABLES TWO TYPES OF FAULT TO BE DISTINGUISHED:
- Destructive misfiring - over 15% - resulting in catalyticconverter damage. It causes the injection warning li-ght to flash immediately.
- Pollutant misfiring - below 15% - causing the OBDpollution limit to be exceeded. It causes the injectionwarning light to come on if it is detected during threeconsecutive journeys.
IV - CONDITIONS FOR DETECTION
Check that programming has been correctly carriedout.
Check that the prerequisites for switching on the igni-tion and for detecting misfiring correspond.
Detection is carried out as soon as the coolant tempe-rature is above 7.5˚C , in three operating rangesbetween idle speed and 4,500 rpm .
The pollutant misfiring test can also be carried out bymaintaining the engine at idle speed with all the powerconsumers on for 10 minutes .
V - REPAIR CONFIRMATION
Using the tool diagnostic tool , check:
Following this test, if the diagnostic tool has indicatedmisfiring faults DF065 , DF059 , DF060 , DF061 , orDF062 , refer to the appropriate fault finding procedurefor the symptom concerned.
Equipment required
diagnostic tool
Note:
- In comparison to the Sagem 2000 injection, Sagem 3000 has the following functions:
• injection cut-off to cylinders causing misfiring,
• appearance of a fault indicating non-conformityof the flywheel target.
- If distortion of the target is too marked, the compu-ter cannot implement an adjustment that is suffi-cient to detect misfiring correctly.
WARNING
At the end of this test, it is essential that the ignitionis not switched off before the result is read on thediagnostic tool. Switching the ignition off will lead tothe results being misinterpreted.
ET 057 Misfiring on cylinder 1 No
ET 058 Misfiring on cylinder 2 No
ET 059 Misfiring on cylinder 3 No
ET 060 Misfiring on cylinder 4 No
17B-47
PETROL INJECTIONCatalytic converter fault finding 17B
The purpose of catalytic converter fault finding is to de-tect a fault which could cause hydrocarbon pollutantemissions to exceed the OBD limit.
The catalytic converter's capacity to store oxygen is in-dicative of its condition. As the catalytic converterages, its capacity to store oxygen reduces along withits ability to treat pollutant gases.
I - CONDITIONS FOR STARTING FAULT FINDING
Fault finding on the catalytic converter can only be car-ried out after the engine has been running for about 16.5 minutes , and if all the necessary conditions for switching on the ignition are still met:
- no electrical faults,
- no misfiring detected,
- no catalytic converter fault finding performed sincethe ignition was switched on,
- programming has been carried out,
- main loop and double loop active,
- coolant temperature higher than 75˚C ,
- engine speed read by the diagnostic tool as between1472 rpm and 3868 rpm .
II - FAULT DETECTION
Fault finding is carried out when driving under stabi-lised conditions.
When the conditions for starting fault finding are met,richness excitation peaks are applied, which has theeffect of sending bursts of oxygen into the catalyticconverter.
1 - If the catalytic converter is functioning normally
It absorbs oxygen and the voltage of downstream oxy-gen sensor PR099 remains at an average value.
2 - If it needs replacing
It rejects the oxygen and downstream oxygen sensorPR099 starts to pulse. The voltage of the oxygen sen-sor fluctuates (the OBD warning light comes on afterthree journeys).
III - REPAIR CONFIRMATION
If after the test, the diagnostic tool has detected a cata-lytic converter fault DF110: « Catalytic converter »refer to the fault finding procedure for this fault.
WARNING
At the end of this test, it is essential that the ignitionis not switched off before the result is read on thediagnostic tool. Switching off the ignition will lead tothe results being misinterpreted.
17B-48
PETROL INJECTIONOxygen sensor fault finding 17B
The purpose of fault finding on the upstream oxygensensor is to detect faults that would cause emissions ofhydrocarbon, carbon monoxide or nitrogen oxide to ex-ceed the OBD limit. It is carried out by measuring andcomparing periods of upstream oxygen sensor vibra-tion.
I - POSSIBLE CAUSES OF FAULTS
There are possible types of fault in the upstream oxy-gen sensor:
- mechanical damage to an electrical component(breakage, cut in wire) which leads to an electricalfault,
- chemical damage to the component, which causesthe response time of the sensor to slow down, thus in-creasing its switching period.
II - CONDITIONS FOR STARTING FAULT FINDING
When test conditions are reached, the computer takesan average of sensor cycle readings PR121« Average upstream oxygen sensor cycle » , takingaway the effects of interference, which is compared toan average OBD limit cycle.
III - TEST CONDITIONS
Fault finding on the oxygen sensor can only be carried out after the engine has been running for about 15 mi-nutes , and if all the necessary conditions for switching on the ignition are still met:
- no electrical faults detected,
- programming has been carried out,
- no oxygen sensor fault finding performed since theignition was switched on,
- no misfiring detected,
- coolant temperature higher than 75˚C ,
- engine speed given by the diagnostic tool as between1472 rpm and 3868 rpm .
- manifold pressure between 292 mbar and 900 mbar .
IV - FAULT DETECTION
Fault finding is carried out when driving, according tothe conditions previously outlined, and prevents fuelvapours bleeding from the absorber.
V - REPAIR CONFIRMATION
If, after the test, the diagnostic tool has detected anupstream oxygen sensor fault DF092: « Upstreamoxygen sensor circuit » refer to the fault finding pro-cedure for this fault.
Equipment required
diagnostic tool
WARNING
At the end of this test, it is essential that the ignitionis not switched off before the result is read on thediagnostic tool. Switching off the ignition will lead tothe results being misinterpreted.
17B-49
PETROL INJECTIONSpeed limiter: Operating principle 17B
Entry conditions:
- switch in speed limiter position,
- 19 mph (30 km/h) minimum, 125 mph (200 km/h)maximum (guideline only),
- « + » , « - » or « R » buttons pressed.
Exit conditions:
- accelerator depressed firmly (beyond the safety resis-tance point),
- switch in the « off » position,
- « 0 » button depressed,
- injection computer intervention (fault or overspeed),
Note:
If the warning light on the instrument panel flashes,it informs to the driver that the cruising speed can-not be maintained.
19A-1
COOLING SYSTEMGeneral information 19A
When a faulty vehicle arrives, check:
- the condition and tension of the water pump drivebelt,
- that the fan, the radiator and the radiator grille are notobstructed by an object which may impede the flow ofair.
Vehicles in the current range have cooling circuits with the following basic specifications:
- Pressurised sealed circuit (expansion bottle valve),
- circuit using type « D » coolant only.
IMPORTANT
The circuits are designed to be pressurised; takecare at high temperatures (risk of ser ious scalding).
Never remove the valve from the expansion bottlewhile the engine is hot.
Similarly, take care when working under the bonnet,as the radiator fan(s) may start up unexpectedly.
Do not open the bleed valve(s) while the engine isrunning.
WARNING
The coolant helps to keep the engine running pro-perly (heat exchange).
The system does not operate using pure water.
WARNING
Drain with the engine warm.
Flushing and refilling should be carried out with awarm or cold engine.
Never flush a hot engine (risk of serious thermalshock).
WARNING
When carrying out a repair that requires a the cir-cuit to be completely drained, it is essential to flushthe circuit with clean water, blow compressed airthrough the circuit to eliminate water, fill and drainthe circuit and then measure the effective protec-tion.
The criteria to be met are:
- Protection down to - 25˚C ±±±± 2 for cold and tempe-rate climates,
- Protection down to - 40 ˚C ±±±± 2 for very cold clima-tes
Note:
Refer to the vehicle's maintenance service bookletfor information on cooling circuit service intervals.
For any further information, refer to the WorkshopRepair Manual of the vehicle concerned.
Note:
Summary of expansion bottle valve ratings.
Expansion bottle valve with:
• a yellow hand: 1.4 bar
• a white hand: 1.6 bar
• a grey hand: 1.8 bar
Note:
Ready-to-use coolant or antifreeze must be dilutedwith distilled water in accordance with the guideli-nes marked on the container.
19A-2
COOLING SYSTEMSpecifications 19A
Grade and quantity of coolant
Thermostat
Engine Suffix Quantity(litres)
Grade
K4J730
6
GLACEOL RX
(type D).
Only use
coolant
fluid
732
K4M760 6
761 6.5
K9K
722 5.3
728 6.5
729 6.8
732 7.5
F4R
770 6
771 6.5
776
F9Q
800 7.2
804 7.6
808 7.2
M9R 700 7.5
Engine Start of ope-ning (˚C)
End of ope-ning (˚C)
K4J 89 99 ±±±± 2
K4M 89 99 ±±±± 2
K9K 89 99 ±±±± 2
F9Q 89 99 ±±±± 2
F4R 89 99 ±±±± 2
M9R 89 99 ±±±± 2
19A-3
COOLING SYSTEMChecking 19A
I - RECOMMENDATIONS FOR REPAIR II - CHECKING THE CIRCUIT SEALING
Checking the cooling system and the expansion bottle valve
Check the cooling system and the expansion bottlevalve using the cooling system diagnostic and fillingtool (mot. 1700) . For guidance on the use of thistool see NT 3857A, How to use the cooling circuitdiagnostic and filling tool .
IMPORTANT
The circuits are designed to be pressurised; takecare at high temperatures (risk of serious scal-ding).
Never remove the valve from the expansionbottle while the engine is hot.
Similarly, take care when working under the bon-net, as the radiator fan(s) may start up unexpec-tedly.
Do not open the bleed valve(s) while the engineis running.
Note:
The expansion bottle valve must be replaced ifcoolant is leaking from the valve.
107138
Note:
For any further information, refer to the Works-hop Repair Manual of the vehicle concerned.
19A-4
COOLING SYSTEMDiagram
K4J, and 730 or 732 – K4M, and 760 or 761
19A
105003
7
9
9
6
5
8
4
3
2
1
10
(1) Engine
(2) Cooling radiator
(3) Heating radiator
(4) Expansion tank
(5) Water pump
(6) Thermostat
(7) 9 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Automatic gearbox coolant-oilintercooler (if fitted to the vehi-cle)
Note:
The expansion bottle degassing valve rating is 1.4bar .
19A-5
COOLING SYSTEMDiagram
K9K, and 722 or 728 or 729
19A
110741
1
8
2
7
11
10
99
6
5
4
3
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 11 mm choke (K9K 722)
(8) 9 mm by-pass choke (K9K 728 /729)
(9) Bleed screws
(10) Coolant-engine oil intercooler
(11) Coolant-oil intercooler (K9K729)
Note:
The expansion bottle degassing valve rating is 1.4bar .
19A-6
COOLING SYSTEMDiagram
F9Q, and 800 or 808
19A
102269
5
4
3
2
1
8
7
10
9
9
6
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 8 mm choke
(8) 9 mm choke
(9) Bleed screws
(10) Coolant-oil intercooler
Note:
The expansion bottle degassing valve rating is 1.4bar .
19A-7
COOLING SYSTEMDiagram
F4R, and 770 or 771
19A
102740
6
11
54
3
2
1
8
7
10
9
9
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 8.3 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Coolant-oil intercooler
(11) Automatic gearbox coolant-oilintercooler (if fitted to the vehi-cle)
Note:
The expansion bottle degassing valve rating is 1.4bar .
19A-8
COOLING SYSTEMDiagram
F4R, and 776
19A
106628
13
96
5
7
11
3
2
8
1
4
10
129
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 9 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Water-oil intercooler
(11) Thermostat mounting
(12) Turbocharger
(13) Electric water pump
Note
The expansion bottle valve rating is 1.4 bar .
19A-9
COOLING SYSTEMDiagram
F9Q, and 804
19A
112266
139
9
10
12
14
6
2
37
5 1
4
11
8
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) 8 mm choke
(8) 16 mm choke
(9) Bleed screws
(10) Water-oil intercooler
(11) Cylinder head coolant outlet unit
(12) Turbocharger
(13) Exhaust gas cooler
(14) Electric water pump
Note
The expansion bottle valve rating is 1.4 bar .
19A-10
COOLING SYSTEMDiagram
K9K, and 732
19A
112268
1
2
3
4
5
6
7
77
8
9
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) Bleed screws
(8) Water-oil intercooler
(9) Exhaust gas cooler
Note:
The expansion bottle degassing valve rating is 1.4bar .
19A-11
COOLING SYSTEMDiagram
M9R, and 700
19A
114452
(1) Engine
(2) Cooling radiator
(3) Heater radiator
(4) Expansion bottle
(5) Water pump
(6) Thermostat
(7) Choke
(8) Choke
(9) Bleed screws
(10) Water-oil heat exchanger
(11) Exhaust gas recirculation sole-noid valve
Note:
The expansion bottle degassing valve rating is 1.4bar .
19A-12
COOLING SYSTEMCooling circuit: Draining - Refilling 19A
DRAINING
Use the following tools:
- (Car. 1363) ,
- (Mot. 1202-01) ,
- (Mot. 1202-02) ,
- (Mot. 1448) .
Remove the expansion bottle cap.
Open the cooling system at the cooling radiator bot-tom hose using the (Car. 1363) .
Blast compressed air into the circuit through the ex-pansion bottle cap orifice to remove as much wateras possible.
CLEANING
For cleaning (see 19A, Cooling, Cooling system:cleaning).
FILLING
Use GLACEOL RX (TYPE D) coolant.
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for hose clips (largemodel)
Mot. 1202-02 Clip pliers for hose clips (smallmodel)
Mot. 1448 Remote operation pliers for coo-ling system hose clips
Mot. 1700 Cooling system filling and dia-gnostic tool
IMPORTANT
The circuits are designed to be pressurised; takecare at high temperatures (risk of ser ious burns).
Never remove the cap from the expansion bottlewhile the engine is hot.
Similarly, take care when working under the bonnet,as the radiator fan(s) may start up unexpectedly.
Do not open the bleed valve(s) while the engine isrunning.
WARNING
The coolant helps to keep the engine running pro-perly (heat exchange).
The system does not operate using pure water.
WARNING
Drain the fluid with the engine warm.
Flushing and refilling should be carried out with awarm or cold engine.
Never flush a hot engine (risk of serious thermalshock).
WARNING
When carrying out a repair that requires a completechange, it is essential to flush the circuit with cleanwater, blast compressed air through the circuit todrive out the water, fill and bleed the circuit andthen measure the effective protection.
The parameters to be observed are:
- Protection down to - 25˚C ±±±± 2 for cold and tempe-rate climates,
- Protection down to - 40 ˚C ±±±± 2 for very cold clima-tes.
Note:
Before carrying out any operation, protect electricalequipment using plastic bags.
Note:
The engine must be switched off and the air condi-tioning system deactivated to prevent the enginecooling fans operating as soon as the engine isstarted.
19A-13
COOLING SYSTEMCooling circuit: Draining - Refilling 19A
Refill the cooling system using the cooling systemdiagnostic and filling tool (Mot. 1700) . For guidanceon the use of this tool see Technical Note 3857A,Using the cooling system diagnostic and fillingtool .
Fill up the expansion bottle until the coolant over-flows.
Refit the expansion bottle cap.
Bleed the circuit (see 19A, Cooling system, Coo-ling circuit: Bleeding, page 19A-15) .
19A-14
COOLING SYSTEMEngine cooling circuit: Cleaning 19A
CLEANING THE COOLING SYSTEM
To clean the cooling system, fill with water via theexpansion bottle.
Blast compressed air into the circuit through the ex-pansion bottle cap orifice to remove as much wateras possible.
Connect the top and bottom hoses.
IMPORTANT
The circuits are designed to be pressurised; takecare at high temperatures (risk of ser ious burns).
Do not remove the cap from the expansion bottlewhile the engine is hot.
Similarly, take care when working under the bonnet,as the radiator fan(s) may start up unexpectedly.
Do not open the bleed valve(s) while the engine isrunning.
WARNING
Drain the fluid with the engine warm.
Flushing and refilling should be carried out with awarm or cold engine.
Never flush a hot engine (risk of serious thermalshock).
Note:
In some cases it will be necessary to disconnectthe radiator top hose to correctly flush the enginecooling radiator.
19A-15
COOLING SYSTEMCooling circuit: Bleeding 19A
BLEEDING
Run the engine at 1500 rpm , rapidly varying the en-gine speed (until you reach maximum speed) 2 to 3times approximately every 2 minutes until the engi-ne cooling fan starts up for a second time.
Run the engine at 2500 rpm , until the engine coo-ling fan has run three times (time required for auto-matic degassing).
IMPORTANT
Do not open the bleed screw(s) while the engineis running or hot.
Do not open the expansion bottle while theengine is running or hot (above 50˚C ).
Adjust the level, if necessary.
Retighten the expansion bottle cap while theengine is hot.
Using approved equipment, measure the degreeof coolant protection.
Check for any leaks.
Make sure the passenger compartment heatingis working properly.
K9K, and 722 or 728 or 729 or 732
F4R, and 770 or 771 or 776 – F9Q, and 800 or 804or 808 – K4J, and 730 or 732 – K4M, and 760 or761
19A-16
COOLING SYSTEMCooling radiator: Removal - Refitting 19A
REMOVAL
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the front wheels,
- the engine undertray,
- the wheel arch liners.
Disconnect:
- the fog lights connector (if fitted to vehicle),
- the headlight washer pipes (if fitted).
Remove:
- the bumper mountings,
- the bumper.
Disconnect the two connectors (1) .
Unclip the bonnet opening cable (2) .
Remove:
- the clip (3) ,
- the mounting (4) .
Disconnect the windscreen washer pipes.
Special tooling required
Car. 1363 Trim removal lever
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Tightening torquesm
intercooler hose clip 5.5 Nm
battery cover mountingbolts
4 Nm
wheel mounting bolts 110 Nm
F4R, and 776 – F9Q, and 800 or 804 or 808 – K9K,and 722 or 728 or 729 or 732
WARNING
Procedure for removing the air inlet duct on the intercooler:
- risk of leaks and of coming loose if this proce-dure is not adhered to.
- detach the hose using tool (Car. 1363) ,
- do not use degreaser, brake cleaner, or anyother product,
- clean the bearing face on the intercooler andthe hose with a dry, lint-free cloth,
- always replace the clip with a new one.
- replace the new clip in the same position if thehose is not replaced,
- it is essential to replace the hose and/or theintercooler if they are damaged,
102504
43
2
11
19A-17
COOLING SYSTEMCooling radiator: Removal - Refitting 19A
Remove the cross member (5) .
Drain the cooling circuit through the radiator bottomhose.
Disconnect:
- the radiator top hose,
- the expansion bottle hoses on the radiator,
- the fan unit connector.
Disconnect the intercooler inlet ducts (6) and outletducts (7) .
Remove the intercooler.
102365
5
F4R, and 776 – F9Q, and 800 or 804 or 808 – K9K,and 722 or 728 or 729 or 732
102473
102474
6
7
19A-18
COOLING SYSTEMCooling radiator: Removal - Refitting 19A
Separate the condenser from the radiator.
Remove the radiator.
Separate the fan unit from the radiator.
REFITTING
Proceed in the reverse order to removal.
Tighten to torque the intercooler hose clip ( 5.5Nm ) .
For refitting plastic clips, use:
- hose clip pliers (Mot. 1202-01) ,
- hose clip pliers (Mot. 1202-02)
- remote operation hose clip pliers (Mot. 1448) .
Perform the following operations:
- fill the cooling circuit (see 19A, Cooling, Draining- filling the cooling circuit ),
- bleed the cooling circuit (see 19A, Cooling, Blee-ding the cooling circuit ),
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel mounting bolts ( 110 Nm ) .WARNING
Be careful not to damage the air conditioningpiping.
F4R, and 776 – F9Q, and 800 or 804 or 808 – K9K,and 722 or 728 or 729 or 732
WARNING
Ensure that the fins of the cooling unit (radiator,condenser) are not damaged when moved.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
Note
Be sure to initialise the xenon bulb system (if fit-ted on vehicle; see 80C, Xenon bulbs, Xenonheadlight: Adjustment ).
19A-19
COOLING SYSTEMCooling radiator: Removal - Refitting
K9K, and 732
19A
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal- fitting ).
Remove:
- the engine covers,
- the front wheels,
- the engine undertray,
- the right and left-hand wheel arch liners,
- the front bumper (see MR 371 Bodywork, 55A,Exterior protection, Front bumper ).
Disconnect the connectors (1) from the relay board,
Unclip the bonnet opening cable (2) ,
Remove:
- the clip (3) ,
- the mounting (4) .
Disconnect the screen washer pipes.
Remove:
- the front end panel bolts (5) ,
- the front end panel.
Drain the cooling system via the radiator bottom ho-se, using tool (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) .
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Tightening torquesm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
wheel bolts 110 Nm
102504
102365
19A-20
COOLING SYSTEMCooling radiator: Removal - Refitting
K9K, and 732
19A
Disconnect the ducts (6) and (7) from the intercoo-ler.
Remove the intercooler.
Disconnect:
- the cooling radiator top hose,
- the expansion bottle hoses (8) ,
- the fan unit resistor connector (9) .
- the fan unit connector
102473
102474
109537
112661
19A-21
COOLING SYSTEMCooling radiator: Removal - Refitting
K9K, and 732
19A
Separate the condenser from the cooling radiator.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the radiator assembly from the fan unit.
Separate the cooling radiator from the fan unit.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Position the fan unit on the cooling radiator.
Refit the cooling radiator assembly and the fan unit.
II - FINAL OPERATION
Reposition the condenser on the cooling radiator.
Connect:
- the hoses onto the cooling radiator,
- the fan unit connectors;
- the fan unit resistor connector,
Refit the intercooler.
Connect the intercooler ducts.
Refit the front end panel.
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm )
- the front end panel lower mounting bolts ( 44Nm )
Clip the bonnet opening cable
Reconnect:
- the connectors to the relay board,
- the screen washer pipes.
Fill with and bleed the coolant (see 37A, Cooling,Bleeding the cooling circuit ).
Refit:
- the front bumper (see MR 371, Bodywork, 55A,Exterior protection, Front bumper ),
- the right and left-hand wheel arch liners,
- the front wheels,
- the engine covers.
Tighten to torque the wheel bolts ( 110 Nm )
Connect the battery (see 80A, Battery: Removal -Refitting ).
CA or CAREG
WARNING
Be careful not to damage the air conditioningpiping.
CA or CAREG
WARNING
Be careful not to damage the air conditioningpiping.
19A-22
COOLING SYSTEMWater pump: Removal - Refitting
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
19A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting .
Remove:
- the engine undertray,
- the engine covers,
- the front right-hand wheel.
Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining - Refilling ).
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned; Waitapproximately ten minutes, then remove the residueusing a wooden spatula.
Replace the water pump seal every time the waterpump is removed.
Refit:
- the water pump,
- the water pump mounting bolts.
Tightening torquesm
water pump mountingbolts
9 Nm
front right-hand wheelmounting bolts
110 Nm
102422
IMPORTANTDo not scratch the aluminium sealing surfaces.
Wear goggles.
Wear gloves during the operation.
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
Note:
Apply two drops of LOCTITE FRENETANCH tothe water pump mounting bolts.
19A-23
COOLING SYSTEMWater pump: Removal - Refitting
C84 or G84 or S84, and F9Q, and 800 or 804 or 808
19A
Tighten to torque and in order the water pumpmounting bolts ( 9 Nm ) .
Refit:
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Fill the cooling system (see 19A, Cooling, Draining- Filling the cooling system ).
Connect the battery (see 80A, Battery: Removal -Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-ding the cooling system ).
Refit:
- the engine undertrays,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheelmounting bolts ( 110 Nm ) .
102422
19A-24
COOLING SYSTEMWater pump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
19A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove
- the engine covers,
- the front right-hand wheel,
- the engine undertray
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
Remove:
- the timing tensioning roller,
- the water pump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned; waitapproximately ten minutes, then remove the residueusing a wooden spatula.
Tightening torquesm
water pump M8 moun-ting bolt
22 Nm
water pump M6 moun-ting bolts
10 Nm
front right-hand wheelmounting bolts
110 Nm
14505
IMPORTANT
Do not scratch the aluminium sealing surfaces.
Wear goggles.
Wear gloves during the operation.
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
WARNING
Applying excess sealant could cause it to besqueezed out when parts are tightened. The pro-duct-fluid mix may cause damage to some com-ponents (engine, radiator, etc.).
19A-25
COOLING SYSTEMWater pump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
19A
Apply at (1) a bead of LOCTITE 518 mastic 0.6 mmto 1 mm wide.
10063
1
19A-26
COOLING SYSTEMWater pump: Removal - Refitting
K4J, and 730 or 732 – K4M, and 760 or 761
19A
Refit:
- the water pump,
- the water pump mounting bolts.
Pretighten the water pump M6 mounting bolts to 8Nm and the water pump M8 mounting bolts to 8Nm .
Tighten to torque and in order:
- the water pump M8 mounting bolt ( 22 Nm ) ,
- the water pump M6 mounting bolts ( 10 Nm ) .
Refit:
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Fill the cooling system (see 19A, Cooling, Draining- Filling the cooling system ).
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-ding the cooling system ).
Refit the front right-hand wheel
Refit:
- the engine undertray,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheelmounting bolts ( 110 Nm ) .
14505
Note:
Apply one to two drops of LOCTITE FRENE-TANCH to the mounting bolts (1) and (4) of thewater pump.
6
5
4
3
2
1
8
7
19A-27
COOLING SYSTEMWater pump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
19A
REMOVALPosition the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine covers,
- the engine undertray,
- the front right-hand wheel.
Drain the engine cooling system (see 19A, Cooling,Cooling system: Draining-refilling ).
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
Disconnect the alternator electrical connections.
Remove the alternator upper mounting (1) .
Undo the alternator lower mounting (2) .
Tilt the alternator forward.
Remove:
- the inner timing cover mounting bolts (3) ,
- the inner timing cover.
Tightening torquesm
water pump mountingbolts
11 Nm
front right-hand wheelmounting bolts
110 Nm
102267
102266
1
2
33
19A-28
COOLING SYSTEMWater pump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
19A
Remove:
- the water pump mounting bolts (4) ,
- the water pump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any sealant still adhering.
Apply the product to the section to be cleaned; waitapproximately ten minutes, then remove the residueusing a wooden spatula.
Replace the water pump seal every time the waterpump is removed.
Refit:
- the water pump,
- the water pump mounting bolts (1) to (5) .
Tighten to torque and in order the water pumpmounting bolts ( 11 Nm ) .
102262
IMPORTANT
Do not scratch the aluminium sealing surfaces.
Wear goggles.
Wear gloves during the operation.
44
102262
WARNING
The sealing surfaces must be clean, dry and freefrom grease (avoid finger marks).
Note:
Apply two drops of LOCTITE FRENETANCH tothe water pump mounting bolts.
1
5
4
3
2
19A-29
COOLING SYSTEMWater pump: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
19A
Refit:
- the inner timing cover (5) ,
- the timing belt (see 11A, Top and front of engine,Timing belt ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ).
Fill the cooling system (see 19A, Cooling, Draining- Filling the cooling system ).
Connect the battery (see 80A, Battery: Removal -Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-ding the cooling system ).
Refit:
- the engine undertray,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque:
- the front right-hand wheel mounting bolts ( 110Nm )
102266
5
19A-30
COOLING SYSTEMWater pump: Removal - Refitting
F4R, and 770 or 771 or 776
19A
REMOVAL
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting .
Remove:
- the engine undertray,
- the engine covers,
- the front right-hand wheel.
Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining-refilling ).
Remove:
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
Remove:
- the water pump mounting bolts (6) ,
- the water pump.
REFITTING
Clean the gasket faces using DECAPJOINT to dis-solve any seal still adhering.
Apply the product to the section to be cleaned; Waitapproximately ten minutes, then remove the residueusing a wooden spatula.
Replace the water pump seal every time the waterpump is removed.
Refit:
- the water pump,
- the water pump mounting bolts.
Tightening torquesm
water pump mountingbolts
9 Nm
front right-hand wheelmounting bolts
110 Nm
102422
66666
IMPORTANTDo not scratch the aluminium sealing surfaces.
Wear goggles.
Wear gloves during the operation.
WARNING
The gasket faces must be clean, dry and freefrom grease (avoid finger marks).
Note:
Apply two drops of LOCTITE FRENETANCH tothe water pump mounting bolts.
19A-31
COOLING SYSTEMWater pump: Removal - Refitting
F4R, and 770 or 771 or 776
19A
Tighten to torque and in order the water pumpmounting bolts ( 9 Nm ) .
Refit:
- the timing belt (see 11A, Top and front of engine,Timing belt: Removal - Refitting ).
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting ).
Fill the cooling system (see 19A, Cooling, Draining- Filling the cooling system ).
Connect the battery (see 80A, Battery: Removal -Refitting ).
Bleed the cooling system (see 19A, Cooling, Blee-ding the cooling system ).
Refit:
- the engine undertrays,
- the front right-hand wheel,
- the front right-hand wheel mounting bolts.
Tighten to torque the front right-hand wheelmounting bolts ( 110 Nm ) .
102422
5
4
32
1
19A-32
COOLING SYSTEMWater pump: Removal - Refitting
K9K, and 732
19A
REMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine covers,
- the engine undertray.
Drain the cooling circuit via the radiator bottom hose,using (Mot. 1202-01) or (Mot. 1202-02) or (Mot.1448) .
Remove:
- the accessories belt (see 11A, Top and Front ofEngine, Accessories belt ).
- the timing belt (see 11A, Top and front of engine,Timing belt
Loosen the alternator lower mounting bolt by threeturns.
Remove the alternator upper mounting bolt.
Tilt the alternator against the radiator assembly.
Remove:
- the inner timing cover mounting bolts,
- the timing cover.
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Tightening torquesm
water pump mountingbolts
11 Nm
wheel mounting bolts 130 Nm
battery cover mountingbolts
4 Nm 102267
102266
19A-33
COOLING SYSTEMWater pump: Removal - Refitting
K9K, and 732
19AII - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the water pump mounting bolts
- the water pump.
III - CLEANING
REFITTING
I - OPERATION FOR REFITTING PART CONCERNED
Refit:
- the water pump,
- the water pump mounting bolts.
Tighten to torque and in order the water pumpmounting bolts ( 11 Nm ) .
102262
IMPORTANT
- Do not scratch the aluminium sealing surfaces.
- Wear goggles.
- Clean the gasket faces with DECAPJOINT todissolve the part of the gasket still present.
Apply the product to the part to be cleaned, waitapproximately 10 minutes, then remove residueusing a wooden spatula.
WARNING
The water pump seal every time the water pumpis removed.
Note:
Apply one or two drops of LOCTITE FRENE-TANCH to the water pump mounting bolts.
102262
19A-34
COOLING SYSTEMWater pump: Removal - Refitting
K9K, and 732
19AII - FINAL OPERATION
Refit:
- the inner timing cover,
- the alternator,
- the timing belt (see 11A, Top and front of engine:Timing belt ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt ).
Perform the following operations:
- fill the cooling circuit (see 19A, Cooling, Draining- Filling the cooling circuit ),
- bleed the cooling circuit (see 19A, Cooling, Blee-ding the cooling circuit ),
Connect the battery starting with the positive termi-nal (see 80A Battery: Removal - Refitting ).
Tighten to torque:
- the wheel mounting bolts ( 130 Nm )
- the battery cover mounting bolts ( 4 Nm )
102266
WARNING
Carry out the necessary programming.
19A-35
COOLING SYSTEMWater pump: Removal - Refitting
M9R, and 700
19AREMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine undertray,
- the front right-hand wheel,
- the front right-hand wheel arch liner,
- the engine undertray.
Special tooling required
Mot. 1390 Support for removingand refitt ing theengine and gearboxassembly
Tightening torquesm
water pump mountingbolts
25 Nm
water pump pulleymounting bolts
21 Nm
front end panel uppermounting bolts
21 Nm
front end panel lowermounting bolts
44 Nm
WARNING
When carrying out a repair that requires a com-plete change, it is essential to flush the circuitwith clean water, blast compressed air throughthe circuit to drive out the water, fill and bleed thecircuit and then measure the effective protection.
The parameters to be observed are:
- protection down to - 25 ˚C ± 2 for cold and tem-perate countries,
- protection down to - 40 ˚C ± 2 for very coldcountries.
IMPORTANT
The circuits are designed to be pressurised, sobe careful at high temperatures (risk of seriousburns).
Do not remove the cap from the expansion bottlewhile the engine is hot.
When working under the bonnet, be aware thatthe radiator cooling fan(s) may start without war-ning.
Do not open the bleed screw(s) with the enginerunning.
19A-36
COOLING SYSTEMWater pump: Removal - Refitting
M9R, and 700
19A
Remove:
- the right-hand side stiffener mounting bolts,
- the right-hand side stiffener (1) ,
- the rear mounting (see 19D, Suspended enginemounting, Rear mounting: Removal - Refitting).
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ).
Remove the accessories belt (see 11A, Top andfront of engine, Accessories belt: Removal - Re-fitting ).
Unclip the air inlet scoop (2) .
Remove the Protection and Switching Unit covermounting bolts (3) .
101212
114855
114933
112658
19A-37
COOLING SYSTEMWater pump: Removal - Refitting
M9R, and 700
19A
Disconnect the connectors (4) .
Unfasten the bonnet opening cable (5) .
Remove:
- the clip (6) ,
- the mounting (7) .
Disconnect the screen washer tubes.
Drain the cooling system (see 19A, Cooling, Coo-ling system: Draining - Filling ).
Remove:
- the front end panel mounting bolts (8) ,
- the front end panel.
Remove the « Cooling radiator - condenser -intercooler » assembly from its housing and move itforwards.
Fit the (Mot. 1390) on two pads.
Undo
- the right-hand suspended mounting support moun-ting bolts,
- the upper engine tie-bar mounting bolts.
Remove the upper engine tie-bar.
102504 102365
19A-38
COOLING SYSTEMWater pump: Removal - Refitting
M9R, and 700
19A
At the same time, turn the (Mot. 1390) forwards, lif-ting the right-hand suspended engine mounting (9)and bring the compressor pulley (10) level.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the water pump pulley mounting bolts (11) ,
- the water pump pulley (12) .
114863
114858
19A-39
COOLING SYSTEMWater pump: Removal - Refitting
M9R, and 700
19A
Remove:
- the water pump mounting bolts,
- the water pump (13) .
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
The water pump seal must be replaced.
Apply soapy water to the seal before refitting the wa-ter pump.
Refit the water pump.
Check that the water pump is supported by the cylin-der block before tightening the bolts.
Tighten to torque and in order the water pumpmounting bolts ( 25 Nm ) .
Tighten to torque the water pump pulley mountingbolts ( 21 Nm ) .
II - FINAL OPERATION
Position
- the « Engine - Gearbox » assembly on the vehicle,
- the « Cooling radiator - condenser - intercooler »assembly on the half sub-frame.
Refit:
- the right-hand suspended engine mounting (see19D, Engine mounting, Right-hand suspendedengine mounting: Removal - Refitting ).
- the front end panel.
- the front end panel mounting bolts,
Tighten to torque:
- the front end panel upper mounting bolts ( 21Nm ) ,
- the front end panel lower mounting bolts ( 44Nm ) .
Clip:
- the bonnet opening cable,
- the air inlet scoop.
Refit the clips.
Connect the screen washer pipes.
Refit:
- the front bumper (see MR 365 Bodywork, 55A Ex-terior protection, Front bumper ),
- the accessories belt (see 11A, Top and front ofengine, Accessories belt: Removal - Refitting )
- the rear suspended engine mounting (see 19D,Engine mounting, Rear suspended enginemounting: Removal - Refitting ).
- the half sub-frame cross member side stiffener,
- the front right-hand wheel arch liner,
- the engine undertray.
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
114863
WARNING
Clean the pump shaft cooling hole on the cylin-der block.
19A-40
COOLING SYSTEMPlenum chamber: Removal - Refitting
M9R, and 700
19AREMOVAL
I - REMOVAL PREPARATION OPERATION
Position the vehicle on a two-post lift (see 02A, Lif-ting equipment, Underbody lift ).
Remove the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
Disconnect the injection computer connectors (1) .
Remove:
- the battery tray mounting bolts (2) ,
- the wiring harness mounting nut (3) .
Move the wiring harness to one side.
Unpick the wiring harness (4) from the battery - ter-minal.
Remove the battery tray.
Drain the cooling system via the radiator bottomhose using the (Mot. 1202-01) or (Mot. 1202-02) or(Mot. 1448) (see 19A, Cooling, Cooling system:Draining - Filling).
Special tooling required
Mot. 1202-01 Clip pliers for coolingsystem hose clips(large model)
Mot. 1202-02 Pliers for small hoseclips
Mot. 1448 Remote operation clippliers for cooling sys-tem hose clips
Mot. 1700 Cooling circuit fillingand diagnostic tool
Tightening torquesm
coolant outlet unitmounting bolts on thecylinder head
11 Nm
battery tray mountingbolts
21 Nm
wiring harness moun-ting nut
8 Nm
WARNING
When carrying out a repair that requires a completechange, it is essential to flush the circuit with cleanwater, blast compressed air through the circuit todrive out the water, fill and bleed the circuit andthen measure the effective protection.
The parameters to be observed are:
- protection down to -25˚C ±2 for cold and tempe-rate countries,
- protection up to -40˚C ±2 for countries with extre-mely cold climates.
IMPORTANT
The circuits are designed to be pressurised, so becareful at high temperatures (risk of serious burns).
Do not remove the cap from the expansion bottlewhile the engine is hot.
During an operation under the bonnet, be awarethat one (or several) of the radiator cooling fan(s)may operate unexpectedly.
Do not open the bleed screw(s) with the engine run-ning.
112659
19A-41
COOLING SYSTEMPlenum chamber: Removal - Refitting
M9R, and 700
19A
Disconnect the coolant temperature sensor connec-tor (5) .
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove the cooling hose clips using the (Mot.1202-01) or (Mot. 1202-02) or (Mot. 1448) on thecoolant outlet unit.
Disconnect the cooling hoses from the coolant outletunit.
Unpick the wiring harness on the coolant outlet unit.
Remove:
- the coolant outlet unit mounting bolts,
- the coolant outlet unit.
REFITTING
I - REFITTING PREPARATION OPERATION
replace the seal of the coolant outlet unit.
II - REFITTING PART CONCERNED
Remove:
- the coolant outlet unit.
- the coolant outlet unit mounting bolts,
114934
113293
113291
WARNING
The seal faces must be clean, dry and free fromgrease (avoid finger marks).
19A-42
COOLING SYSTEMPlenum chamber: Removal - Refitting
M9R, and 700
19A
Tighten to torque and in order the coolant outletunit mounting bolts on the cylinder head ( 11 Nm) .
Connect the coolant outlet unit cooling hoses.
Refit the cooling hose clips using the (Mot. 1202-01)or (Mot. 1202-02) or (Mot. 1448) on the coolant out-let unit.
III - FINAL OPERATION
Connect the coolant temperature sensor connector.
Refit the battery tray.
Remove:
- the battery tray mounting bolts,
- the wiring harness,
- the wiring harness mounting nut.
Tighten to torque:
- the battery tray mounting bolts ( 21 Nm ) ,
- the wiring harness mounting nut ( 8 Nm ) .
Connect the injection computer connectors.
Clip on the battery - terminal wiring harness.
Refit the battery (see 80A, Battery, Battery: Remo-val - Refitting ).
Fill the cooling system using the (Mot. 1700) (see19A, Cooling, Cooling system: Draining - Refil-ling ).
113291
19B-1
EXHAUSTGeneral information 19B
The whole exhaust pipe is made of stainless steel.
The catalytic converter reaches high temperatures; donot park the vehicle close to flammable materials.
SPECIAL NOTES ON THE EXHAUST PIPE
1 - Exhaust pipe cutting line
The exhaust pipe is a single unit type.
When replacing one of the components, cut the ex-haust pipe:
- correctly identify the area to be cut.
- use the cutting tool correctly (Mot. 1199-01) ,
- correctly position the After-Sales sleeve.
2 - Identifying the cut zone
Two punch marks on the exhaust pipe indicate thearea to be cut (see 19B, Exhaust, General informa-tion on exhausts ).
Before cutting the pipe between the catalytic converterand the expansion chamber, remove the protectiveplate.
Special tooling required
Mot. 1199-01 35/50 mm diameterand 50/95 mm diame-ter exhaust pipe cut-ting tool. Completeassembly in kit.
WARNING
Any damaged heat shields must be replaced.
The sealing between the exhaust manifold and thecatalytic converter must be perfect.
All seals removed must be replaced.
Take care not to damage the catalytic converterduring removal and refitting.
F4R, and 776
109581
109580
19B-2
EXHAUSTGeneral information 19B
Cut zone 1
Cut zone 2Before cutting the pipe, mark the halfway point (D)between marks (P1) and (P2) .
The distance between the two marks is 80 mm
3 - Using tool Mot. 1199-01
Position the tool on the pipe.
Tighten the two bolts on the cutting tool so that it gripsthe exhaust pipe.
Turn the cutting tool with the handle while gripping thepipe.
As the cut is made, continue to tighten the two bolts ofthe tool (do not overtighten the tool against the pipe, toprevent deformation during the cutting operation).
101504
101503
100649
102118
P1
80 mm
D
P2
19B-3
EXHAUSTGeneral information 19B
4 - Special notes on the replacement part
5 - Fitting the After-Sales sleeve
Apply exhaust pipe mastic inside the sleeve.
To prevent any exhaust leaks, position the sleeve cor-rectly on both lugs.
Place the sleeve on the worn section of the pipe. Adjustthe clip diameter by tightening slightly.
Place the sleeve end on the worn section of the pipe.
Adjust the sleeve diameter by tightening gently.
Cut zone 1
Cut zone 2
6 - Special feature of cut zone 2
Remove the bolt securing the rubber mounting bush(2) onto the body.
Lower the exhaust pipe.
Position tool (Mot. 1199-01) on the pipe.
Cut the exhaust pipe .
101960
WARNING
When replacing the middle section of the exhaustpipe (pipe on diesel version, expansion chamber onpetrol versions), the replacement part needs to beshortened by 60 mm .
95478
60 mm
1
101501
101500
19B-4
EXHAUSTGeneral information 19B
Tighten to torque the nut (1) on the exhaust sleeve(25 Nm) .
When tightening to torque, a click indicates that the tor-que of (25 Nm) has been reached.
Check that:
- there is no contact with the underbody,
- the presence and correct positioning of all the ex-haust pipe heat shields.
WARNING
Do not reuse a used bracket.
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must bepositioned so that they cannot come into contactwith the underbody.
Any damaged heat shields must be replaced.
19B-5
EXHAUSTPipe assembly
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
19B
K4J, and 730 or 732
112063
2
1
(1) Cut zone 1
(2) Cut zone 2
K4M, and 760 or 761
112062
1
2
19B-6
EXHAUSTPipe assembly
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
19B
(1) Cut zone 1
(2) Cut zone 2
F4R, and 770 or 771 or 776
112061
1
2
(1) Cut zone 1
(2) Cut zone 2
19B-7
EXHAUSTPipe assembly
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808
19B
K9K, and 722
112060
1
2
(1) Cut zone 1
(2) Cut zone 2
K9K, and 728 or 729 or 732
112059
1
2
19B-8
EXHAUSTPipe assembly
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808
19B
(1) Cut zone 1
(2) Cut zone 2
F9Q, and 800 or 808
112059
1
2
(1) Cut zone 1
(2) Cut zone 2
F9Q, and 804
112058
1
2
19B-9
EXHAUSTPipe assembly
K9K, and 722 or 728 or 729 or 732 – F9Q, and 800 or 804 or 808
19B
(1) Cut zone 1
(2) Cut zone 2
19B-10
EXHAUSTCatalytic pre-converter: Removal - Refitting
F4R, and 776
19B
Remove the engine in order to remove the catalyticpre-converter (see 10A, Engine and peripherals, En-gine - gearbox ).
REMOVAL
Remove:
- the heat shield mountings (1) ,
- the heat shield.
Disconnect the oxygen sensor connectors (2) .
Remove:
- the upper bracket (3) and upstream stays (4) ,
- the catalytic converter/gearbox stay mounting (5) ,
- the catalytic converter mounting nuts, (6) on theturbocharger,
- the catalytic converter.
Remove the oxygen sensor on the workbench.
REFITTING
Refit the oxygen sensors.
Tighten to torque the upstream stay mountingbolts (on the engine) ( 38 Nm ) .
Pretighten in order:
- the upper bracket mounting bolts,
- the nuts securing the catalytic converter to the tur-bocharger,
- the upstream catalytic converter stay mountingbolt.
Tighten to torque and in order:
- the catalytic converter mounting bolt (on theupstream stay) ( 8.5 Nm ) ,
Tightening torquesm
upstream stay moun-ting bolts (on theengine)
38 Nm
catalytic convertermounting bolt (on theupstream stay)
8.5 Nm
upper bracket moun-ting bolt (on the exhaustmanifold)
8.5 Nm
upper bracket moun-ting bolt (on the catalyticconverter)
8.5 Nm
catalytic converter nuts(on the turbocharger)
40 Nm
oxygen sensors 34 Nm
exhaust flange studs 8.5 Nm
106246
111
21926
WARNING
Be sure to replace all the exhaust flange and tur-bocharger sealing joints.
5
3
666
2
4
19B-11
EXHAUSTCatalytic pre-converter: Removal - Refitting
F4R, and 776
19B- the upper bracket mounting bolt (on the ex-haust manifold) ( 8.5 Nm ) ,
- the upper bracket mounting bolt (on the cataly-tic converter) ( 8.5 Nm ) ,
- the catalytic converter nuts (on the turbochar-ger) ( 40 Nm ) ,
- the oxygen sensors ( 34 Nm ) ,
- the exhaust flange studs ( 8.5 Nm ) .
Proceed in the reverse order to removal.
19B-12
EXHAUSTCatalytic pre-converter: Removal - Refitting
F9Q, and 804
19B
Remove:
- the engine covers,
- the battery, starting with the negative terminal,
- the upper engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting: Removal -Refitting ).
Remove:
- the engine undertray,
- the exhaust mounting bolts,
- the front right-hand driveshaft (see 29A, Drives-hafts, Front right-hand driveshaft: Removal -Refitting ).
- the lower engine tie-bar (see 19D, Engine moun-ting, Suspended engine mounting: Removal -Refitting ).
Remove:
- the catalytic pre-converter lower stay mountingbolts (1)
- the catalytic pre-converter lower stay.
Tightening torquesm
connector clip betweenthe turbocharger andthe catalytic pre-conver-ter
20 Nm
catalytic pre-converterupstream stay moun-ting nuts on the engine
30 Nm
catalytic pre-converterupstream stay moun-ting nuts on the cataly-tic pre-converter
30 Nm
catalytic pre-convertergearbox-side downs-tream stay mountingbolts on the engine
50 Nm
catalytic pre-convertergearbox-side downs-tream stay mountingbolts on the catalyticpre-converter
50 Nm
catalytic pre-convertertiming-end downstreamstay mounting bolts onthe engine
50 Nm
catalytic pre-convertertiming-end downstreamstay mounting nuts onthe catalytic pre-conver-ter
30 Nm
catalytic pre-converteroutlet exhaust flangestuds
7 Nm
exhaust flange nuts 21 Nm
battery cover mountingbolts
4 Nm
111864
11
19B-13
EXHAUSTCatalytic pre-converter: Removal - Refitting
F9Q, and 804
19B
Remove:
- the catalytic pre-converter upper stay mountingbolts (2) ,
- the catalytic pre-converter upper stay,
- the turbocharger and catalytic pre-converter moun-ting clip bolt (3) ,
- the catalytic pre-converter.
111862
22
3
19B-14
EXHAUSTCatalytic pre-converter: Removal - Refitting
F9Q, and 804
19BREFITTING
On the workbench, refit the gearbox-side downs-tream stay to the catalytic pre-converter.
Tighten the gearbox-side downstream stay moun-ting bolts on the catalytic pre-converter so that theymake contact.
Fit the catalytic pre-converter to the engine.
Tighten the gearbox-side downstream stay moun-ting bolts on the engine so that they make contact.
Refit:
- the connector clip between the turbocharger andthe catalytic pre-converter,
- the catalytic pre-converter upstream stay.
Pretighten in order:
- the catalytic pre-converter upstream stay mountingnuts on the engine,
- the catalytic pre-converter upstream stay mountingnuts on the catalytic pre-converter,
Loosen then tighten in order and until they make contact:
- the catalytic pre-converter gearbox-side downs-tream stay mounting bolts on the engine,
- the catalytic pre-converter gearbox-side downs-tream stay mounting bolts on the catalytic pre-con-verter.
Refit the catalytic pre-converter downstream stay onthe timing end.
Pretighten in order:
- the catalytic pre-converter timing-end downstreamstay mounting bolts on the engine,
- the catalytic pre-converter timing-end downstreamstay mounting nuts on the catalytic pre-converter,
- the connector clip between the turbocharger andthe catalytic pre-converter.
Tighten to torque:
- the connector clip between the turbocharger
and the catalytic pre-converter ( 20 Nm ) ,
- the catalytic pre-converter upstream staymounting nuts on the engine ( 30 Nm ) ,
- the catalytic pre-converter upstream staymounting nuts on the catalytic pre-converter (30 Nm ) ,
- the catalytic pre-converter gearbox-sidedownstream stay mounting bolts on the engine( 50 Nm ) ,
- the catalytic pre-converter gearbox-sidedownstream stay mounting bolts on the cataly-tic pre-converter ( 50 Nm ) ,
- the catalytic pre-converter timing-end downs-tream stay mounting bolts on the engine ( 50Nm ) ,
- the catalytic pre-converter timing-end downs-tream stay mounting nuts on the catalytic pre-converter ( 30 Nm ) .
Tighten to torque:
- the catalytic pre-converter outlet exhaust flan-ge studs ( 7 Nm ) .
- the exhaust flange nuts ( 21 Nm ) ,
Proceed in the reverse order to removal.
Make sure that there is no contact with the underbo-dy.
Connect the battery, starting with the positive termi-nal.
tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Always replace:
- the catalytic converter seal,
- the connector clip between the turbochargerand the catalytic pre-converter.
Note:
Make sure there is no contact between the cata-lytic pre-converter and the turbocharger oil returnpipe.
WARNING
Any damaged heat shields must be replaced.
WARNING
carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
19B-15
EXHAUSTCatalytic converter: Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
19B
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the engine undertray.
Remove the downstream oxygen sensor.
Cut the exhaust pipe (see 19B, Exhausts, Generalinformation ).
Remove:
- the exhaust bracket mounting nuts (1) ,
- the catalytic converter.
Special tooling required
Mot. 1495-01 22 mm socket forremoving/refitting oxy-gen sensors
Tightening torquesm
oxygen sensor 45 Nm
exhaust bracket studs 7 Nm
exhaust bracket nuts) 21 Nm
battery cover mountingbolts
4 Nm
F4R, and 770 or 771 – K4J, and 730 or 732 – K4M,and 760 or 761
101793
11
19B-16
EXHAUSTCatalytic converter: Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
19BREFITTING
Refit the downstream oxygen sensor.
Tighten to torque the oxygen sensor ( 45 Nm )using the (Mot. 1495-01) .
Refit and tighten to torque if necessary the exhaustbracket studs ( 7 Nm ) .
Fit:
- the catalytic converter,
- the sleeve (see 19B, Exhausts, General informa-tion ).
Proceed in the reverse order to removal.
Tighten to torque the exhaust bracket nuts) ( 21Nm )
Tighten the sleeve while easing the exhaust to ensu-re alignment.
Reconnect the oxygen sensor.
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Refit the engine undertray.
Make sure that there is no contact with the underbo-dy.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must bepositioned so that they cannot come into contactwith the underbody.
Any damaged heat shields must be replaced.
WARNING
Always replace:
- the exhaust bracket seal.
- all the disconnected air inlet plastic pipes.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
19B-17
EXHAUSTCatalytic converter: Removal - Refitting
F9Q, and 800 or 808
19B
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the front right-hand wheel,
- the engine undertray.
Remove the nuts (1) from the exhaust bracket (atthe catalytic converter outlet).
Remove the mounting bolt (2) from the exhaust piperubber mounting bush on the body.
Tightening torquesm
nuts mounting the cata-lytic converter onto theturbocharger
30 Nm
catalytic converter staynut (timing end)
30 Nm
catalytic converter staymounting bolt (timingend)
44 Nm
catalytic converter staymounting nut (flywheelend)
21 Nm
exhaust bracket studs(at the catalytic conver-ter outlet)
7 Nm
exhaust bracket nuts (atthe catalytic converteroutlet)
21 Nm
exhaust pipe supportmounting bolt (on thebody)
21 Nm
battery cover mountingbolts
4 Nm
wheel bolts 110 Nm
101118
Note:
Mark with a pen the position of the exhaust rub-ber mounting bush supports on the vehicle body.
102116
1
2
19B-18
EXHAUSTCatalytic converter: Removal - Refitting
F9Q, and 800 or 808
19B
Remove the (3) silencer rubber mounting bush bolt.
Withdraw the exhaust pipe towards the rear of thevehicle.
Remove the catalytic converter stay mounting bolts(4) (flywheel end).
Remove:
- the catalytic converter stay mounting bolts (5) (timi-ng end),
- the catalytic converter stay (timing end).
Remove the engine tie-bar (6) .
102117
102479
3
44
101120
102313
55
6
19B-19
EXHAUSTCatalytic converter: Removal - Refitting
F9Q, and 800 or 808
19B
Remove:
- the engine lifting bracket,
- the nuts (7) securing the catalytic converter to theturbocharger,
- the catalytic converter from underneath the vehicle.
REFITTING
The order for fitting catalytic converter stays must berespected.
Pretighten in order:
- the catalytic converter stay mounting bolts (timingend),
- the stay mounting bolts (flywheel end),
- the catalytic converter nuts on the turbocharger,
Tighten to torque the nuts mounting the catalyticconverter onto the turbocharger ( 30 Nm ) .
Refitting the stay at the timing end
Tighten to torque and in order:
- the catalytic converter stay nut (timing end) ( 30Nm ) (8) ,
- the catalytic converter stay mounting bolt (timi-ng end) ( 44 Nm ) (9) .
101121
WARNINGDo not reuse an old sleeve.
The « sleeve tightening nuts and bolts » must bepositioned so that they cannot come into contactwith the underbody.
Any damaged heat shields must be replaced.
WARNING
The gaskets must always be replaced.
777
101120
8 9
19B-20
EXHAUSTCatalytic converter: Removal - Refitting
F9Q, and 800 or 808
19BRefitting the stay at the timing end
Tighten to torque and in order the catalytic conver-ter stay mounting nut (flywheel end) ( 21 Nm )(10) .
Proceed in the reverse order to removal.
Tighten to torque:
- the exhaust bracket studs (at the catalytic con-verter outlet) ( 7 Nm ) .
- the exhaust bracket nuts (at the catalytic con-verter outlet) ( 21 Nm ) ,
- the exhaust pipe support mounting bolt (on thebody) ( 21 Nm ) .
Refit the lower engine tie-bar (see 19D, Enginemounting, Suspended engine mounting ).
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Make sure that there is no contact with the underbo-dy.
Connect the battery, starting with the positive termi-nal.
Tighten to torque:
- the battery cover mounting bolts ( 4 Nm ) ,
- the wheel bolts ( 110 Nm ) .
102479
Note:
Make sure there is no contact between the cata-lytic conver ter and the turbocharger oil returnpipe.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
10
19B-21
EXHAUSTCatalytic converter: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
19B
REMOVALPut the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the engine undertray.
Remove:
- the exhaust pipe bracket mounting bolts (1) ,
- the catalytic converter stay mounting bolt (2) .
Loosen the other stay mountings on the gearbox.
Remove the stay (3) .
Tightening torquesm
turbocharger outletstuds
7 Nm
catalytic convertermounting nuts on theturbocharger
26 Nm
upstream stay moun-ting bolts on the engine
44 Nm
downstream staymounting bolts on thegearbox
21 Nm
upstream stay moun-ting bolt on the catalyticconverter
25 Nm
downstream staymounting bolt on thecatalytic converter
21 Nm
bolt securing theexhaust pipe bracketonto the body
21 Nm
catalytic converter out-let exhaust bracketstuds
7 Nm
exhaust bracket nuts 21 Nm
ball joint bracket boltswith their springs
21 Nm
battery cover mountingbolts
4 Nm
102076
3
2
1
19B-22
EXHAUSTCatalytic converter: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
19B
Remove the mounting bolt (4) from the exhaust piperubber mounting bush on the body.
Remove the mounting bolt (5) from the silencer rub-ber mounting bush.
Withdraw the exhaust pipe towards the rear of thevehicle.
Remove:
- the catalytic converter upstream stay mountingbolts,
- the catalytic converter stay (6) ,
- the catalytic converter mounting nuts on the turbo-charger (7) ,
- the catalytic converter.
102116
Note:
Mark with a pen the position of the exhaust rub-ber mounting bush supports on the vehicle body.
102117
4
5
102077
19B-23
EXHAUSTCatalytic converter: Removal - Refitting
K9K, and 722 or 728 or 729 or 732
19BREFITTING
Tighten to torque the turbocharger outlet studs ( 7Nm ) .
Fit the catalytic converter.
Pretighten in order:
- the upstream stay bolts on the engine,
- the upstream stay bolts on the catalytic converter,
- the downstream stay bolts on the gearbox,
- the downstream stay bolts on the catalytic conver-ter,
- the catalytic converter/turbocharger mounting nuts.
Tighten to torque and in order
- the catalytic converter mounting nuts on theturbocharger ( 26 Nm ) ,
- the upstream stay mounting bolts on the engine( 44 Nm ) ,
- the downstream stay mounting bolts on thegearbox ( 21 Nm ) ,
- the upstream stay mounting bolt on the cataly-tic converter ( 25 Nm ) ,
- the downstream stay mounting bolt on the cata-lytic converter ( 21 Nm ) ,
- the bolt securing the exhaust pipe bracket ontothe body ( 21 Nm ) ,
Tighten to torque:
- the catalytic converter outlet exhaust bracketstuds ( 7 Nm ) ,
- the exhaust bracket nuts ( 21 Nm ) .
Tighten to torque the ball joint bracket bolts withtheir springs ( 21 Nm ) .
Proceed in the reverse order to removal.
Refit the engine undertray.
Make sure that there is no contact with the underbo-dy.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Always replace:
- the catalytic converter seal,
- the turbocharger - catalytic converter bracketstuds.
Note:
Make sure there is no contact between the cata-lytic conver ter and the turbocharger oil returnpipe.
K9K, and 722 or 728 or 729
K9K, and 732
WARNING
Any damaged heat shields must be replaced.
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
19B-24
EXHAUSTCatalytic converter: Removal - Refitting
M9R, and 700
19BREMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery, Battery:Removal - Refitting ).
Remove:
- the engine protectors,
- the scuttle panel grille (see MR 365 Bodywork,55A, Exterior protection, Scuttle panel grille ),
- the acoustic protection clips on the scuttle panelpartition,
- the acoustic protection.
Remove:
- the nuts (1) mounting the catalytic converter to theturbocharger,
- the engine undertray.
Equipment required
roller-type stud removal tool
safety belt
Tightening torquesm
studs on the turbochar-ger
14.5 Nm
catalytic convertermounting clamp moun-ting bolts on the cylinderblock
21 Nm
catalytic convertermounting nuts on theturbocharger
21 Nm
catalytic converter half-clamp mounting bolts
21 Nm
stay mounting bolt onthe catalytic converter
8 Nm
stay mounting nuts onthe cylinder block
21 Nm
stay mounting nuts onthe catalytic converter
21 Nm
bolts of the ball-jointedbracket with springs
21 Nm
silencer rubber moun-ting bush mounting bolt
21 Nm
exhaust pipe rubbermounting bush moun-ting bolt
21 Nm
IMPORTANT
Wear protective gloves during all operations.
114986
19B-25
EXHAUSTCatalytic converter: Removal - Refitting
M9R, and 700
19B
Remove:
- the lower engine tie-bar (see 19D, Engine moun-ting, rear suspended engine mounting: Remo-val - Refitting ).
- the catalytic converter stay mounting bolt (2) ,
- the catalytic converter stay mounting nuts (3) ,
- the nuts (4) mounting the stay on the cylinderblock,
- the catalytic converter stay,
- the catalytic converter studs using a roller-typestud removal tool .
Remove the bolts from the ball-jointed bracket (5)with springs.
114771 114991
19B-26
EXHAUSTCatalytic converter: Removal - Refitting
M9R, and 700
19B
Remove:
- the exhaust pipe rubber mounting bush mountingbolt (6) ,
- The silencer rubber mounting bush mounting bolt(7) .
Detach the exhaust pipe.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the catalytic converter half-clamp mounting bolts(8) ,
- the catalytic converter half-clamps (9) .
Remove the catalytic converter, timing end.
Fit the catalytic converter using a safety belt to thelifting eye on the timing end.
102116
102117
Note:
Mark with a pen the position of the exhaust rub-ber mounting bush supports on the vehicle body.
114980
19B-27
EXHAUSTCatalytic converter: Removal - Refitting
M9R, and 700
19B
Remove:
- the catalytic converter mounting clamp mountingbolts (10) ,
- the catalytic converter mounting clamps.
Remove the safety belt .
Move the engine towards the front of the vehicle.
Remove the catalytic converter.
REFITTING
I - REFITTING PREPARATION OPERATION
Remove the seal from the ball-jointed bracket.
Remove the turbocharger studs using a roller-typestud removal tool .
Clean and degrease the bearing faces:
- on the exhaust pipe,
- on the catalytic converter in case of reuse,
- the turbocharger,
Refit the new studs onto the turbocharger using aroller-type stud removal tool .
Tighten to torque the studs on the turbocharger (14.5 Nm ) .
Fit the new catalytic converter mounting clamps ontothe cylinder block.
Finger tighten the catalytic converter mountingclamp mounting bolts on the cylinder block until con-tact is made.
Tighten to torque the catalytic converter mountingclamp mounting bolts on the cylinder block ( 21Nm ) .
114981
114843
19B-28
EXHAUSTCatalytic converter: Removal - Refitting
M9R, and 700
19BII - REFITTING OPERATION FOR PART CONCERNED
Move the engine towards the front of the vehicle.
Fit:
- the new seal between the turbocharger and the ca-talytic converter,
- the catalytic converter.
Refit the catalytic converter onto the turbocharger.
Fit:
- the new catalytic converter nuts onto the turbochar-ger,
- the new catalytic converter half-clamps.
Refit:
- the catalytic converter studs using a roller-typestud removal tool ,
- the catalytic converter half-clamp mounting bolts,
- the catalytic converter stay,
- the catalytic converter stay mounting bolt,
- the stay mounting nuts on the catalytic converter,
- the stay mounting nuts on the cylinder block.
Tighten to torque:
- the catalytic converter mounting nuts on theturbocharger ( 21 Nm ) ,
- the catalytic converter half-clamp mountingbolts ( 21 Nm ) ,
- the stay mounting bolt on the catalytic conver-ter ( 8 Nm ) ,
- the stay mounting nuts on the cylinder block (21 Nm ) ,
- the stay mounting nuts on the catalytic conver-ter ( 21 Nm ) .
III - FINAL OPERATION
Refit the lower engine tie-bar (see 19D, Enginemounting, Rear suspended engine mounting:Removal - Refitting ).
Tighten to torque the lower engine tie-bar (see 19D,Engine mounting, Rear suspended enginemounting: Tightening torque ).
Refit the new seal to the ball-jointed bracket.
Fit the exhaust pipe.
Refit:
- the exhaust pipe rubber mounting bush mountingbolt, aligning the marks,
- the silencer rubber mounting bush mounting bolt,aligning the marks,
- the ball-jointed bracket bolts with springs.
Tighten to torque:
- the bolts of the ball-jointed bracket with springs( 21 Nm ) ,
- the silencer rubber mounting bush mountingbolt ( 21 Nm ) ,
- the exhaust pipe rubber mounting bush moun-ting bolt ( 21 Nm ) .
Refit:
- the engine undertray,
- the acoustic protection,
- the acoustic protection clips on the scuttle panelpartition,
- the scuttle panel grille (see MR 365 Bodywork,55A, Exterior protection, Scuttle panel grille ),
- the engine protectors.
Connect the battery (see 80A, Battery, Battery: Re-moval - Refitting ).
114844
19B-29
EXHAUSTExpansion chamber: Removal - Refitting
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
19B
REMOVAL
Position the vehicle on a lift.
Remove the engine undertray.
Cut the exhaust pipe (see 19B, Exhausts, GeneralVehicle Information ).
Remove:
- the bolts (1) securing the expansion chamber to therubber mounting bush support,
- the expansion chamber.
REFITTING
Fit:
- the expansion chamber,
- the sleeve (see 19B, Exhausts, General informa-tion ).
Tighten to torque:
- the bolts securing the rubber mounting bushsupport on the expansion chamber ( 8 Nm ) ,
- the bolts securing the rubber mounting bushsupport on the body ( 21 Nm ) .
Tighten the sleeves, while easing the exhaust pipeto ensure the correct alignment of the pipe .
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Make sure that there is no contact with the underbo-dy.
Tightening torquesm
bolts securing the rub-ber mounting bush sup-port on the expansionchamber
8 Nm
bolts securing the rub-ber mounting bush sup-port on the body
21 Nm
101818
Note:
If the rubber mounting bushes are damaged,mark the position of the support on thebodywork, then replace the « support / rubbermounting bush assembly » .
1
WARNINGCut the new expansion chamber pipe (see 19B,Exhaust, General Vehicle Information ).
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nuts and bolts » assem-bly must be positioned so that it cannot comeinto contact with the underbody.
Any damaged heat shields must be replaced.
19B-30
EXHAUSTSilencer: Removal - Refitting 19B
REMOVAL
Position the vehicle on a two-post lift.
Cut the exhaust pipe (see 19B, Exhausts, Generalinformation ).
Remove:
- the silencer mounting bolts (1) on the rubber moun-ting bush support,
- the the silencer.
REFITTING
Fit:
- the silencer,
- the sleeve (see 19B, Exhausts, General informa-tion ).
Tighten to torque:
- the bolts securing the rubber mounting bush onthe silencer ( 8 Nm ) ,
- the bolts securing the rubber mounting bushsupport on the body ( 21 Nm ) .
Tighten the sleeve, while easing in the exhaust pipeto ensure the correct alignment of the pipe.
Make sure that all the exhaust pipe heat shields arein place and properly secured.
Make sure that there is no contact with the underbo-dy.
Tightening torquesm
bolts securing the rub-ber mounting bush onthe silencer
8 Nm
bolts securing the rub-ber mounting bush sup-port on the body
21 Nm
101817
Note:
If the rubber mounting bushes are damaged:
- mark the position of the mounting on the vehiclebody,
- replace the « support / rubber mounting bushfitting assembly » .
1
WARNING
Do not reuse an old sleeve.
The « sleeve tightening nut and bolts assembly »must be positioned so that it cannot come intocontact with the underbody.
Any damaged heat shields must be replaced.
19B-31
EXHAUSTParticle filter: Function
F9Q, and 804
19B
I - SAFETY ADVICE
Due to the dangers of high temperatures, be sure to observe the following instructions:
- never open or separate the pressure tapping circuit,except at the level of the unions on the exhaust pipe(only the supplier can guarantee pressure tapping cir-cuit sealing),
- Position the pressure pipes correctly. If the pipes arenot positioned correctly, their flexible sections may betwisted which will create low points and this may re-sult in the pipes rupturing when fluid freezes and ex-pands.
II - OPERATING PRINCIPLE
The particle filter, placed underbody on the catalyticpre-convertor outlet, limits the pollutant emissions byaccumulating the unburnt particles from the exhaust fu-mes (loading or filtering phase), then these particlesare eliminated by combustion (regeneration phase).
Using sensors, the injection computer measures thetemperature as well as the pressure of the exhaust fu-mes upstream and downstream of the particle filter.
The injection computer continuously evaluates the le-vel of clogging of the particle filter using the pressuredifference upstream and downstream of the particle fil-ter. When it is clogged, the two temperature values in-form the injection computer that the temperatureconditions are high enough (approximately 600˚C ) totrigger regeneration.
This consists of burning the particles held in the parti-cle filter: to do this, the injection switches to « delayedinjection » mode and the fuel not burned in the com-bustion chambers burns the residues contained in theparticle filter cells.
The extent to which the particle filter is clogged de-pends on the user's driving style:
- during an average trip (combined cycle and motorwayof more than 15 minutes ), the particle filter automa-tically burns the particles without being noticed by thecustomer (apart from some white smoke): this is« spontaneous regeneration » ,
- if the operating temperature is not high enough to trig-ger spontaneous regeneration, clogging increasesuntil it exceeds 35 g ; an acceleration request to trig-ger spontaneous regeneration is then sent to the dri-ver via an instrument panel warning light; the samehappens if several attempts to regenerate have failed.
- if these conditions are still not met and clogging rea-ches 45 g (min) . « Static regeneration » , using dia-gnostic tool must be performed in the workshop (« SERVICE » warning light comes on and the« CHECK ANTIPOLLUTION » message appears:(see 19B, Exhaust, Particle filter: Cleaning ).
Equipment required
diagnostic tool
IMPORTANT
Do not park and run the engine in a place wherecombustible substances and materials such asgrass or leaves can come into contact with the hotexhaust system.
19B-32
EXHAUSTParticle filter: Removal - Refitting
F9Q, and 804
19B
REMOVALPosition the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the engine undertray.
Cut the exhaust pipe after the particle filter (see 19B,Exhaust : repair precautions ) and (see 19B, Ex-haust: General information ).
Remove the downstream pressure pipe (1) from itsadapter (2) bolted to the exhaust pipe.
Tightening torquesm
rubber mounting bushsupport mounting nut onthe particle filter
25 Nm
exhaust bracket nutsbetween the connectionhose and the catalyticpre-converter
21 Nm
rubber mounting bushnuts on the sub-frame
25 Nm
exhaust sleeve nut 25 Nm
downstream pressuremeasurement tappingon its adapter
21 Nm
connection clip boltbetween the silencerand the particle filter
25 Nm
exhaust flange nutsbetween the connectionhose and the catalyticpre-converter
21 Nm
nuts mounting the rub-ber mounting bush sup-port onto the sub-frame
25 Nm
106673
WARNING
When the pressure measurement tapping isremoved, the adapter must be held (2) with alock wrench.
WARNING
The pressure measurement circuit must never beopened except at the adapters on the exhaustpipe.
19B-33
EXHAUSTParticle filter: Removal - Refitting
F9Q, and 804
19B
Remove the heat shield (3) mounting clip then moveit aside slightly
Unpick the downstream pressure measurement tap-ping and also the downstream temperature sensorcabling from the heat shield.
Pass the downstream pressure measurement tap-ping into the engine compartment whilst leaving thepressure sensor complete.
Disconnect the particle filter pressure sensor con-nector (4) located in the engine compartment.
Remove the retaining clip (5) from the cabling on theparticle filter pressure sensor mounting.
Disconnect the upstream and downstream tempera-ture sensor offset connectors (6) .
Unpick the upstream and downstream temperaturesensor offset connectors (6) .
Remove:
- the bolt (7) securing the filter particle pressure sen-sor mounting located in the engine compartment.
- the particle filter pressure sensor assembly (8) andits mounting.
111881
111882
111885
111885
19B-34
EXHAUSTParticle filter: Removal - Refitting
F9Q, and 804
19B
Remove:
- the nuts (9) on the exhaust flange between the con-nection hose and the catalytic pre-converter,
- the sub-frame rubber mounting bush bolts (10) ,
- the particle filter.
Remove the particle filter assembly:
- the rubber mounting bush,
- the upstream and downstream temperature sen-sors from their adapters on the exhaust line (see19B, Exhaust, Particle filter temperature sen-sor: Removal - Refitting ).
- the upstream pressure measurement tapping at itsadapter on the exhaust pipe (see 19B, Exhaust,Particle filter pressure sensor: Removal - Refit-ting ).
- the connection hose (see 19B, Exhaust, Connec-tion hose: Removal - Refitting ).
REFITTING
With particle filter removed, refit:
- the connection hose and its new seals (see 19B,Exhaust, Connection hose: Removal - Refitting).
107038
WARNING
Always replace:
- the seal between the hose and particle filter,
- the seal between the hose and the catalytic pre-converter,
- any adapter on the exhaust pipe that has beenloosened,
WARNING
Always clean the bearing surfaces of the connec-tion hose - par ticle filter flanges thoroughly.
19B-35
EXHAUSTParticle filter: Removal - Refitting
F9Q, and 804
19B- the upstream and downstream temperature sen-sors on their adapters on the exhaust pipe (see19B, Exhaust, Particle filter temperature sen-sors: Removal - Refitting ).
- the upstream pressure measurement tapping at itsadapter on the exhaust line (see 19B, Exhaust,Particle filter pressure sensor: Removal - Refit-ting ).
- the rubber mounting bush on the particle filter.
Torque tighten the rubber mounting bush supportmounting nut on the particle filter ( 25 Nm ) .
Place the pressure sensor and its mounting in theengine compartment before fitting the particle filter.
Tighten to torque:
- the exhaust bracket nuts between the connec-tion hose and the catalytic pre-converter ( 21Nm ) .
- the rubber mounting bush nuts on the sub-fra-me ( 25 Nm ) .
Fit the exhaust sleeve (see 19B, Exhaust : GeneralVehicle Information ) by applying sealing mastic forthe exhaust.
Tighten to torque the exhaust sleeve nut ( 25 Nm )at the same time as making sure that the exhaustpipe is correctly aligned.
Coat the downstream pressure measurement tap-ping threads with ANTI-SEIZE high temperaturegrease.
WARNING
When fitting the particle filter, be sure to pass thedownstream pressure measurement tappingbehind the heat shield.
WARNING
Make sure that the grease does not flow beyondthe threading.
106673
WARNING
All the adapters on the exhaust pipe (12) must bereplaced.
19B-36
EXHAUSTParticle filter: Removal - Refitting
F9Q, and 804
19B
Fit the rigid part of the downstream pressure measu-rement tapping then position it so that it is parallel (±±±±3˚ ) to the exhaust pipe longitudinal axis.
Tighten to torque the downstream pressuremeasurement tapping on its adapter ( 21 Nm )bolted to the exhaust pipe.
Proceed in the reverse order to removal.
Tighten to torque:
- the connection clip bolt between the silencerand the particle filter ( 25 Nm ) ,
- the exhaust flange nuts between the connec-tion hose and the catalytic pre-converter ( 21Nm ) ,
- the nuts mounting the rubber mounting bushsupport onto the sub-frame ( 25 Nm ) .
Make sure that there is no contact with the underbo-dy.
106672
WARNING
Make sure, after tightening the pressure measu-rement tappings, that this pressure measurementtapping has no low points (siphon) susceptible towater accumulation.
To do this:
- check that the rigid sections of the pressurepipes are correctly positioned in relation to theexhaust pipe longitudinal axis,
- at the retaining clips, manipulate the pressuremeasurement tappings on the heat shield (turnthe tapping in the clip so as to avoid the lowpoints).
WARNING
Any damaged heat shields must be replaced.
19B-37
EXHAUSTParticle filter: Removal - Refitting
F9Q, and 804
19B
Use the diagnostic tool to clear any faults which maybe stored by the injection computer before restartingthe engine.
REINITIALISING THE PARTICLE FILTER PARAMETERS
Command RZ008: ADAPTATIVES AFTER REPLACEMENT OF THE PARTICLE FILTER
Command SC030 enables the parameters to be re-set to 0 depending on the type of operation carried out.
- PR391 : distance travelled since the particle filterwas last replaced,
- PR415 : distance travelled since the last regenera-tion
- PR412 : time since the last regeneration,
- PR383 : mass of soot in the particle filter.
Once the command has finished, check that the pa-rameters are at 0, so that the computer establishesa new regeneration strategy when driving and cansignal the system faults.
After repairing: Repeat the conformity check fromthe start.
WARNING
Connect the battery, starting with the positive ter-minal. carry out the necessary programming (see80A, Battery: Removal - Refitting ).
WARNING
With the engine running, carry out a leak test andcheck, using a leak detector for 5 minutes , thatthere is no leak on the adapters on the exhaustpipe.
Note:
This command is only carried out after replacingthe particle filter.
19B-38
EXHAUSTParticle filter pressure sensor: Removal - Refitting
F9Q, and 804
19B
(A) Particle filter pressure sensor.
(B) Upstream pressure measurement tapping endpiece.
(C) Downstream pressure measurement tappingend piece.
REMOVAL
Remove the particle filter (see 19B, Exhaust, Parti-cle filter: Removal and Refitting ).
Tightening torquesm
upstream pressuremeasurement tappingon its union bolted ontothe exhaust pipe
21 Nm
107038
C
B
A
19B-39
EXHAUSTParticle filter pressure sensor: Removal - Refitting
F9Q, and 804
19B
Remove the upstream pressure pipe (1) from its in-termediary adapter (2) bolted to the exhaust pipe.
Remove:
- the mounting nut (3) from the particle filter pressuresensor mounting (4) ,
- the particle filter pressure sensor:
106670
WARNING
When removing the pressure measurement tap-ping (1) from its adapter it is essential to openthe adapter (2) with a lock wrench.
WARNING
The pressure measurement circuit must never beopened except at the level of the adapters on theexhaust pipe.
1
2
111885
WARNING
Never separate the pressure measurement tap-pings (5) from the particle filter pressure sensor(6) ; replace the « sensor - pipes - end pieces »assembly if necessary, this is supplied assem-bled by the Parts Department (see Particlefilter : repair precautions, Safety instructions).
3
6
5
4
6
19B-40
EXHAUSTParticle filter pressure sensor: Removal - Refitting
F9Q, and 804
19BREFITTING
Coat the upstream pressure measurement tappingthreads with ANTI-SEIZE high temperature grease.
106673
WARNING
Each exhaust pipe intermediary adapter (7) thatis removed must be replaced.
WARNING
Make sure that the grease does not flow beyondthe threading.
7
19B-41
EXHAUSTParticle filter pressure sensor: Removal - Refitting
F9Q, and 804
19B
Fit the rigid part of the upstream pressure measure-ment tapping then position it so that it is parallel ( ±±±±3˚ ) with the exhaust pipe longitudinal axis.
Tighten to torque the upstream pressure measure-ment tapping on its union bolted onto the ex-haust pipe ( 21 Nm ) .
Refit the particle filter (see 19B, Exhaust, Particlefilter: Removal - Refitting ).
Use the diagnostic tool to clear any faults which may
be stored by the injection computer before restartingthe engine.
106672
WARNING
Make sure, after tightening the pressure measu-rement tappings, that this pressure measurementline assembly has no low points (siphon) suscep-tible to water accumulation.
To do this:
- check that the rigid sections of the pressurepipes are correctly positioned in relation to theexhaust pipe longitudinal axis,
- at the retaining clips, manipulate the pressuremeasurement tappings on the heat shield (turnthe tapping in the clip so as to avoid the lowpoints).
19B-42
EXHAUSTParticle filter temperature sensors: Removal - Refitting
F9Q, and 804
19B
(A) Upstream particle filter temperature sensor
(B) Downstream particle filter temperature sensor
I - (A) UPSTREAM PARTICLE FILTER TEMPERATURE SENSOR
1 - Removal
Remove the particle filter (see 19B, Exhaust, Parti-cle filter: Removal - Refitting ).
Equipment required
diagnostic tool
Tightening torquesm
adapter, if it has beenreplaced
44 Nm
upstream particle filtertemperature sensor.
30 Nm
adapter, if it has beenreplaced
44 Nm
downstream particle fil-ter temperature sensor
30 Nm
Tightening torquesm
107038
19B-43
EXHAUSTParticle filter temperature sensors: Removal - Refitting
F9Q, and 804
19B
Remove the upstream particle filter temperaturesensor (1) from its adapter (2) bolted onto the ex-haust pipe.
2 - Refitting
Tighten to torque the adapter, if it has been repla-ced ( 44 Nm ) .
Coat the threads on the upstream particle filter tem-perature sensor with ANTI-SEIZE high temperaturegrease.
Tighten to torque the upstream particle filter tem-perature sensor. ( 30 Nm ) .
Check that:
- that there is no contact with the wiring harness,
- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
Refit the particle filter (see 19B, Exhaust, Particlefilter: Removal - Refitting ).
II - (B) DOWNSTREAM PARTICLE FILTER TEMPERATURE SENSOR
1 - Removal
Position the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove the engine undertray.
Disconnect the downstream particle filter temperatu-re sensor offset connector (3) .
106671
WARNING
When the upstream particle filter temperaturesensor (1) is removed, the adapter must be held(2) with a lock-wrench.
WARNING
Always replace any adapter (2) that has beenremoved from the exhaust pipe.
WARNING
Make sure that the grease does not flow beyondthe threading.
111882
19B-44
EXHAUSTParticle filter temperature sensors: Removal - Refitting
F9Q, and 804
19B
Unpick the downstream particle filter temperaturesensor offset connector (3) from its mounting.
Remove the downstream particle filter temperaturesensor (4) from its adapter (5) bolted onto the ex-haust pipe.
2 - Refitting
Tighten to torque the adapter, if it has been repla-ced ( 44 Nm ) .
Coat the threads on the downstream particle filtertemperature sensor with ANTI-SEIZE high tempera-ture grease.
Tighten to torque the downstream particle filtertemperature sensor ( 30 Nm ) .
Check that:
- there is no contact with the wiring harness,
- the extent of wear on the wiring harness.
Replace the wiring harness if necessary.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal
Before restarting the engine, use the diagnostictool to clear any faults stored by the injection com-puter.
111885
106671
WARNINGWhen the downstream particle filter temperaturesensor (4) is removed, the adapter must be held(5) with a lock wrench.
WARNINGAlways replace any adapter (3) that has beenremoved from the exhaust pipe.
WARNING
Make sure that the grease does not flow beyondthe threading.
WARNING
Carry out the necessary programming (see sec-tion 80A, Battery: Removing - Refitting ).
19B-45
EXHAUSTConnecting hose: Removal - Refitting
F9Q, and 804
19B
REMOVAL
Remove:
- the particle filter (see 19B, Exhaust, Particle fil-ter: Removal - Refitting ).
- the upstream temperature sensor and its adapteron the exhaust pipe (see 19B, Exhaust, Particlefilter temperature sensor: Removal - Refitting ).
- the upstream pressure measurement tapping at itsadapter on the exhaust pipe (see 19B, Exhaust,Particle filter pressure sensor: Removal - Refit-ting ).
Remove:
- the nuts for the exhaust flange between the con-nection hose and the particle filter,
- the connection hose.
REFITTING
Refit:
- the connection hose with new seals,
- the upstream temperature sensor and its adapteron the exhaust pipe (see 19B, Exhaust, Particlefilter temperature sensor: Removal - Refitting ).
- the upstream pressure measurement tapping at itsadapter on the exhaust pipe (see 19B, Exhaust,Particle filter pressure sensor: Removal - Refit-ting ).
Tighten to torque the exhaust flange nuts ( 21 Nm) between the connection hose and the particle filter.
Refit the particle filter (see 19B, Exhaust, Particlefilter: Removal - Refitting ).
Tightening torquesm
exhaust flange nuts 21 Nm
WARNING
Always replace:
- the flange seal between the connection hoseand the catalytic pre-converter,
- the flange seal between the connection hoseand particle filter,
WARNING
Always clean the bearing surfaces thoroughly on:
- the hose connection flanges for the catalyticpre-converter connection,
- the flange between the connection hose andthe particle filter,
19B-46
EXHAUSTParticle filter: Cleaning
F9Q, and 804
19BPROCEDURE FOR FORCED REGENERATION OF THE PARTICLE FILTER USING THE CLIP DIAGNOSTIC TOOL
Command SC017: REGENERATION OF THE PARTICLE FILTER
To run this command, select the specific com-mands mode on the Clip tool, and select commandSC017 or VP040 .
Follow this procedure:
- run command SC017 or VP040 ,
- during regeneration, the engine speed will be heldat 1500 rpm , and the engine noise changes (de-layed injection),
- the exhaust fumes rise in temperature and burn thesoot retained in the particle filter,
- the command lasts for approximately 30 minutes ,
- when the engine speed returns to idle speed thecommand has terminated,
- check the quantity of soot contained in the particlefilter PR383 < 10 .
Once forced regeneration of the particle filter is com-plete:
- deal with the present faults,
- clear the stored faults.
Allow the engine to cool down.
Drain the engine oil.
Replace the oil filter.
Top up the oil.
Note:
Only run this command under the following con-ditions:
- fault DF308 Particle filter clogged , or DF312Number of regenerations exceeded , orDF383 Particle filter regeneration impossiblepresent,
- soot weight in the particle filter greater than45 g .
IMPORTANT
During the forced regeneration of the particle fil-ter, the temperature in the exhaust pipe risessignificantly.
Try to carry out this procedure outside the works-hop if possible or use an exhaust gas extractorapproved for high temperatures.
WARNING
Check the engine oil level before running thecommand to avoid any engine racing.
The level should be between « MIN » and« MAX » on the dipstick.
Note:
If necessary, regeneration can be stopped bypressing the engine start button twice in succes-sion.
Note:
Be prepared for strong odours and thick smokeduring particle filter regeneration.
Note:
The level should be between « MIN » and« MAX » on the dipstick.
19B-47
EXHAUSTParticle filter: Cleaning
F9Q
19B
PROCEDURE FOR PARTICLE FILTER FORCED REGENERATION USING THE CLIP DIAGNOSTIC TOOL
Connect the diagnostic tool to the vehicle.
For the particle filter forced regeneration procedure,see MR 366 or MR 372 Fault finding, 13B, Dieselinjection, Fault finding, Interpretation of com-mands, Particle filter regeneration .
When particle filter forced regeneration is complete, using the diagnostic tool:
- deal with the present faults,
- clear the stored faults.
Put the vehicle on a two-post lift.
Remove the oil filter using the (Mot. 1329) .
Coat the new oil filter sealing ring with engine oil.
Tighten the oil filter until the seal makes contact withthe engine.
Tighten the new oil filter manually 3/4 of a turn.
Wipe away any excess oil.
Remove the engine oil filler cap.
Remove the engine undertray.
Remove the sump drain plug using the (Mot. 1018)or an 8 mm square male drain pipe union .
Allow all the engine oil to flow into a drain tray.
Special tooling required
Mot. 1329 76 mm diameter oil fil-ter removing tool
Mot. 1018 Sump plug tool.
Equipment required
diagnostic tool
kit for particle filter
Tightening torquesm
engine drain plug 20 Nm
rubber mountingbushes on the body
21 Nm
rubber mounting bushon the connector pipe
8 Nm
rubber mounting bushon the rear silencer
8 Nm
IMPORTANT
During forced regeneration of the particle filter,the temperature in the exhaust pipe rises signifi-cantly.
Be sure either to carry out the operation outsidethe workshop, or to use the kit for particle filter, approved for high temperatures, on the exhaustgas extractors in the workshop.
WARNING
To prevent engine racing, check the engine oillevel using the dipstick before running the forcedregeneration command.
The engine oil level must be between the« MIN » and « MAX » marks on the dipstick.
Note:
If required, the forced regeneration proceduremay be stopped by pressing the engine Start but-ton twice in succession.
Note:
Be prepared for strong odours and thick smokeduring particle filter forced regeneration.
IMPORTANT
Allow the engine to cool before draining the oil.
19B-48
EXHAUSTParticle filter: Cleaning
F9Q
19BRubber-lipped seal
Refit the drain plug with its new seal (no fitting direc-tion).
Tighten to torque the engine drain plug ( 20 Nm ) .
Clean any traces of the drained oil from the sump.
Refit the engine undertray.
Refill the engine oil.
Refit the filler plug.
Wait for 10 minutes .
Check the oil level using the dipstick.
Top up if necessary.
After any particle filter forced regeneration opera-tion, always replace:
- the particle filter rubber mounting bush on the axlesub-frame (see MR 364 or MR 370, 19B, Exhaust,Particle filter: Removal - Refitting ),
- the particle filter pressure sensor with its upstreamand downstream pressure measurement tappings(see MR 364 or MR 370, 19B, Exhaust, Particlefilter pressure sensor : Removal - Refitting ),
- the exhaust connector pipe rubber mounting bushon the body,
- the rear silencer rubber mounting bush on the bo-dy.
For the connector pipe and rear silencer rubber mounting bushes, tighten to torque:
- the mounting bolt of the rubber mounting busheson the body ( 21 Nm ) ,
- the mounting bolts of the rubber mounting bushon the connector pipe ( 8 Nm ) ,
- the mounting bolts of the rubber mounting bushon the rear silencer ( 8 Nm ) ,
113765
Note:
The engine oil level must be between the« MIN » and « MAX » marks on the dipstick.
19C-1
RESERVOIRDraining the fuel tank
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
19CDRAINING THE FUEL TANK
Disconnect the fuel inlet union (1) .
Position and fit a (3) « T » (Mot. 1311-08) union.
Fit a pipe (2) long enough to carry the fuel into a con-tainer to the « T » -union outlet.
Special tooling required
Mot. 1311-08 Union for measuringfuel pressure
WARNING
During this operation, it is essential to:
- refrain from smoking or bringing red hot objectsclose to the work area,
- guard against petrol splashes caused by the resi-dual pressure in the pipes,
- protect sensitive areas from fuel outflow.
WARNING
The ignition must be switched off during this opera-tion.
K4J, and 730 or 732 – F4R, and 770 or 771 or 776
101496
1
2
3
19C-2
RESERVOIRDraining the fuel tank
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
19C
Disconnect the fuel inlet union (1) .
Position and fit a (3) « T » (Mot. 1311-08) union.
Fit a pipe (2) long enough to carry the fuel into a con-tainer to the « T » -union outlet.
Remove the protection and switching unit cover.
Place the electrical connector (4) to one side withoutdisconnecting it.
Disconnect the brown connector (6) from the Protec-tion and Switching Unit.
K4M, and 760 or 761
101803
3
2
1
102502
102503
4
6
19C-3
RESERVOIRDraining the fuel tank
K4J, and 730 or 732 – K4M, and 760 or 761 – F4R, and 770 or 771 or 776
19C
Connect terminal (5) of the brown connector to a +battery supply to operate the fuel pump.
Let the petrol flow out until it comes intermittently.
Disconnect the + battery supply from terminal (5) .
102501
Note:
It is also possible to use the pneumatic siphoningPump tool for draining the fuel tank (see catalo-gue entitled Equipment) , to be adapted on theunion at « T » (Mot. 1311-08) .
1
5
12
19C-4
RESERVOIRDraining the fuel tank
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
19C
DRAINING THE FUEL TANK
Disconnect the battery, starting with the negativeterminal.
Lift up the cushion from the rear bench seat (seeWorkshop repair Manual 365 Bodywork, 76A,Rear seat mountings and runners, Completeseat base ).
Remove the carpet retaining clip.
Take out the carpet.
Remove:
- the closure panel mounting bolts (1) ,
- the closure panel,
- the inspection flap blanking cover (2) .
Equipment required
petrol or diesel tank drain pneumatic siphoningpump
IMPORTANT
During this operation:
- refrain from smoking or bringing red hot objectsclose to the work area,
- beware of fuel splashes when disconnecting theunion,
- protect sensitive areas from fuel outflow.
99641
Note:
Since diesel vehicles are not fitted with an electri-cal fuel pump, the petrol or diesel tank drainpneumatic siphoning pump tool must be usedto drain the tank.
102460
102461
2
11
19C-5
RESERVOIRDraining the fuel tank
C84 or G84 or S84, and F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
19C
Disconnect:
- the fuel tank sender connector (3) ,
- the body height sensor connector (4) (if fitted),
- union (5) .
Make preparations for the fuel outflow.
Connect the rubber suction pipe of the petrol or die-sel tank drain pneumatic siphoning pump to thediesel fuel supply quick-release union, and the si-phoning pump's backflow pipe to the container (5) .
Run the petrol or diesel tank drain pneumatic si-phoning pump .
Let the fuel flow out until it comes intermittently.
Drain the tank.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
102462
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
5
4 3
19C-6
RESERVOIRFuel tank: Description
F4R or K4J or K4M
19C
102487
10
9
8
7
65
5
4
3
13
2
2
2
22
12
1
11
No. Description
1 Tank
2 Mounting holes
3 Filler neck
4 Neck mounting clips
5 Brake pipe retaining clips
6 Fuel supply pipe
7 Petrol vapour supply pipe
8 Petrol vapour absorber supply pipe (from the tank)
9 Fresh air vent
10 Petrol vapour absorber
11 Overfill prevention valve and leak prevention valve in case of vehicle roll-over
12 Anti-backflow pipe (degassing - filling)
13 Petrol suction assembly
19C-7
RESERVOIRFuel tank: Description
F4R or K4J or K4M
19C
13036
10
9
8
7
6
5
4
3
2
1
No. Description
1 Connection to petrol vapour absorber
2 Overfill prevention ball
19C-8
RESERVOIRFuel tank: Description
F4R or K4J or K4M
19C
ROLE OF THE FILLER NECK AND VALVES
1 - Overpressure/underpressure safety valves
If the petrol vapour recirculation circuit is blocked, thisvalve prevents the fuel tank being subjected to excesspressure (the tank expands) or underpressure (as fuelis used, the tank collapses).
2 - Restriction valve
This valve prevents diesel fuel or leaded petrol pumpnozzles from entering the tank.
3 - Overfill prevention valve and vehicle roll-over leak prevention valve
The ball acts as an overfill prevention valve.
When the vehicle is stationary, during filling, the ballrests on its seat, retaining a specific volume of air in thetank.
When the vehicle is moving, the ball leaves its seat,enabling a connection between the tank and the petrolvapour absorber.
When the tank is full, a sufficient volume of air to allowthe fuel contained within it to expand must remain inthe tank, but not so much as to make the tank burst.
The vehicle roll-over leak prevention valve preventsthe fuel tank from emptying via the pipe to the petrolvapour absorber.
4 - Filler neck
The filler neck for unleaded petrol has the following:
- a smaller diameter filling opening (restriction valve).Leaded petrol damages the toxic fume filter system:catalytic converter and oxygen sensor,
- a valve blocking the filling opening (to prevent petrolvapour release or backflow of petrol),
- a leak-tight cap.
3 Filling anti-backflow pipe
4 Restriction valve
5 Excess pressure/underpressure safety valve
6 Air outlet hole during filling
7 Volume of air allowing fuel expansion
8 Fuel inlet for filling
9 Usable fuel volume
10 Overfill prevention valve and vehicle roll-over leak prevention valve
No. Description
19C-9
RESERVOIRFuel tank: Description
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
19C
110881
3
2
2
222
1
10
8
9
7
65
4
No. Description
1 Tank
2 Mounting holes
3 Filler neck
4 Neck mounting clips
5 Brake pipe retaining clips
6 Fuel supply pipe
7 Fuel return pipe
8 Drying the reservoir and leak prevention valve in case of vehicle roll-over
9 Anti-backflow pipe (degassing - filling)
10 Diesel suction assembly
19C-10
RESERVOIRFuel tank: Description
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
19C
13036-1
3
2
1
8
7
6
5
4
No. Description
1 Fresh air vent
2 Overfill prevention ball
19C-11
RESERVOIRFuel tank: Description
F9Q, and 800 or 804 or 808 – K9K, and 722 or 728 or 729 or 732
19C
ROLE OF THE FILLER NECK AND VALVES
1 - Overfill prevention valve and vehicle roll-over leak prevention valve
The ball acts as an overfill prevention valve.
When the vehicle is stationary, during filling, the ballrests on its seat, retaining a specific volume of air in thetank.
When the vehicle is moving, the ball leaves its seat,thus allowing the reservoir to be open to the air.
When the tank is full, a sufficient volume of air to allowthe diesel fuel contained within it to expand must re-main in the tank, but not so much as to make the tankexplode.
The vehicle roll-over leak prevention valve preventsthe fuel tank from emptying via the air pipe.
2 - Filler neck
The filler neck for unleaded fuel has a leaktight cap.
3 Filling anti-backflow pipe
4 Air outlet hole during filling
5 Volume of air allowing fuel expansion
6 Fuel inlet for filling
7 Usable fuel volume
8 Drying the reservoir and leak prevention valve in case of vehicle roll-over
No. Description
19C-12
RESERVOIRFuel tank: Removal - Refitting 19C
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Drainingthe fuel tank ).
Remove the « pump-sender-filter » assembly (see19C, Fuel tank, Pump-sender-filter ) for petrol en-gines or the sender (see 19C, Fuel tank, Sender )for diesel engines.
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the engine undertray,
- the nuts mounting the exhaust clamp on the mani-fold,
- the bolt mounting the expansion chamber on thebody,
- the bolts connecting the silentbloc mounting to thesilencer,
- the exhaust pipe from the sub-frame and the rearaxle.
Disconnect the headlight height adjustment sensorwiring (depending on vehicle equipment level).
Unclip the headlight height adjustment sensor linka-ge (depending on vehicle equipment level).
Remove the petrol vapour absorber (see 14A, Anti-pollution, Petrol vapour absorber ).
Unclip the petrol vapour absorber pipes.
Disconnect the connectors on the « Pump-Sender-Filter » assembly (see 19C, Fuel tank, Pump-Sen-der-Filter ).
Remove:
- the mounting bolts (1) from the fuel tank and theheat shield,
- the heat shield mounting clips (2) ,
- the heat shield (3) .
Equipment required
component jack
Tightening torquesm
wheel bolt 110 Nm
fuel tank mounting 21 Nm
battery cover mountingbolts
4 Nm
IMPORTANT
During this operation, be sure to:
- refrain from smoking or bringing red-hot objectsnear the working area,
- watch out for fuel splashes when disconnectingthe union,
- protect sensitive areas from fuel outflow.
F4R or K4J or K4M
102465
3
2
1
19C-13
RESERVOIRFuel tank: Removal - Refitting 19C
Remove mounting clips (4) from the brake and fuelpipes.
Unclip:
- the fuel pipe unions at the catalytic converter,
- the clips from the fuel pipes.
Remove fuel tank filler neck hose connection clips(5) .
Move the hoses to one side.
Position the component jack under the tank.
Remove the fuel tank mounting bolts (6) .
Lower the fuel tank.
Remove the tank by turning it around the exhaust pi-pe.
Take care not to damage the brake pipes or the par-king brake cable.
102467
102468
444
5
102466
102459
66
19C-14
RESERVOIRFuel tank: Removal - Refitting 19C
REFITTING
Reshape the heat shield.
Take care not to bring the heat shield into contactwith the fuel tank.
The tank hose securing clips must always be repla-ced.
Proceed in the reverse order to removal.
Tighten to torque:
- the wheel bolt ( 110 Nm ) ,
- the fuel tank mounting ( 21 Nm ) .
Check that the fuel pipe unions click into place.
Refit the « pump-sender-filter » assembly (see 19C,Fuel tank, Pump-sender-filter ) for petrol enginesor the sender (see 19C, Fuel tank, Sender ) for die-sel engines.
Connect the battery, starting with the positive termi-nal.
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
19C-15
RESERVOIRFiller neck: Removal - Refitting 19C
REMOVAL
Drain the fuel tank (see 19C, Fuel tank, Drainingthe fuel tank ).
Put the vehicle on a two-post lift.
Disconnect the battery, starting with the negativeterminal.
Remove:
- the rear right-hand wheel,
- the rear right-hand wheel arch liner.
Disconnect the anti-backflow pipe (1) .
Remove filler pipe clips (2) .
Remove the filler neck mounting bolts (3) .
Remove:
- the filler neck mounting bolts (4) ,
- the filler neck.
REFITTING
Always replace the clips with new ones.
Proceed in the reverse order to removal.
Connect the battery, starting with the positive termi-nal.
Tightening torquesm
battery cover mountingbolts
4 Nm
IMPORTANT
During this operation, be sure to:
- refrain from smoking or bringing red hot objectsnear the working area,
- watch out for fuel splashes when disconnectingthe union,
- protect sensitive areas from fuel outflow.
102468
2 1
102469
104559
WARNING
Carry out the necessary programming (see 80A,Battery: Removal - Refitting ).
3
4
19C-16
RESERVOIRFiller neck: Removal - Refitting 19C
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
19C-17
RESERVOIRSender unit: Removal - Refitting
F9Q or K9K or M9R
19C
REMOVALDisconnect the battery, starting with the negativeterminal.
Lift up the rear bench seat base (see MR 365 Bo-dywork, 76A, Rear seat runners and frames,Complete seat base ).
Remove the carpet retaining clip.
Move the carpet to one side.
Remove:
- the closure panel mounting bolts (1) ,
- the closure panel,
- the blanking cover (2) on the inspection flap.
Special tooling required
Mot. 1397 Universal spanner forremoving fuel sendernut
Tightening torquesm
battery cover mountingbolts
4 Nm
IMPORTANT
During this operation:
- refrain from smoking or bringing red hot objectsclose to the working area,
- beware of fuel splashes when disconnecting theunion,
- protect sensitive areas from fuel outflow.
102461
19C-18
RESERVOIRSender unit: Removal - Refitting
F9Q or K9K or M9R
19C
Disconnect:
- electrical connectors (3) ,
- quick-release union(s) (4) .
Prepare for fuel outflow.
Fit the correct blanking plugs into the unions (seeMR 364 Mégane, 13B, Injection: Cleanliness gui-delines ).
Remove the nut from the sender using tool (Mot.1397) (5) .
Remove the sender unit, being careful with the float.
104546 104547
WARNING
Refit the sender nut as soon as the sender hasbeen removed to prevent any deformation of thefuel tank.
19C-19
RESERVOIRSender unit: Removal - Refitting
F9Q or K9K or M9R
19CREFITTING
Replace the O-ring seal.
Refit the sender unit by aligning mark (6) on the sen-der with mark (7) on the tank.
Position nut (9) .
Tighten the nut (9) until mark (8) on the nut is alignedwith mark (7) on the tank and mark (6) on the sen-der.
Proceed in the reverse order to removal.
Connect the battery starting with the positive termi-nal (see MR 364 Mégane, 80A, Battery: Removal -Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
102470
19C-20
RESERVOIRPump-sender unit-filter: Removal - Refitting
K4M – F4R – K4J
19C
REMOVALDisconnect the battery, starting with the negativeterminal.
Lift up the rear bench seat base (see MR 365 Bo-dywork, 76A, Rear seat runners and frames,Complete seat base ).
Remove the carpet retaining clip.
Move the carpet to one side.
Remove:
- the closure panel mounting bolts (1) ,
- the closure panel,
- the blanking cover (2) on the inspection flap.
Disconnect:
- electrical connectors (3) ,
- quick-release union(s) (4) .
Prepare for fuel outflow.
Special tooling required
Mot. 1397 Universal spanner forremoving fuel sendernut
Tightening torquesm
battery cover mountingbolts
4 Nm
IMPORTANT
During this operation:
- refrain from smoking or bringing red hot objectsclose to the working area,
- beware of fuel splashes when disconnecting theunion,
- protect sensitive areas from fuel outflow.
102461
104546
11
2
19C-21
RESERVOIRPump-sender unit-filter: Removal - Refitting
K4M – F4R – K4J
19C
Remove the nut from the pump/sender/filter assem-bly using tool (Mot. 1397) (5) .
Remove the pump/sender/filter assembly, being ca-reful not to damage the float.
REFITTING
Replace the O-ring seal.
Refit the pump/sender/filter assembly, aligning mark(6) on the pump/sender/filter assembly with mark (7)on the tank.
Position the nut (9) .
Tighten the nut (9) until the mark (8) on the nut is ali-gned with mark (7) on the tank and mark (6) on thepump/sender/filter assembly.
Proceed in the reverse order to removal.
Connect the battery starting with the positive termi-nal (see MR 364 Mechanical systems, 80A, Batte-ry: Removal - Refitting ).
Tighten to torque the battery cover mounting bolts( 4 Nm ) .
104547
WARNING
Refit the pump/sender/filter assembly nut assoon as the pump/sender/filter assembly hasbeen removed to prevent any deformation of thefuel tank.
102470
19C-22
RESERVOIRPetrol filter: General information
F4R, and 770 or 771 or 776 – K4J, and 730 or 732 – K4M, and 760 or 761
19C
The fuel filter is located in the fuel tank; it is built intothe « pump-sender-filter » assembly and cannot be re-moved.
The filter is intended to have a long service life.
Checking the fuel supply pressure and the pump deli-very rate is the equivalent of running fault finding on the« pump-sender-filter » assembly.
102299
WARNING
The « pump-sender-filter » assembly must be repla-ced if one of the components is faulty.
19C-23
RESERVOIRFuel level sensor: Checking 19C
Checking the sender unit
MEASURING HEIGHT H
Place the removed sender on a flat surface.
H is the height measured between the float pin andthe working plane.
Capacity Resistance value between terminals A1 and B2 (Ω) ±±±± 10 Ω
Height H (mm) ±±±± 6mm
Tank full 20 upper stop
Tank 3/4 full 95 150
Tank 1/2 full 170 111
Tank 1/4 full 245 72
Spare 290 40
Tank empty 320 lower stop
Note:
All these values are given as a guide.
19D-1
ENGINE MOUNTINGSuspended engine mounting
K4J, and 730 or 732 – K4M, and 760, and JR5
19D
Tightening torques (in Nm)
103235
6554
33
2
11
7
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
19D-2
ENGINE MOUNTINGSuspended engine mounting
K9K, and 722 or 728
19D
Tightening torques (in Nm)
103236
2
1
1
10
7
7
8
9
66
44
333
5
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 21
(8) 62
(9) 180
(10) 62
19D-3
ENGINE MOUNTINGSuspended engine mounting
F9Q, and 800 or 804 or 808
19D
Tightening torques (in Nm)
103237
10
99
888
7 6 12
555
44433
2
111
11
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21 for M8 bolts
62 for M10bolts
(10) 62
(11) 180
(12) 62
19D-4
ENGINE MOUNTINGSuspended engine mounting
K4M, and 761
19D
Tightening torques (in Nm)
103274
33
2
11
7
8
8
9
6
55
4
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 180
(7) 62
(8) 21 for M8 bolts
62 for M10bolts
(9) 62
19D-5
ENGINE MOUNTINGSuspended engine mounting
F4R, and 770 or 771 or 776
19D
Tightening torques (in Nm)
103275
7
3
6
2
55
9
9
12
11
10
88
1
11
44
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21
(10) 62
(11) 180
(12) 62
19D-6
ENGINE MOUNTINGSuspended engine mounting
F4R, and 770 or 771 or 776
19D
Tightening torques (in Nm)
103244
11
1010
99
9
888
7 6
555
13
444
33
2
11
1
12
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 21
(10) 62
(11) 180
(12) 62
19D-7
ENGINE MOUNTINGSuspended engine mounting
K9K, and 729, and DP0
19D
Tightening torques (in Nm)
110743
9
77
77
11
1
666544
3333
2
8
(1) 62
(2) 105
(3) 62
(4) 105
(5) 62
(6) 62
(7) 62
(8) 62
(9) 62
19D-8
ENGINE MOUNTINGSuspended engine mounting
K9K, and 732
19D
Tightening torques (in Nm)
113926
(1) 62
(2) 62
(3) 105
(4) 115
(5) 62
(6) 180
(7) 105
(8) 62
(9) 105
(10) 62
(11) 62
19D-9
ENGINE MOUNTINGSuspended engine mounting: Tightening torque
K9K, and 732
19D
113926
No. Description Tightening
torque
(Nm)
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(2) Bolt mounting the lower engine tie-bar onto its support 180
(3) Bolt mounting the lower engine tie-bar onto its support 62
(4) Bolt mounting the upper engine tie-bar onto the bodywork 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolt mounting the right-hand suspended mounting support on the body 62
(7) Bolt mounting the right-hand suspended mounting support on the engine 62
(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 62
(9) Bolt mounting the left-hand suspended mounting support on the body 62
(10) Left-hand rubber pad mounting nut on the gearbox mounting 62
(11) Left-hand rubber pad mounting bolts on the body mounting 105
19D-10
ENGINE MOUNTINGSuspended engine mounting: Tightening torque
M9R, and 700
19D
114630
No. Description Tightening tor-que (Nm)
(1) Bolt mounting the lower engine tie-bar on the sub-frame 105
(2) Bolt mounting the lower engine tie-bar onto its support 180
(3) Lower engine tie-bar support mounting bolt 62
(4) Bolt mounting the upper engine tie-bar onto the bodywork 105
(5) Bolt mounting the upper engine tie-bar onto the engine 115
(6) Bolt mounting the right-hand suspended mounting support on the body 62
(7) Bolt mounting the right-hand suspended mounting support on the engine 62
(8) Bolt mounting the left-hand suspended mounting support onto the gearbox 105
(9) Bolt mounting the left-hand suspended mounting support on the body 62
(10) Left-hand rubber pad mounting nut on the gearbox mounting 62
(11) Left-hand rubber pad mounting bolts on the body mounting 62
19D-11
ENGINE MOUNTINGSuspended engine mounting: Tightening torque
B84 or C84, and F4R, and 774
19D
106075
No. Tightening torque (Nm)
(1) 62
(2) 105
(3) 105
(4) 62
(5) 62
(6) 180
(7) 105
(8) 62
(9) 62
(10) 21
(11) 105
(12) 180
(13) 62
19D-12
ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting
K9K, and 732
19D
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Remove:
- the engine undertray,
- the scuttle panel grille (see MR365 Bodywork,55A, Exterior protection, Scuttle panel grille ),
- the battery (see 80A, Battery: Removal - Refit-ting ).
Disconnect the engine management computer con-nectors (1) .
Unclip:
- the battery negative terminal wiring harness,
- the wiring harness from the battery tray.
Remove:
- the battery tray mounting bolts (2) ,
- the battery tray with the computer and its support.
Position the (Mot. 1453) .
Mark the position of the suspended mounting on thebody.
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Tightening torquesm
left-hand suspendedmounting bolts on thegearbox
62 Nm
left-hand suspendedmounting bolts on thebody
62 Nm
left-hand rubber padmounting bolts on thebody mounting
105 Nm
left-hand rubber padmounting nut on thegearbox mounting
62 Nm
101822
102450
19D-13
ENGINE MOUNTINGLeft-hand suspended engine mounting: Removal - Refitting
K9K, and 732
19DII - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the left-hand rubber pad mounting nut (3) on thegearbox mounting,
- the left-hand rubber pad mounting bolts (4) on thebody mounting,
- the rubber pad,
- the bolts (5) mounting the left-hand suspendedmounting on the body,
- the left-hand suspended mounting on the body,
- the bolts (6) mounting the left-hand suspendedmounting on the gearbox.
- the gearbox left-hand suspended mounting.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit the gearbox left-hand suspended mounting.
Refit the bolts mounting the left-hand suspendedmounting on the gearbox.
Tighten to torque the left-hand suspended moun-ting bolts on the gearbox ( 62 Nm ) .
Refit the left-hand suspended mounting on the body.
Refit the bolts mounting the left-hand suspendedmounting on the body,
Tighten to torque the left-hand suspended moun-ting bolts on the body ( 62 Nm ) .
Refit the left-hand rubber pad.
Refit the left-hand rubber pad mounting nut onto thegearbox mounting and the left-hand rubber padmounting bolts onto the body mounting.
Tighten to torque:
- the left-hand rubber pad mounting bolts on thebody mounting ( 105 Nm ) ,
- the left-hand rubber pad mounting nut on thegearbox mounting ( 62 Nm ) .
II - FINAL OPERATION
Remove the (Mot. 1453) .
Refit:
- the battery tray with the engine management com-puter and its support,
- the battery tray mounting bolts.
Clip:
- the battery negative terminal wiring harness,
- the wiring harness onto the battery tray.
Connect the engine management computer connec-tors.
Refit:
- the scuttle panel grille (see MR 365, 55A, Exteriorprotection, Scuttle panel grille ),
- the engine undertray,
Connect the battery (see 80A, Battery: Removal -Refitting ).
112655
19D-14
ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - Refitting
K9K, and 732
19D
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove the scuttle panel grille (see MR 365, Bo-dywork, 55A, Exterior protection, Scuttle panelgrille ).
Position the (Mot. 1453) .
Mark the position of the suspended mounting on thebody.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the upper engine tie-bar mounting bolt (2) on theengine,
- the upper engine tie-bar mounting bolt (1) on thebody,
- the upper engine tie-bar.
- the bolts (3) mounting the suspended mounting onthe body,
Special tooling required
Mot. 1453 Multiple-adjustingengine mounting sup-port with retainingstraps
Tightening torquesm
bolts mounting theright-hand suspendedmounting on the body
62 Nm
bolts mounting theright-hand suspendedmounting support on theengine
62 Nm
upper engine tie-barmounting bolt on theengine
115 Nm
upper engine tie-barmounting bolt on thebody
105 Nm
102450
113927
19D-15
ENGINE MOUNTINGRight-hand suspended engine mounting: Removal - Refitting
K9K, and 732
19D- the bolts (4) mounting the suspended mounting onthe engine,
- the suspended mounting.
REFITTING
I - REFITTING OPERATION FOR PART CONCERNED
Refit:
- the right-hand suspended mounting support,
- the bolts mounting the right-hand suspendedmounting support on the body,
- the bolts mounting the right-hand suspendedmounting on the engine,
- the upper engine tie-bar.
- the upper engine tie-bar mounting bolt onto the bo-dy,
- the upper engine tie-bar mounting bolt onto the en-gine,
Tighten to torque:
- the bolts mounting the right-hand suspendedmounting on the body ( 62 Nm )
- the bolts mounting the right-hand suspendedmounting support on the engine ( 62 Nm )
- the upper engine tie-bar mounting bolt on theengine ( 115 Nm )
- the upper engine tie-bar mounting bolt on thebody ( 105 Nm )
II - FINAL OPERATION
Remove the (Mot. 1453)
Refit the scuttle panel grille (see MR 365, Bo-dywork, 55A, Exterior protection, Scuttle panelgrille ).
Connect the battery (see 80A, Battery: Removal -Refitting).
19D-16
ENGINE MOUNTINGRear suspended engine mounting: Removal - Refitting
K9K, and 732
19D
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove the engine undertray
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the bolt mounting the engine tie-bar on the sub-fra-me (1) ,
- the bolt mounting the engine tie-bar on its support(2) .
REFITTING
I - REFITTING PREPARATION OPERATION
Refit:
- the bolt mounting the engine tie-bar on its support
- the bolt mounting the engine tie-bar on the sub-fra-me
Tighten to torque:
- the bolt mounting the engine tie-bar on its sup-port ( 180 Nm ) ,
- the bolt mounting the engine tie-bar on the sub-frame ( 105 Nm ) .
II - FINAL OPERATION
Refit the engine undertray.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Tightening torquesm
bolt mounting theengine tie-bar on itssupport
180 Nm
bolt mounting theengine tie-bar on thesub-frame
105 Nm
112653
19D-17
ENGINE MOUNTINGRear suspended engine mounting: Removal - Refitting
M9R, and 700
19D
REMOVAL
I - REMOVAL PREPARATION OPERATION
Place the vehicle on a two-post lift (see 02A, Liftingequipment, Underbody lift ).
Disconnect the battery (see 80A, Battery: Removal- Refitting ).
Remove the engine undertray.
II - OPERATION FOR REMOVAL OF PART CONCERNED
Remove:
- the bolt mounting the engine tie-bar on the sub-fra-me,
- the bolt mounting the engine tie-bar on its support.
Remove the engine tie-bar.
- by pushing it back (1) to detach it from its support,
- by pivoting it (2) to the right.
REFITTING
I - REFITTING PREPARATION OPERATION
Refit:
- the bolt mounting the engine tie-bar on its support
- the bolt mounting the engine tie-bar on the sub-fra-me
Tighten to torque:
- the bolt mounting the engine tie-bar on its sup-port ( 180 Nm ) ,
- the bolt mounting the engine tie-bar on the sub-frame ( 105 Nm ) .
II - FINAL OPERATION
Refit the engine undertray.
Connect the battery (see 80A, Battery: Removal -Refitting ).
Tightening torquesm
bolt mounting theengine tie-bar on itssupport
180 Nm
bolt mounting theengine tie-bar on thesub-frame
105 Nm
114650
114632